System and method for making nuclear fuel elements with a controlled number of nuclear particles

A system for producing a nuclear fuel element having a target number of nuclear fuel kernels, comprising:

• a channel having an exit, the channel being configured to receive nuclear fuel kernels, wherein the nuclear fuel kernels have a mean kernel size of 200 to 800 microns;
• a conveyer configured to transmit the nuclear fuel kernels along the channel to the exit;
• an optical counter configured to count a number of the nuclear fuel kernels which pass through the exit of the channel, and
• a motor configured to:
• drive the conveyer to cause the conveyer to move the kernels along the channel toward the exit until a target number of the nuclear fuel kernels exits the channel through the exit, and
• stop the conveyer after receiving a first signal from the optical counter;
• wherein the optical counter comprises:
• a laser positioned at the exit of the channel, wherein the laser is configured to transmit a beam, wherein the beam is interrupted each time one of the nuclear fuel kernels exits the channel;
• a sensor configured to receive the beam from the laser, wherein the sensor is configured to transmit a second signal each time the beam is interrupted;
• and
• a control circuit, wherein the control circuit is configured to:
• receive the second signal from the sensor each time the beam is interrupted, and count the nuclear fuel kernels which exit the channel;
• and
• transmit the first signal to the motor when the target number of the nuclear fuel kernels exits the channel;
• wherein the system further comprises a vibrating mold;
• wherein the vibrating mold is configured to:
• receive the target number of the nuclear fuel kernels from the exit of the channel;
• receive a particulate matrix material;
• and
• homogeneously distribute the target number of the nuclear fuel kernels within the particulate matrix material.

A method for producing a nuclear fuel element having a target number of nuclear fuel using kernels, wherein the method uses a system comprising:

• a channel having an exit, the channel being configured to receive nuclear fuel kernels;
• a conveyer configured to transmit the nuclear fuel kernels along the channel to the exit;
• an optical counter configured to count a number of the nuclear fuel kernels which pass through the exit of the channel, and
• a motor configured to:
• drive the conveyer until a target number of the nuclear fuel kernels exits the channel through the exit, and
• stop the conveyer after receiving a first signal from the optical counter;
• wherein the optical counter comprises:
• a laser positioned at the exit of the channel, wherein the laser is configured to transmit a beam, wherein the beam is interrupted each time one of the nuclear fuel kernels exits the channel;
• a sensor configured to receive the beam from the laser, wherein the sensor is configured to transmit a second signal each time the beam is interrupted;
• and
• a control circuit, wherein the control circuit is configured to:
• receive the second signal from the sensor each time the beam is interrupted, and count the nuclear fuel kernels which exit the channel;
• and
• transmit the first signal to the motor when the target number of the nuclear fuel kernels exits the channel;
• wherein the method comprises:
• feeding nuclear fuel kernels along the channel having the exit;
• driving the conveyer with the motor to transmit the nuclear fuel kernels along the channel to the exit;
• using the optical counter to count a number of the nuclear fuel kernels which pass through the exit of the channel;
• stopping the conveyer upon receipt of the first signal, after the target number of the nuclear fuel kernels exits the channel;
• feeding the target number of the nuclear fuel kernels into a mold for shaping the nuclear fuel element;
• filling the mold containing the target number of the nuclear fuel kernels with a particulate matrix material so as to homogeneously distribute the target number of the nuclear fuel kernels within the particulate matrix material;
• and
• converting the particulate matrix material into a solid matrix material with the nuclear fuel kernels distributed therein;
• wherein a volume of nuclear material in the solid matrix material is known.