from: dozier, tami sent: wednesday, may 19, 2021 7:14 pm
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From: Dozier, Tami Sent: Wednesday, May 19, 2021 7:14 PM To: AdvancedReactors-GEISDocsPEm Resource Subject: HA-LEU Supply (Enrichment, De-conversion, Fuel Fab & Transportation) Attachments: BWXT-28Apr2020Nagley.pdf
Hearing Identifier: AdvancedReactors_GEIS_Public Email Number: 15 Mail Envelope Properties (BY3PR09MB7585BF37BA486B792176DDB4F42B9) Subject: HA-LEU Supply (Enrichment, De-conversion, Fuel Fab & Transportation) Sent Date: 5/19/2021 7:13:56 PM Received Date: 5/19/2021 7:14:00 PM From: Dozier, Tami Created By: [email protected] Recipients: "AdvancedReactors-GEISDocsPEm Resource" <[email protected]> Tracking Status: None Post Office: BY3PR09MB7585.namprd09.prod.outlook.com Files Size Date & Time MESSAGE 3 5/19/2021 7:14:00 PM BWXT-28Apr2020Nagley.pdf 1331661 Options Priority: Normal Return Notification: No Reply Requested: No Sensitivity: Normal Expiration Date:
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Scott Nagley – Vice President, Nuclear Operations Group
GAIN/NEI/EPRI Webinar - April 28 & 29, 2020
HA-LEU Supply(Enrichment, De-conversion, Fuel Fab & Transportation)
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BWXT has been at the forefront of the commercial nuclear power generation and government nuclear industries for decades, achieving an impressive number of firsts along the way.
About BWXT
12 major manufacturing facilities totaling 3.9 million square feet
15 U.S. Department of Energy laboratories, environmental cleanup projects and NASA sites
8,000+ fuel elements delivered to U.S. national laboratories, universities and international customers
60+ years producing naval nuclear propulsion systems
6,600highly skilled employees with ~65% holding government clearances
2 U.S. NRC Category 1 SNM licensed facilities –the only 2 in the U.S.
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o Create a sustainable supply of HA-LEU (up to 19.75% U235) to support national security and civil activities as outlined by NELA/AEIA
o S. 903/HR 3306 Nuclear Energy Leadership Act (NELA), S. 2657 American Energy Innovation Act (AEIA)
Similar bills working through Senate and HouseIncludes HA-LEU supply requirements
» 10 MT HA-LEU by 2022» Additional 40 MT HA-LEU by 2025
o Activities include:Deployment of DoD microreactorsResearch and test reactorsCivil advanced reactorsNASA nuclear thermal propulsionMedical isotope production
Objective
In a recent USNIC survey of advanced reactor developers, availability of HA-LEU was identified as the #1 thing that ‘keeps them up at night’.
ORNL’s High Flux Isotope Reactor (HFIR)
NASA’s Nuclear Thermal Propulsion Engine System, of
which BWXT is providing support for reactor and fuel design analysis.
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o There is no existing domestic enrichment capacity to enrich uranium to HA-LEU. Downblending HEU is the only near term option (< 5 years) to produce metric ton quantities of HA-LEU.
o Currently:There is no HEU allocated for downblendingto HA-LEU
» Research reactor HEU supply forecasted to last through 2041
There is no commercial downblendingcapability to produce HA-LEU in metric ton quantitiesThere is no funding for downblending of HEU to HA-LEU
Problem Statement
Enrichment DownblendNU HEU
U-10MoU3Si2
TRISOUN / UCO / UO2
Research / Isotopes / Power / Propulsion
HA-LEU Sustainable Supply Overview
HA-LEUMetal
HA-LEUOxide
Oxidation
Reduction
Elements / Compacts / Targets / Assemblies
Scrap Recovery
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o BWXT is currently able to downblend HEU to HA-LEU during initial steps of fuel manufacturing process (e.g., TRISO) for demonstration quantities
o BWXT Nuclear Fuel Services, Inc. (NFS) is the only commercial company in the U.S. that is licensed and capable to downblend metric ton quantities of HEU
NFS currently downblends HEU to LEU (≤ 4.95% U235) in support of the NNSA Tritium mission (DBOT)BWXT has produced over 2,000 MT of LEU via downblending since 1995 (NFS & NOG-L combined)
o NFS is prepared to add equipment to existing capacity to accommodate blending to higher assays
1-2 MT HEU annually to produce up to 10 MT HA-LEU» Product quantities depend on HEU and blendstock assays» Product form as uranium oxide and metal
Downblending Bridge Opportunity
BWXT’s Nuclear Fuel Services – Erwin, Tennessee
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o Since the Paducah Gaseous Diffusion Plant ceased enrichment operations in 2013, no U.S. enrichment technology is in production use
o For defense purposes, enrichment technologies used and the uranium itself must be unencumbered (U.S. origin)
o Enrichments requiredLEU (up to 4.95% U235)
» Tritium production (in TVA reactors)HA-LEU (up to 19.75% U235)
» DOD microreactors, advanced reactors, research reactors, and conversion of HEU research reactors to HA-LEU
» Non-defense related activities may use encumbered materials
HEU (up to 93% U235) » Naval fuel and weapons program modernization» Replenish HEU used for HA-LEU via downblending
Establishing Domestic U.S. Uranium Enrichment Capabilities
BWXT is fully prepared to support DOE/NNSA in their endeavor to establish new U.S. technology-based enrichment capabilities.
2020 2030 2040 2050 2060
500 MT
0 MT
Met
ric T
ons
(MT)
HEU
Defense, HEU Reserve
NR, Sciences, Downblend to HA-LEU
Domestic HEU Supply
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o Strategy: Perform chemical conversion at the HA-LEU enrichment plant and recycle tails (<5% U235) to the LEU enrichment plant
Avoid shipping HA-LEU as UF6
o BWXT Demonstrated ExperienceUF6 to U-oxidesU - metal and alloys to
» U – oxides (UO2, UO3, & U3O8)» UN – solutions (up to 750 g U / L)» U – silicide (U3Si2)» U – aluminides (UAlx)
U- oxides to » U – carbides (UC & UC2) & oxycarbides (UCO)» U – nitride
UN – crystals to U - oxides
HA-LEU De-conversion
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o Initial capacity = 120% of HA-LEU enrichment plant annual capacity
o Low-Risk Technical Approach (tried and true chemical processes)
Convert all UF6 to U-oxide firstConvert U-oxide to U-metal buttons
» Initial quantities determined by research reactor demand (2 to 3 MT HA-LEU initially)
Design and install U-salts production capability based on market demand
» UF4 capability will be established as an intermediate for U-metal conversion
o Include HA-LEU Scrap Recovery capability
HA-LEU De-conversion - Modular Design with Expansion in Mind
Ship U-oxide to fuel fab facility for TRISO or other oxide, oxycarbide,
carbide or U-salt application as markets develop
Ship U-metal to fuel fab facility for research reactor (U-Mo or U-
Silicide) or other applications as markets develop
UF4 (green salt) intermediate product if desired
U-Metal Storage
Convert to U-Metal
U-Oxide Storage
Convert to U-Oxide
HA-LEUF6 from Enrichment Facility Product Storage
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o Strategy: Make maximum use of existing licensed facilities for HA-LEU Fuel Fab
o BWXT Demonstrated CapabilitiesResearch & Test Reactor FuelAdvanced Reactor Fuel
» TRISOMedical Isotope Targets (HEU & HA-LEU)Nuclear Thermal Propulsion for Space (NASA) Applications
HA-LEU Fuel Fabrication
ORNL’s High Flux Isotope Reactor (HFIR)ORNL’s High Flux Isotope Reactor (HFIR)MIT Research Reactor Fuel ElementU-metal Foils
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o Strategy: Make maximum use of existing/licensed shipping containers while developing more efficient containers forHA-LEU
o BWXT RecommendationMake fuel form (e.g., TRISO) in the same factory as reactor fabricationShip manufactured fuel components or cores versus shipping fuel forms (e.g., TRISO)
o BWXT Demonstrated CapabilitiesPackage design, inspection and maintenanceSafety analysis, licensing and QA ProgramHolds NRC certificates for two Type B Containers:
» UNC-2600 (HEU)» BWXT 5X22 (HEU)
Extensive experience using and maintaining:» ES-3100 HEU transportation package» LR-230 transportation package for LEU nitrate solution» Research reactor fresh fuel packages for ATR, NIST & HFIR
HA-LEU Transportation & Shipping Containers
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o Potential HA-LEU sources:Downblend HEU (unirradiated)Reprocess and downblend HEU (irradiated)New enrichment capacity
o Existing ASTM specification for HA-LEU metal (C1462-00, re-approved 2013) is not adequate
o ASTM committee C26.02 (Fuel & Fertile Materials)Collaborative assembly of designers, developers, producers, manufacturers, users and regulatorsCredible specifications based on industry consensus
Industry Collaboration on HA-LEU Requirements
As an advanced reactor community, we must collaborate on HA-LEU quality requirements and create a high fidelity demand signal in order for HA-LEU to become a commodity.
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o Start immediately – provide funding to establish the capability to downblend HEU to produce and store HA-LEU as uranium metal and oxide
HEU allocation from U.S. stockpile is neededShort term “bridge” solution
o Allocate funding and commence commercial design activities for a new centrifuge manufacturing facility and enrichment facilities all the way to HEU
Replenish HEU stockpile used for U.S. Defense applicationsProvide sustainable HA-LEU supply for DoD microreactors, research and test reactors, and new commercial designs
o Re-establish the U.S. domestic natural uranium supply chain (mining and conversion)
o Collaborate on HA-LEU requirements via ASTM Committee C26.02
The Way Ahead