Nuclear reactor systems and associated devices and methods are described herein. A representative nuclear reactor system includes a reactor vessel having a barrier separating a core region from a shield region. A plurality of fuel rods containing a liquid nuclear fuel are positioned in the core region. A liquid moderator material is also positioned in the core region at least partially around the fuel rods. A plurality of heat exchangers can be positioned in the shield region, and a plurality of heat pipes can extend through the barrier. The moderator material is positioned to transfer heat received from the liquid nuclear fuel to the heat pipes, and the heat pipes are positioned to transfer heat received from the moderator material to the heat exchangers. The heat exchangers can transport the heat out of the system for use in one or more processes, such as generating electricity.

A nuclear reactor system includes a nuclear reactor core disposed in a pressure vessel. Nuclear reactor system further includes control drums disposed longitudinally within the pressure vessel and laterally surrounding fuel elements and at least one moderator element of the nuclear reactor core to control reactivity. Each of the control drums includes a reflector material and an absorber material. Nuclear reactor system further includes a control drum controller with a counterweight to impart a reverse torque on the control drum. Control drum controller includes a driven pulley coupled to the counterweight, a tension member coupled to the driven pulley to rotatably control the driven pulley and apply torque to the driven pulley, and an actuator to apply a tension force to the tension member. The actuator counteracts the reverse torque with the applied tension force, and the tension member applies the torque in response to the tension force.

The fuel cartridge may include a plurality of fuel channels, a first header disposed on a first side of a fuel matrix, a second header disposed on a second side of the fuel matrix opposite to the first side, and a plurality of cooling tubes through which a working fluid flows. Each of the plurality of cooling tubes may pass through each corresponding cooling channel of the plurality of cooling channels, where each of the plurality of cooling tubes has a first end connected to the first header and a second end connected to the second header. The fuel cartridge may include an interior space for sealingly containing the fuel matrix may include a pressure boundary independent from an interior of the plurality of cooling tubes, such that the interior space is not in fluid communication with the plurality of cooling tubes.

The fuel cartridge may include a plurality of fuel channels, a first header disposed on a first side of a fuel matrix, a second header disposed on a second side of the fuel matrix opposite to the first side, and a plurality of cooling tubes through which a working fluid flows. Each of the plurality of cooling tubes may pass through each corresponding cooling channel of the plurality of cooling channels, where each of the plurality of cooling tubes has a first end connected to the first header and a second end connected to the second header. The fuel cartridge may include an interior space for sealingly containing the fuel matrix may include a pressure boundary independent from an interior of the plurality of cooling tubes, such that the interior space is not in fluid communication with the plurality of cooling tubes.

This disclosure describes various configurations and components of a molten fuel fast or thermal nuclear reactor for managing the operating temperature in the reactor core. The disclosure includes various configurations of direct reactor auxiliary cooling system (DRACS) heat exchangers and primary heat exchangers as well as descriptions of improved flow paths for nuclear fuel, primary coolant and DRACS coolant through the reactor components.

This disclosure describes various configurations and components of a molten fuel fast or thermal nuclear reactor for managing the operating temperature in the reactor core. The disclosure includes various configurations of direct reactor auxiliary cooling system (DRACS) heat exchangers and primary heat exchangers as well as descriptions of improved flow paths for nuclear fuel, primary coolant and DRACS coolant through the reactor components.

A modular nuclear reactor system includes a lift-out, replaceable nuclear reactor core configured for replacement as a singular unit during a single lift-out event, such as rather than lifting and replacing individual fuel assemblies and/or fuel elements. The system includes a reactor vessel and a power generation system configured to convert thermal energy in a high temperature working fluid received from the reactor vessel into electrical energy. The reactor vessel includes: a vessel inlet and an adjacent vessel outlet arranged near a bottom on the vessel; a vessel receptacle configured to receive a unified core assembly; locating datums in the base of the vessel receptacle and configured to constrain a core assembly in multiple degrees of freedom; and an interstitial zone surrounding the vessel receptacle and housing a set of control or moderating drums.

A simple nuclear reactor in which most of the reflector material is outside of the reactor vessel is described. The reactor vessel is a cylinder that contains all of the fuel salt and a displacement component, which may be a reflector, in the upper section of the reactor vessel. Other than the displacement component, the reflector elements including a radial reflector and a bottom reflector are located outside the vessel. The salt flows around the outside surface of the displacement component through a downcomer heat exchange duct defined by the exterior of the displacement component and the interior surface of the reactor vessel. This design reduces the overall size of the reactor vessel for a given volume of salt relative to designs with internal radial or bottom reflectors.

A simple nuclear reactor in which most of the reflector material is outside of the reactor vessel is described. The reactor vessel is a cylinder that contains all of the fuel salt and a displacement component, which may be a reflector, in the upper section of the reactor vessel. Other than the displacement component, the reflector elements including a radial reflector and a bottom reflector are located outside the vessel. The salt flows around the outside surface of the displacement component through a downcomer heat exchange duct defined by the exterior of the displacement component and the interior surface of the reactor vessel. This design reduces the overall size of the reactor vessel for a given volume of salt relative to designs with internal radial or bottom reflectors.

Methods of fabricating structures, such as parts for use in nuclear power generation systems, are described herein. A representative method of fabricating a part for a nuclear reactor system includes coating a plurality of particles of a powder of a first material with a second material, and then pressing and/or heating the coated powder into a monolithic structure. The second material can be substantially solidly insoluble with the first material such that, after pressing and/or heating, the particles of the first material define grains of the monolithic structure and the second material substantially encapsulates the grains in the monolithic structure. The first material can be susceptible to corrosion by a select process, and the second material can be resistant to corrosion by the select process such that the bulk first material of the monolithic structure is resistant to corrosion by the select process.