Spent nuclear fuel is added to an electro-reduction cell, wherein the electro-reduction cell includes a halide salt electrolyte, and anode, and a cathode including an alloy of uranium and a first metal forming a low melting point alloy with uranium, the first metal being one or more of: iron; chromium; nickel; manganese; and cobalt. The spent nuclear fuel is electrochemically reduced at a potential sufficient to reduce plutonium and lanthanides in the spent nuclear fuel, to form a molten alloy of the first metal, uranium and higher actinides present in the spent nuclear fuel. The alloy is extracted from the electro-reduction cell while uranium oxide is present in the electro-reduction cell. The spent nuclear fuel includes uranium oxide and at least 1 mol of lanthanides per tonne of uranium in the spent nuclear fuel, and the electro-reduction cell is operated at a temperature above the melting point of the alloy.

Spent nuclear fuel is added to an electro-reduction cell, wherein the electro-reduction cell includes a halide salt electrolyte, and anode, and a cathode including an alloy of uranium and a first metal forming a low melting point alloy with uranium, the first metal being one or more of: iron; chromium; nickel; manganese; and cobalt. The spent nuclear fuel is electrochemically reduced at a potential sufficient to reduce plutonium and lanthanides in the spent nuclear fuel, to form a molten alloy of the first metal, uranium and higher actinides present in the spent nuclear fuel. The alloy is extracted from the electro-reduction cell while uranium oxide is present in the electro-reduction cell. The spent nuclear fuel includes uranium oxide and at least 1 mol of lanthanides per tonne of uranium in the spent nuclear fuel, and the electro-reduction cell is operated at a temperature above the melting point of the alloy.

An anti-proliferation technique is disclosed to reduce the likelihood of nuclear proliferation due to the use fissionable fuel salts. The technique includes doping the fuel salt with one or more elements (referred to herein as activation dopants) that, upon exposure to neutrons such as would occur in the fuel salt when a reactor is in operation, undergo a nuclear reaction to, directly or indirectly, form highly active “protecting isotopes” (of the same element as the activation dopant or a different element). A sufficient mass of activation dopants is used so that the Figure of Merit (FOM) of the fuel salt is decreased to below 1.0 within some target number of days of fission. This allows the FOM of the fuel salt to be controlled so that the fuel becomes too dangerous to handle before to the creation of a significant amount of weaponizable isotopes.

A method of direct oxide reduction includes forming a molten salt electrolyte in an electrochemical cell, disposing at least one metal oxide in the electrochemical cell, disposing a counter electrode comprising a material selected from the group consisting of osmium, ruthenium, rhodium, iridium, palladium, platinum, silver, gold, lithium iridate, lithium ruthenate, a lithium rhodate, a lithium tin oxygen compound, a lithium manganese compound, strontium ruthenium ternary compounds, calcium iridate, strontium iridate, calcium platinate, strontium platinate, magnesium ruthenate, magnesium iridate, sodium ruthenate, sodium iridate, potassium iridate, and potassium ruthenate in the electrochemical cell, and applying a current between the counter electrode and the at least one metal oxide to reduce the at least one metal oxide. Related methods of direct oxide reduction and related electrochemical cells are also disclosed.

A method of direct oxide reduction includes forming a molten salt electrolyte in an electrochemical cell, disposing at least one metal oxide in the electrochemical cell, disposing a counter electrode comprising a material selected from the group consisting of osmium, ruthenium, rhodium, iridium, palladium, platinum, silver, gold, lithium iridate, lithium ruthenate, a lithium rhodate, a lithium tin oxygen compound, a lithium manganese compound, strontium ruthenium ternary compounds, calcium iridate, strontium iridate, calcium platinate, strontium platinate, magnesium ruthenate, magnesium iridate, sodium ruthenate, sodium iridate, potassium iridate, and potassium ruthenate in the electrochemical cell, and applying a current between the counter electrode and the at least one metal oxide to reduce the at least one metal oxide. Related methods of direct oxide reduction and related electrochemical cells are also disclosed.

The present disclosure provides systems and methods for fast molten salt reactor fuel-salt preparation. In one implementation, the method may comprise providing fuel assemblies having fuel pellets, removing the fuel pellets and spent fuel constituents from the fuel assemblies, granulating the removed fuel pellets or process feed to a chlorination process, processing the granular spent fuel salt into chloride salt by ultimate reduction and chlorination of the uranium and associated fuel constituents chloride salt solution, enriching the granular spent fuel salt, chlorinating the enriched granular spent fuel salt to yield molten chloride salt fuel, analyzing, adjusting, and certifying the molten chloride salt fuel for end use in a molten salt reactor, pumping the molten chloride salt fuel and cooling the molten chloride salt fuel, and milling the solidified molten chloride salt fuel to predetermined specifications.

The present disclosure provides systems and methods for fast molten salt reactor fuel-salt preparation. In one implementation, the method may comprise providing fuel assemblies having fuel pellets, removing the fuel pellets and spent fuel constituents from the fuel assemblies, granulating the removed fuel pellets or process feed to a chlorination process, processing the granular spent fuel salt into chloride salt by ultimate reduction and chlorination of the uranium and associated fuel constituents chloride salt solution, enriching the granular spent fuel salt, chlorinating the enriched granular spent fuel salt to yield molten chloride salt fuel, analyzing, adjusting, and certifying the molten chloride salt fuel for end use in a molten salt reactor, pumping the molten chloride salt fuel and cooling the molten chloride salt fuel, and milling the solidified molten chloride salt fuel to predetermined specifications.

An anti-proliferation technique is disclosed to reduce the likelihood of nuclear proliferation due to the use fissionable fuel salts. The technique includes doping the fuel salt with one or more elements (referred to herein as activation dopants) that, upon exposure to neutrons such as would occur in the fuel salt when a reactor is in operation, undergo a nuclear reaction to, directly or indirectly, form highly active “protecting isotopes” (of the same element as the activation dopant or a different element). A sufficient mass of activation dopants is used so that the Figure of Merit (FOM) of the fuel salt is decreased to below 1.0 within some target number of days of fission. This allows the FOM of the fuel salt to be controlled so that the fuel becomes too dangerous to handle before to the creation of a significant amount of weaponizable isotopes.

A method of producing uranium halides is disclosed in which chlorine gas is introduced into a liquid uranium-nickel alloy. NaCl salt is surrounding the crucible containing the liquid uranium-nickel alloy, producing a eutectic mixture of NaCl—UCl.sub.3. Upon chlorination, the metal halide dissolves in the matrix salt forming a solution. Adding the reactant metal, uranium to the nickel, the alloy is able to remain molten throughout processing. The liquid metal alloy may be removed from the salt bath, while the halogen gas continues to enter the system through the sparge until the desired composition of NaCl—UCl.sub.3—UCl.sub.4 is achieved. The method and system can be used to produce other metal halide salts such as actinide, lanthanide or transition metal halides contained in a matrix salt consisting of alkali and/or alkaline earth halides.

A method of direct oxide reduction includes forming a molten salt electrolyte in an electrochemical cell, disposing at least one metal oxide in the electrochemical cell, disposing a counter electrode comprising a material selected from the group consisting of osmium, ruthenium, rhodium, iridium, palladium, platinum, silver, gold, lithium iridate, lithium ruthenate, a lithium rhodate, a lithium tin oxygen compound, a lithium manganese compound, strontium ruthenium ternary compounds, calcium iridate, strontium iridate, calcium platinate, strontium platinate, magnesium ruthenate, magnesium iridate, sodium ruthenate, sodium iridate, potassium iridate, and potassium ruthenate in the electrochemical cell, and applying a current between the counter electrode and the at least one metal oxide to reduce the at least one metal oxide. Related methods of direct oxide reduction and related electrochemical cells are also disclosed.