Nuclear Fuel Cycle

The nuclear fuel cycle is the series of industrial processes which involve the production of electricity from uranium in nuclear power reactors. The nuclear fuel cycle starts with the mining of uranium and ends with the disposal of nuclear waste. With the reprocessing of used fuel as an option for nuclear energy, the stages form a true cycle.Uranium is a slightly radioactive metal that occurs throughout the Earth's crust.

Stages in Nuclear Fuel Cycle are: 

• Uranium mining

Both excavation and in situ techniques are used to recover uranium ore. Excavation may be underground and open pit mining.
In general, open pit mining is used where deposits are close to the surface and underground mining is used for deep deposits, typically greater than 120 m deep. Open pit mines require large holes on the surface, larger than the size of the ore deposit, since the walls of the pit must be sloped to prevent collapse. As a result, the quantity of material that must be removed in order to access the ore may be large. Underground mines have relatively small surface disturbance and the quantity of material that must be removed to access the ore is considerably less than in the case of an open pit mine. Special precautions, consisting primarily of increased ventilation, are required in underground mines to protect against airborne radiation exposure.
An increasing proportion of the world's uranium now comes from in situ leach (ISL) mining, where oxygenated groundwater is circulated through a very porous orebody to dissolve the uranium oxide and bring it to the surface. ISL may be with slightly acid or with alkaline solutions to keep the uranium in solution. The uranium oxide is then recovered from the solution as in a conventional mill.

• Uranium milling

Milling, which is generally carried out close to a uranium mine, extracts the uranium from the ore. Milling produces a uranium oxide concentrate which is shipped from the mill. It is sometimes referred to as 'yellowcake' and generally contains more than 80% uranium. The original ore may contain as little as 0.1% uranium or even less.
In a mill, uranium is extracted from the crushed and ground-up ore by leaching, in which either a strong acid or a strong alkaline solution is used to dissolve the uranium oxide. The uranium oxide is then precipitated and removed from the solution. After drying and usually heating it is packed in 200-litre drums as a concentrate, sometimes referred to as 'yellowcake'.

The remainder of the ore, containing most of the radioactivity and nearly all the rock material, becomes tailings, which are emplaced in engineered facilities near the mine (often in mined out pit). Tailings need to be isolated from the environment because they contain long-lived radioactive materials in low concentrations and toxic materials such as heavy metals; however, the total quantity of radioactive elements is less than in the original ore, and their collective radioactivity will be much shorter-lived.

• Conversion and enrichment

The uranium oxide product of a uranium mill is not directly usable as a fuel for a nuclear reactor and additional processing is required. Only 0.7% of natural uranium is 'fissile', or capable of undergoing fission, the process by which energy is produced in a nuclear reactor. The form, or isotope, of uranium which is fissile is the uranium-235 (U-235) isotope. The remainder is uranium-238 (U-238). For most kinds of reactor, the concentration of the fissile uranium-235 isotope needs to be increased – typically to between 3.5% and 5% U-235. Isotope separation is a physical process to concentrate (‘enrich’) one isotope relative to others.

• Fuel Fabrication

Enriched UF6 is transported to a fuel fabrication plant where it is converted to uranium dioxide (UO2) powder and pressed into small pellets. These pellets are inserted into thin tubes, usually of a zirconium alloy (zircalloy) or stainless steel, to form fuel rods. The rods are then sealed and assembled in clusters to form fuel assemblies for use in the core of the nuclear reactor.

Some 27 tonnes of fresh fuel is required each year by a 1000 MWe reactor.

• Power generation and burn-up

Inside a nuclear reactor the nuclei of U-235 atoms split (fission) and, in the process, release energy. This energy is used to heat water and turn it into steam. The steam is used to drive a turbine connected to a generator which produces electricity. Some of the U-238 in the fuel is turned into plutonium in the reactor core. The main plutonium isotope is also fissile and this yields about one third of the energy in a typical nuclear reactor. The fissioning of uranium (and the plutonium generated in situ) is used as a source of heat in a nuclear power station in the same way that the burning of coal, gas or oil is used as a source of heat in a fossil fuel power plant.

• Used fuel

With time, the concentration of fission fragments and heavy elements formed in the same way as plutonium in the fuel will increase to the point where it is no longer practical to continue to use the fuel. So after 18-36 months the used fuel is removed from the reactor.

Used fuel assemblies taken from the reactor core are highly radioactive and give off a lot of heat. They are therefore stored in special ponds which are usually located at the reactor site, to allow both their heat and radioactivity to decrease. The water in the ponds serves the dual purpose of acting as a barrier against radiation and dispersing the heat from the spent fuel.

Used fuel can be stored safely in these ponds for long periods. It can also be dry stored in engineered facilities, cooled by air. However, both kinds of storage are intended only as an interim step before the used fuel is either reprocessed or sent to final disposal. The longer it is stored, the easier it is to handle, due to decay of radioactivity.

• Reprocessing

Reprocessing separates uranium and plutonium from waste products (and from the fuel assembly cladding) by chopping up the fuel rods and dissolving them in acid to separate the various materials. Recovered uranium can be returned to the conversion plant for conversion to uranium hexafluoride and subsequent re-enrichment. The reactor-grade plutonium can be blended with enriched uranium to produce a mixed oxide (MOX) fuel, in a fuel fabrication plant.

• Final disposal

The waste forms envisaged for disposal are vitrified high-level wastes sealed into stainless steel canisters, or used fuel rods encapsulated in corrosion-resistant metals such as copper or stainless steel. Many geological formations such as granite, volcanic tuff, salt or shale are suitable.