Table of Contents

Fuel Fabrication

Fuel Fabrication is the final stage of the front-end of the fuel cycle. In this stage, the uranium metal or uranium dioxide is transformed into its final form – a fuel rod, typically up to four metres long, ready to be used in a nuclear reactor.

The cladding around the fuel rod is really important. It captures highly radioactive fission products! It is important that the material used to form the cladding is relatively transparent to neutrons – to mitigate degradation.

Windscale Pile Fuel

Dummy Windscale MK 1 fuel rod made by BNFL, Springfields, 1962.

© The Board of Trustees of the Science Museum

Magnox Fuel

A Magnox fuel rod can, used in Reactor 1 at Sizewell A Nuclear Power Station.

© The Board of Trustees of the Science Museum

 

AGR Fuel

A fuel pin designed to contain pellets of enriched uranium oxide fuel for an Advanced Gas-Cooled Reactor (AGR). The helical ribs help to transfer heat to the surrounding coolant (carbon dioxide gas).

© The Board of Trustees of the Science Museum

How is fuel fabrication carried out?

Forming

Step 1: Forming

The uranium dioxide (UO2) powder is pressed into pellets – these must be very dense and precisely shaped.

Sintering

Step 2: Sintering

The uranium dioxide (UO2) pellets are baked at 1400 °C, hardening to become a ceramic material.

Assembly

Step 3: Assembly

The uranium dioxide (UO2) ceramic pellets are arranged within cladding to form fuel assemblies. The cladding material used depends on the needs of the specific reactor design.

Where is fuel fabrication carried out?

What happens in the UK?

What happens in the UK?

Westinghouse's Springfields plant, near Preston, produces the fuel for the UK's Advanced Gas-Cooled Reactors (AGRs).

Did you know?

Within a fuel fabrication facility, there are careful controls to avoid an unintended criticality incident (like happened in Tokaimura in 1997). The facility will also be inspected by safeguards personnel from the nuclear regulator for accountancy purposes – keeping track of what uranium is where and at what enrichment.