Systems and methods for manufacturing metal fuel are described. Methods for fabricating a metal-fuel-matrix cermet nuclear fuel may include crushed ceramic particles combined with metallic fast reactor fuel via bottom pour casting or injection casting, or a powdered metallurgical process. A maximum quantity of crushed ceramic particles added to the metallic fuel must not exceed that which would fail to yield a continuous matrix of metal fuel. After a short irradiation period, the microstructure of the fuel may be substantially identical to that of injection cast fuel, without crushed ceramic particles, irrespective of the fabrication process. Thus, the extensive existing database for injection cast fuel, without crushed ceramic particles, may be an excellent indicator of expected irradiation performance. Each of the processes may contribute to a solution of the spent nuclear fuel problem and may denature Pu239 during the process.

Systems and methods for manufacturing metal fuel are described. Methods for fabricating a metal-fuel-matrix cermet nuclear fuel may include crushed ceramic particles combined with metallic fast reactor fuel via bottom pour casting or injection casting, or a powdered metallurgical process. A maximum quantity of crushed ceramic particles added to the metallic fuel must not exceed that which would fail to yield a continuous matrix of metal fuel. After a short irradiation period, the microstructure of the fuel may be substantially identical to that of injection cast fuel, without crushed ceramic particles, irrespective of the fabrication process. Thus, the extensive existing database for injection cast fuel, without crushed ceramic particles, may be an excellent indicator of expected irradiation performance. Each of the processes may contribute to a solution of the spent nuclear fuel problem and may denature Pu239 during the process.

Targetry coupled separation refers to enhancing the production of a predetermined radiation product through the selection of a target (including selection of the target material and the material's physical structure) and separation chemistry in order to optimize the recovery of the predetermined radiation product. This disclosure describes systems and methods for creating (through irradiation) and removing one or more desired radioisotopes from a target and further describes systems and methods that allow the same target to undergo multiple irradiations and separation operations without damage to the target. In contrast with the prior art that requires complete dissolution or destruction of a target before recovery of any irradiation products, the repeated reuse of the same physical target allowed by targetry coupled separation represents a significant increase in efficiency and decrease in cost over the prior art.

Targetry coupled separation refers to enhancing the production of a predetermined radiation product through the selection of a target (including selection of the target material and the material's physical structure) and separation chemistry in order to optimize the recovery of the predetermined radiation product. This disclosure describes systems and methods for creating (through irradiation) and removing one or more desired radioisotopes from a target and further describes systems and methods that allow the same target to undergo multiple irradiations and separation operations without damage to the target. In contrast with the prior art that requires complete dissolution or destruction of a target before recovery of any irradiation products, the repeated reuse of the same physical target allowed by targetry coupled separation represents a significant increase in efficiency and decrease in cost over the prior art.

The invention provides a system for collecting metal in an electrorefining process, the system having a hollow cathode; and a container defining an upwardly extending surface adapted to be received by the hollow cathode. An embodiment of the invention provides for metal reduction to occur on laterally facing and medially facing surfaces of the cathode such that electrolyte resides between surfaces of the cathode. Also provided is a metal electrorefining process having the steps of subjecting molten salt containing metal moieties to electrolysis wherein reduced metal accumulates in a cathode-cup construct in a first position; raising the construct to a second position above the molten salt while subjecting the construct to heat from the molten salt; withdrawing the cathode from the construct into a vestibule to the electrorefiner to a third position; and removing the cathode and cup from the electrorefiner to a fourth position.

The invention provides a system for collecting metal in an electrorefining process, the system having a hollow cathode; and a container defining an upwardly extending surface adapted to be received by the hollow cathode. An embodiment of the invention provides for metal reduction to occur on laterally facing and medially facing surfaces of the cathode such that electrolyte resides between surfaces of the cathode. Also provided is a metal electrorefining process having the steps of subjecting molten salt containing metal moieties to electrolysis wherein reduced metal accumulates in a cathode-cup construct in a first position; raising the construct to a second position above the molten salt while subjecting the construct to heat from the molten salt; withdrawing the cathode from the construct into a vestibule to the electrorefiner to a third position; and removing the cathode and cup from the electrorefiner to a fourth position.

Targetry coupled separation refers to enhancing the production of a predetermined radiation product through the selection of a target (including selection of the target material and the material's physical structure) and separation chemistry in order to optimize the recovery of the predetermined radiation product. This disclosure describes systems and methods for creating (through irradiation) and removing one or more desired radioisotopes from a target and further describes systems and methods that allow the same target to undergo multiple irradiations and separation operations without damage to the target. In contrast with the prior art that requires complete dissolution or destruction of a target before recovery of any irradiation products, the repeated reuse of the same physical target allowed by targetry coupled separation represents a significant increase in efficiency and decrease in cost over the prior art.

Targetry coupled separation refers to enhancing the production of a predetermined radiation product through the selection of a target (including selection of the target material and the material's physical structure) and separation chemistry in order to optimize the recovery of the predetermined radiation product. This disclosure describes systems and methods for creating (through irradiation) and removing one or more desired radioisotopes from a target and further describes systems and methods that allow the same target to undergo multiple irradiations and separation operations without damage to the target. In contrast with the prior art that requires complete dissolution or destruction of a target before recovery of any irradiation products, the repeated reuse of the same physical target allowed by targetry coupled separation represents a significant increase in efficiency and decrease in cost over the prior art.

A method of making a nuclear fuel structure may include reducing a metal oxide in a cathode assembly so as to deposit a metal of the metal oxide on the cathode plate of the cathode assembly, and processing the cathode plate with the metal deposited thereon to fabricate the nuclear fuel structure. The cathode plate may include an upper blade including an electrically conductive material, a lower blade portion connected to the upper blade, and a connection structure configured to secure the lower blade portion to the upper blade while providing electrical continuity. The connection structure may be configured to be disconnected from the lower blade portion to detach the lower blade portion from the upper blade.

A method of making a nuclear fuel structure may include reducing a metal oxide in a cathode assembly so as to deposit a metal of the metal oxide on the cathode plate of the cathode assembly, and processing the cathode plate with the metal deposited thereon to fabricate the nuclear fuel structure. The cathode plate may include an upper blade including an electrically conductive material, a lower blade portion connected to the upper blade, and a connection structure configured to secure the lower blade portion to the upper blade while providing electrical continuity. The connection structure may be configured to be disconnected from the lower blade portion to detach the lower blade portion from the upper blade.