# US 2023/0411024 A1 · System and method for making nuclear fuel elements with a controlled number of nuclear particles

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- Number: US 2023/0411024 A1
- Document ID: US20230411024A1
- Status: Published application
- Kind: A1
- Application number: 17/845,385
- Filed: 2022-06-21
- Published: 2023-12-21
- Earliest claimed: 2022-06-21
- Assignees: X-energy, LLC
- Applicants: X-Energy, LLC
- Inventors: Brandon Blamer
- Web page: https://patentgrep.com/patent/US20230411024A1

## CPC

- G21C 21/00: Apparatus or processes specially adapted to the manufacture of reactors or parts thereof (in general section B, e.g. B23)
- G21C 3/045: {Pellets}
- G21C 3/626: {Coated fuel particles}
- G01N 15/0272: {with screening; with classification by filtering (B01D takes precedence)}
- G01N 15/1459: {the analysis being performed on a sample stream}
- G01N 2015/0046: {in gas, e.g. smoke}
- G01N 2015/0277: {Average size only}
- G01N 2015/0288: {Sorting the particles}
- G01N 2015/1486: {Counting the particles}
- G01N 2021/845: {Objects on a conveyor}
- Y02E 30/30: Nuclear fission reactors
- G21C: NUCLEAR REACTORS (fusion reactors, hybrid fission-fusion reactors G21B; nuclear explosives G21J)
- G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q)
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

An optical counter is used in a method and system for producing a nuclear fuel element having a known volume of homogeneously distributed nuclear material. The method includes feeding nuclear fuel particles along a channel having a conveyer configured to transmit the nuclear fuel particles to an exit; driving the conveyer until a target number of nuclear fuel particles exits the channel through the exit; and counting a number of nuclear fuel particles which pass through the exit of the channel with an optical counter. The conveyer is stopped after the target number of nuclear fuel particles exits the channel. The target number of nuclear fuel particles are fed into a mold for shaping the nuclear fuel element, and void space remaining in the mold is filled with a particulate matrix material so as to homogeneously distribute the target number of nuclear fuel particles within the particulate matrix material. The particulate matrix material is then converted into a solid matrix material.

## Claims

### Claim 1

A method for producing a nuclear fuel element having a known volume of homogeneously distributed nuclear material, comprising:
feeding nuclear fuel particles along a channel having an exit, the channel having a conveyer configured to transmit the nuclear fuel particles to the exit;
driving the conveyer until a target number of nuclear fuel particles exits the channel through the exit;
counting a number of nuclear fuel particles which pass through the exit of the channel with an optical counter,
stopping the conveyer after the target number of nuclear fuel particles exits the channel;
feeding the target number of nuclear fuel particles into a mold for shaping the nuclear fuel element;
filling the mold containing the target number of nuclear fuel particles with a particulate matrix material so as to homogeneously distribute the target number of nuclear fuel particles within the particulate matrix material; and
converting the particulate matrix material into the solid matrix material;
wherein a volume of nuclear material in the target number of nuclear fuel particles is known.

### Claim 2 (depends on 1)

The method of claim 1, wherein a volume of particulate matrix material is sufficient to fill any void space in the mold after feeding the target number of nuclear fuel particles into the mold, so that a ratio of the volume of nuclear material in the nuclear fuel particles to the volume of solid matrix material in the fuel element is known.

### Claim 3 (depends on 1)

The method of claim 1, wherein:
the conveyer is a vibratory conveyer having a conveyer surface running along the length of the channel to the exit, and
a motor is configured to vibrate the conveyer surface.

### Claim 4 (depends on 1)

The method of claim 1, wherein:
the channel has a tubular or semi-cylindrical surface and the conveyer comprises a rotatable auger, the rotatable auger being configured to drive the nuclear fuel particles along the tubular or semi-cylindrical surface, and
a motor is configured to rotate the rotatable auger.

### Claim 5 (depends on 1)

The method of claim 1, wherein the conveyer is a sloped metal conveyer.

### Claim 6 (depends on 1)

The method of claim 1, wherein the optical counter comprises:
a laser positioned at the exit from the channel, wherein the laser is configured to transmit a beam, wherein the beam is interrupted each time one of the nuclear fuel particles exits the channel;
a sensor configured to receive the beam from the laser, wherein the sensor is configured to transmit a first signal each time the beam is interrupted; and
a control circuit, wherein the control circuit is configured to:
receive the first signal from the sensor each time the beam is interrupted, and calculate a number of nuclear fuel particles which exit the channel; and
transmit a second signal to a motor driving the conveyer when the target number of nuclear fuel particles exits the channel, wherein the second signal stops the motor.

### Claim 7 (depends on 1)

The method of claim 1, wherein the optical counter comprises:
a camera positioned at the exit from the conveyer, wherein the camera is configured to transmit a first signal each time one of the nuclear fuel particles exits the channel; and
a control circuit, wherein the control circuit is configured to:
receive the first signal from the camera each time one of the nuclear fuel particles exits the channel, and calculate a number of nuclear fuel particles which exit the channel; and
transmit a second signal to a motor driving the conveyer when the target number of nuclear fuel particles exits the channel, wherein the second signal stops the motor.

### Claim 8 (depends on 1)

The method of claim 1, wherein the step of converting the particulate matrix material into the solid matrix material comprises subjecting the nuclear fuel particles and the particulate matrix material within the mold to hot isostatic pressing, cold isostatic pressing, spark plasma sintering, or uniaxial pressing.

### Claim 9 (depends on 1)

The method of claim 1, wherein the particulate matrix material comprises graphite, phenolic resin, or a metal carbide.

### Claim 10 (depends on 9)

The method of claim 9, wherein the metal carbide comprises SiC or ZrC.

### Claim 11 (depends on 9)

The method of claim 9, wherein the particulate matrix material further comprises a binder.

### Claim 12 (depends on 1)

The method of claim 1, wherein the particulate matrix material further comprises a burnable poison selected from the group consisting of gadolinium, boron, hafnium, and compounds thereof.

### Claim 13

A system for producing a nuclear fuel element having a known amount of homogeneously distributed nuclear material, comprising:
a channel having an exit, the channel being configured to receive nuclear fuel particles;
a conveyer configured to transmit the nuclear fuel particles along the channel to the exit;
an optical counter configured to count a number of nuclear fuel particles which pass through the exit of the channel, and transmit a first signal when a target number of nuclear fuel particles exits the channel,
a motor configured to:
drive the conveyer until the target number of nuclear fuel particles exits the channel through the exit, and
stop the conveyer after receiving the first signal from the optical counter.

### Claim 14 (depends on 13)

The system of claim 13, further comprising:
a mold configured to:
receive the target number of nuclear fuel particles and a particulate matrix material; and
homogeneously distribute the target number of nuclear fuel particles within the particulate matrix material.

### Claim 15 (depends on 13)

The system of claim 13, wherein:
the conveyer is a vibratory conveyer having a conveyer surface running along the length of the channel to the exit, and
the motor is configured to vibrate the conveyer surface.

### Claim 16 (depends on 13)

The system of claim 13, wherein:
the conveyer is a conveyer having at least two rollers and an endless belt carried by the at least two rollers, the endless belt running along the length of the channel to the exit; and
the motor is configured to rotate the at least two rollers.

### Claim 17 (depends on 13)

The system of claim 13, wherein the optical counter comprises:
a laser positioned at the exit from the conveyer, wherein the laser is configured to transmit a beam, wherein the beam is interrupted each time one of the nuclear fuel particles 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 calculate a number of nuclear fuel particles which exit the channel; and
transmit the first signal to the motor when the target number of nuclear fuel particles exits the channel.

### Claim 18 (depends on 13)

The system of claim 13, wherein the optical counter comprises:
a camera positioned at the exit from the conveyer, wherein the camera is configured to transmit a second signal each time one of the nuclear fuel particles exits the channel; and
a control circuit, wherein the control circuit is configured to:
receive the second signal from the camera each time one of the nuclear fuel particles exits the channel; and
transmit the first signal to the motor when the target number of nuclear fuel particles exits the channel.

### Claim 19 (depends on 13)

The system of claim 13, wherein the mold is a metal mold, a graphite mold, or a rubber mold.

### Claim 20

A method for producing a nuclear fuel element having a predictable multiplication factor k, comprising:
feeding nuclear fuel particles having a known particle size along a channel having an exit, the channel having a conveyer configured to transmit the nuclear fuel particles to the exit;
driving the conveyer until a target number of nuclear fuel particles exits the channel through the exit;
counting a number of nuclear fuel particles which pass through the exit of the channel with an optical counter;
stopping the conveyer after the target number of nuclear fuel particles exits the channel;
filling a mold with the target number of nuclear fuel particles and a particulate matrix material while vibrating the mold so as to homogeneously distribute the nuclear fuel particles within the particulate matrix material; and
converting the particulate matrix material into a solid matrix material.