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Fuel Fabrication

Fuel fabrication facilities convert enriched UF6 into fuel for nuclear reactors. Fabrication also can involve mixed oxide fuel, which is a combination of uranium and plutonium components. Currently, the NRC regulates several different types of nuclear fuel fabrication operations.

On this page:

• Light Water Reactor Low-Enriched Uranium Fuel
• Light Water Reactor Mixed Oxide Fuel
• Non-Power Reactor Fuel
• Other Types of Fuel Fabrication
• Safety Concerns at Fabrication Facilities

See Location of Major Fuel Cycle Facilities for a list of these facilities licensed by NRC.

Light Water Reactor Low-Enriched Uranium Fuel

Fuel fabrication for light (regular) water power reactors (LWR) typically begins with receipt of low-enriched uranium (LEU) hexafluoride UF6 from an enrichment plant. The UF6, in solid form within containers, is converted to gaseous form by heating, and the UF6 gas is chemically processed to form LEU uranium dioxide (UO2) powder. This powder is then pressed into pellets, sintered into ceramic form, loaded into Zircaloy tubes, and constructed into fuel assemblies. Depending on the type of light water reactor, a fuel assembly may contain up to 264 fuel rods and have dimensions of 5 to 9 inches square by about 12 feet.

Typical Light Water Reactor Fuel Fabrication Facility

Light Water Reactor Mixed Oxide Fuel

Mixed oxide fuel (MOX) differs from LEU fuel in that the dioxide powder from which the fuel pellets are pressed is a combination of UO2 and plutonium oxide (PuO2). The NRC was directed by Congress to regulate the Department of Energy's (DOE's) fabrication of MOX fuel used for disposal of plutonium from international nuclear disarmament agreements. For more information about this fuel, see Mixed Oxide Fuel Fabrication Facility Licensing.

Non-Power Reactor Fuel

Non-power reactors are much smaller reactors that do not generate electrical power but are used for research, testing, and training. Non-power reactors can include research reactors and reactors used to produce irradiated target materials. The fuel design varies with the reactor type and manufacturer. Plate-type fuel consists of several thin plates containing a uranium mixture clad with aluminum. Another fuel is in the shape of rods and consists of a uranium and zirconium/hydride mixture. There are also compact, self-contained, low-power (<5 watts) tank-type reactors. Although use of highly-enriched uranium (HEU) fuel can reduce the size of a non-power reactor, the NRC adopted a policy of discouraging use of HEU fuel. This policy is reflected in 10 CFR 50.64.

Other Types of Fuel Fabrication Facilities

NRC also regulates some fuel fabrication facilities that have DOE contracts to down-blend highly enriched uranium (HEU) with other uranium to create LEU reactor fuel. The HEU being blended down to lower enrichment comes from Russian or U.S. weapons programs as part of an international arms control agreement.

Safety Concerns at Fabrication Plants

Chemical, radiological, and criticality hazards at fuel fabrication facilities are similar to hazards at enrichment plants. Most at risk from these hazards are the plant workers. These facilities generally pose a low risk to the public.

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Last revised Thursday, July 29, 2004