Near warning signs of radioactive material at the Oak Ridge National Laboratory, a group of workers from X-energy is developing a new type of nuclear fuel, producing what resemble gray billiard balls. These “pebbles” contain tiny black spheres, each infused with uranium enriched beyond the levels currently utilized in existing power plants. As the United States aims for a revitalized nuclear power landscape, the focus is on domestic production of reactor fuel, with X-energy at the forefront of this initiative.
President Donald Trump recently set an ambitious target to quadruple domestic nuclear power production over the next 25 years, signing executive orders in May 2023 to expedite development. This effort aligns with plans for advanced nuclear reactors that could be operational by 2030. Trump emphasized the importance of maximizing nuclear fuel production to support long-term nuclear energy expansion in the country.
Investments in Nuclear Fuel Production
In Oak Ridge, X-energy is making significant strides, having broken ground on a nearly $2 billion campus for a new fuel fabrication facility. This facility represents the first of its kind in the United States in over 50 years. Another company, Standard Nuclear, is also based in Oak Ridge, aiming to produce metric tons of fuel for advanced reactors, while the supplier Orano plans to establish a multibillion-dollar uranium enrichment facility nearby.
“This is a unique time,” remarked Tyler Gerczak, principal investigator at Oak Ridge National Laboratory for the collaboration with X-energy’s TRISO-X subsidiary. “The momentum is incredible.”
At the laboratory, X-energy is currently producing small amounts of fuel for testing purposes. Access to the area beyond the safety barriers requires workers to don protective gowns, gloves, and radiation monitors, with mandatory checks for radioactivity upon exit. X-energy specializes in creating TRISO fuel, known as “pebbles,” which the Energy Department describes as the most resilient nuclear fuel available, impervious to melting in reactor conditions.
The initial step in fuel production involves creating a uranium mixture that resembles dark yellow lemonade. This process includes combining uranium powder with nitric acid, followed by the addition of carbon and an organic solution. The mixture transitions to a near-black consistency, which is then solidified into small spheres, each roughly the size of a poppy seed. These spheres undergo high-temperature treatments, receiving protective carbon coatings that enhance their durability.
The resulting pebbles are designed for use in high-temperature gas-cooled nuclear reactors, with approximately 220,000 pebbles required per reactor. They are capable of cycling through the reactor multiple times, potentially being reused up to six times.
Challenges and Goals in Nuclear Energy Expansion
Despite the advances, the U.S. currently lacks operational next-generation reactors and has only constructed two new large reactors from scratch in nearly half a century. These projects, located at a nuclear plant in Georgia, faced significant delays and budget overruns, totaling more than $17 billion. Critics argue that without substantial reductions in construction costs, further investments in nuclear energy may not be justified, especially when compared to other low-carbon energy solutions.
“Without a substantial decrease in construction costs, it’s not worth the avoided greenhouse gas emissions,” stated David Kemp, a policy analyst at the Cato Institute. He expressed skepticism about Trump’s ambitious goal, suggesting that it would require unprecedented speeds in reactor construction.
Next-generation reactors are expected to utilize high-assay low-enriched uranium, a fuel type that enables longer and more efficient operation while generating less waste. Currently, only Russia and China possess the infrastructure for large-scale production of this type of uranium. Recently, Centrus Energy produced the first 20 kilograms of high-assay low-enriched uranium in over 70 years, marking a significant milestone for U.S. capabilities.
Trump’s executive orders underscore the need to increase domestic nuclear fuel production, reducing reliance on foreign sources and facilitating the long-term expansion of American nuclear energy. Benjamin Holtzman, director of new nuclear at the Nuclear Energy Institute, believes that if appropriate measures are adopted now, fuel will be ready for the new generation of nuclear reactors needed to meet rising electricity demands.
X-energy’s CEO J. Clay Sell aims to address the fuel supply issue to prevent it from hindering new reactor development. The Energy Department has allocated funding to X-energy, which has also attracted investments from Amazon. Together, they plan to bring over 5 gigawatts of new U.S. power projects online by 2039.
X-energy currently holds the only application before the Nuclear Regulatory Commission for licensing a new fabrication facility to convert enriched uranium into nuclear reactor fuel products. Additional companies have expressed interest in producing fuel for advanced reactors, indicating that the landscape for nuclear energy in the U.S. is beginning to shift.
From its pilot lab launched in 2016, X-energy has expanded to 100 acres in Oak Ridge for its nuclear fuel production complex. The first factory is projected to begin operations by late 2027 or early 2028, with the capability to produce enough fuel orbs to power 11 advanced reactors. A second facility, anticipated by late 2029, will have a production capacity four times greater.
“I’ve been through two or three nuclear renaissances,” noted Joel Duling, president of TRISO-X. “This isn’t a renaissance. This is a game-changer.” The developments at Oak Ridge signal a pivotal moment in the U.S. nuclear sector, with potential implications for energy independence and sustainability in the years to come.
