A nuclear reactor is constructed in sub-modules and super modules which are manufactured, packaged, and shipped to a construction site. At least some of the modules are packaged in suitable shielding containers or portions of containers, which may be steel. The modules are assembled on-site, and some of the modules remain within their respective shipping containers after assembly. One or more of the shipping containers may be used as concrete forms to support the pouring of concrete in between selected modules. The concrete may be used for structural support, shielding, or both.

A fuel rod support insert for a nuclear fuel assembly spacer grid, a spacer grid and a nuclear fuel assembly are provided. The support insert is for a nuclear fuel assembly spacer grid comprising interlaced straps defining a lattice of cells for receiving fuel rods, the insert being adapted to be secured to the straps for extending in at least one cell. The insert extends along an axis intended to be parallel to that of a cell and comprises two axially spaced end portions for connecting the insert to the straps and at least one elongated blade-like spring extending axially between the end portions for supporting a fuel rod. The spring has a non-rectilinear cross-section in each plane perpendicular to the insert axis.

Carbide-based fuel assembly includes outer structural member of ceramic matrix composite material (e.g., SiCSiC composite), insulation layer of porous refractory ceramic material (e.g., zirconium carbide with open-cell foam structure or fibrous zirconium carbide), and interior structural member of refractory ceramic-graphite composite material (e.g., zirconium carbide-graphite or niobium carbide-graphite). Spacer structures between various layers provide a defined and controlled spacing relationship. A fuel element bundle positioned between support meshes includes a plurality of distributively arranged fuel elements or a solid, unitary fuel element with coolant channels, each having a fuel composition including high assay, low enriched uranium (HALEU). Fuel assemblies are distributively arranged in a moderator block and the upper end of the outer structural member is attached to a metallic inlet tube for hydrogen propellant and the lower end of the outer structural member is interfaced with a support plate, forming a nuclear thermal propulsion reactor.

A segmented fuel assembly for use in a nuclear reactor is disclosed. The segmented fuel assembly comprises a lower nozzle, an upper nozzle, a plurality of guide tubes positioned intermediate the lower nozzle and the upper nozzle, and a plurality of fuel segments positioned intermediate the upper nozzle and the lower nozzle. The plurality of guide tubes are arranged in a first array. Each guide tube defines a longitudinal axis. Each fuel segment comprises a body defining a plurality of coolant flow channels and a plurality of guide tube openings. The guide tube openings are arranged in a second array corresponding to the first array. The guide tubes are positioned in the guide tube openings.

A nuclear reactor is designed to allow efficient packing of components within the reactor vessel, such as by offsetting the core, and/or vertically stacking components. The in-vessel storage system can be separate from the support cylinder and these components can be fabricated and shipped separately and coupled together at the construction site. Furthermore, the in-vessel storage system can be located adjacent to the core rather than being located circumferentially around it, and may also be located beneath the heat exchanger to further improve packing of components within the vessel. Through these, and other changes, the delicate components can be manufactured in a manufacturing facility, assembled, and shipped by commercial transportation options without exceeding the shipping envelope.

A nuclear fuel assembly is constructed with fuel assembly components that are wire wrapped and positioned in hexagonal rings within a fuel assembly duct. The fuel assembly components positioned in an outermost ring of the fuel assembly are wire wrapped with a pitch that is shorter than fuel assembly components positioned at an interior ring of the fuel assembly. The shorter pitch at the outer ring of the fuel assembly increases pressure drop of a coolant fluid at the edge and corner subchannels and thereby reduces the temperature gradient across the fuel assembly, which provides a higher output temperature of the nuclear reactor without substantially increasing peak temperature of the fuel cladding.