Westinghouse said this development allows better nuclear fuel efficiency, longer times between reactor refuels and lower operating costs.

U.S. pressurized water reactors currently operate on 18-month fuel cycles, and Westinghouse said this new higher burnup fuel will enable reductions in feed batch size, thereby improving fuel cycle economics. This is the first time nuclear fuel batch reloads in the United States will be able to exceed a burnup limit of 62 GWd/MTU.

“We are very pleased to receive approval from the Nuclear Regulatory Commission for incremental burnup in our nuclear fuel,” said Tarik Choho, Westinghouse President of Nuclear Fuel. “This milestone marks the start of production of nuclear fuel with increased capacity for Pressurized Water Reactors, vastly improving fuel costs for U.S. utility customers.”

The incremental burnup approval also represents a milestone for the Encore Accident Tolerant Fuel Program, an initiative started in 2012 and funded by the Department of Energy, aimed at increasing performance and safety of nuclear reactors in support of U.S. energy security and climate goals.

Commercial operation is expected by the early 2030s, the companies said.

The agreement is to build four AP300 SMRs in the North Teesside region of Northeast England. The region is experiencing industrial and economic development, which the companies say is driving increasing demand for carbon-free electricity. CNP is also working with strategic partners, including Jacobs and Interpath Advisory, to develop a fully licensed site for the project, with a target of 2027.

Westinghouse says the project is in accordance with the recently published UK Government Alternative Routes to Market for New Nuclear Projects consultation and complementary to the company’s participation in Great British Nuclear’s (GBN) SMR technology selection process.

“This project brings together Westinghouse’s proven technology and mature supply chain with our depth of expertise in nuclear program delivery, in a region that is transforming its industrial landscape,” said Paul Foster, Community Nuclear Power’s CEO. “We are delighted to be working with Westinghouse in support of private deployment in North Teesside.”

In May 2023, Westinghouse launched the AP300 small modular reactor, an SMR based on a large Generation III+ reactor already in operation globally, the AP1000 technology. Unlike every other SMR under development with first-of-a-kind technologies and risks, Westinghouse’s AP300 SMR utilizes the AP1000 engineering, components, and supply chain.

Under the MOU, the companies will seek to explore potential commercial opportunities for Westinghouse’s AP1000, AP300, and eVinci reactor technologies; investigate licensing and regulatory pathways for new nuclear projects in Canada; and examine other potential areas for collaboration in the new-build market.

The MOU signing took place in Paris at the World Nuclear Exhibition where companies and representatives from around the world were gathered to explore the latest innovations and opportunities to collaborate and shape the future of clean nuclear energy.

Nuclear’s Evolution is an educational track at the POWERGEN International® exhibition and summit, which serves as an education, business and networking hub for electricity generators, utilities, and solution providers engaged in power generation. Join us from January 23-25, 2024, in New Orleans, Louisiana!

To effectively decarbonize the broader economy, Ontario’s Independent Electricity System Operator says demand for clean, reliable baseload electricity will rise sharply in coming years and has called for almost 18,000 MW of new nuclear capacity by 2050.

OPG’s current work includes building North America’s first fleet of small modular reactors at its Darlington New Nuclear site. The company has just partnered with companies from Canada, the U.S., and France to ensure a fuel supply for the first unit of its four-unit project.

OPG already plans to develop the “first grid-scale SMR” in North America at the Darlington site, GE Hitachi’s BWRX-300 reactor. OPG is partnering with GEH, SNC-Lavalin, and Aecon on the project, and the first SMR is expected to be completed by the end of 2028, and online by the end of 2029

Subject to Canadian Nuclear Safety Commission (CNSC) regulatory approvals, the additional SMRs could come online between 2034 and 2036. The provincial government said OPG could take learnings from the construction of the first unit to deliver cost savings on the subsequent units. The four units once deployed would produce a total 1,200 MW of electricity.

Westinghouse recently got its first customer for the eVinci microreactor when the Saskatchewan Research Council (SRC) received $80 million to pursue the demonstration of a microreactor. SRC will apply the research and knowledge gained from the licensing and deployment of an initial microreactor to support the Saskatchewan nuclear industry to better understand this type of technology and the potential for future microreactor projects in the province. It is expected to be operational by 2029.

The company also just announced the full acquisition of its long-standing partner Tecnatom from Endesa after obtaining all regulatory approvals. The full acquisition of the Spanish company is meant to boost Westinghouse’s offerings in nuclear refueling, maintenance, inspection services, engineering, training, and digital services and products.

Westinghouse first acquired 50% of Tecnatom in 2021 and operated the company jointly with Endesa. Since then, Westinghouse and Tecnatom partnered in support of projects and commercial opportunities, particularly in inspection services, training and digital solutions. By acquiring the remaining 50%, Westinghouse can fully integrate Tecnatom’s resources, capabilities and products into Westinghouse.

Located in the borough of Etna, the eVinci “accelerator” is an 87,000 square-foot facility that will be home to engineering and licensing operations, testing, prototype trials, business development and sales. It also includes manufacturing space for producing the heat pipes that are central to the eVinci technology, as well as other components. Westinghouse construction on the space began earlier this year and will be completed in Q1 2024.

In June, Westinghouse established eVinci Technologies LLC as a separate business unit within the company to streamline all aspects of bringing the microreactor to the market.

Pennsylvania contributed economic development grants to the project as part of a state initiative to build innovation and grow jobs. The DOE continues to support the eVinci technology through its Nuclear Energy and Advanced Research Projects Agency (ARPA-e). With the federal awards and strategic government partnerships with Idaho National Laboratory and Los Alamos National Laboratory, Westinghouse is advancing the eVinci microreactor design, licensing and manufacturing capabilities.

eVinci Microreactor

The eVinci Microreactor is intended to bring carbon-free, safe and scalable energy where it is needed for a variety of applications, including electricity and heating for remote communities, universities, mining operations, industrial centers, data centers and defense facilities, and soon the lunar surface and beyond, Westinghouse said.

The eVinci microreactor has few moving parts, working essentially as a battery, which Westinghouse says provides the versatility for power systems ranging from several kilowatts to 5 MW of electricity, delivered 24 hours a day, 7 days a week for eight-plus years without refueling.

It can also produce high-temperature heat suitable for industrial applications including alternative fuel production such as hydrogen, and has the flexibility to balance renewable output. The technology is 100 percent factory-built and assembled before it is shipped in a container to any location.

Last year, Power Engineering visited the Westinghouse Waltz Mill site, which provides maintenance services, testing and calibration for nuclear reactor servicing equipment, as well as the research and development (R&D) facility for its eVinci nuclear microreactor.

The microreactor can generate 5 MW of electricity or 13 MW of heat from a 15 MW thermal core. Exhaust heat from the power conversion system can be used for district heating applications or low-temperature steam. eVinci could also be used in hydrogen production, maritime or industrial heat applications.

The core design of eVinci is built around a graphite core, with channels both for heat pipes and TRISO fuel pellets. Hundreds of passive in-core heat pipes are intended to increase system reliability and safety.

Westinghouse engineers laud the microreactor’s passive cooling design. There are no pumps to circulate water or gas. The reactor’s heat pipes replace the reactor coolant pump, reactor coolant system, primary coolant chemistry control and all associated auxiliary systems.

Pipes embedded in the core transfer heat from one end to the other, where it is captured in a heat exchanger. For cooling, each heat pipe contains a small amount of sodium liquid as the working fluid to move heat from the core and is fully encapsulated in a sealed pipe.

Because of the passive nature of eVinci, Westinghouse believes it would require only a small number of onsite personnel.

“If we’re sitting at a consistent power level, even [the control drums] are not moving, they’re stationary,” said Mike Valore, Westinghouse senior Advance Reactor Commercialization director. “The goal for eVinci,” he said, is to be “completely autonomous.”

The design is scaled from the AP1000 reactor and is based on what the company said is an “Nth-of-a-kind” operating plant.  

Westinghhouse said the AP300 SMR is an “ultra-compact, modular-constructed unit.” It will use identical AP1000 technology, to include major equipment, structural components, passive safety, fuel, and I&C systems. The reactor is expected to benefit from a mature supply chain, constructability lessons learned, fast load-follow capabilities and proven O&M procedures and best practices from 18 reactor years of AP1000 operations, a press release said. 

The AP300 is designed to operate for an 80+ year life cycle.  

The AP300 SMR design uses Gen III+ advanced technology, which has regulatory approval in the U.S., Great Britain and China, as well as compliance with European Utility Requirements standards for nuclear power plants. The company said the design will be marketed to the utility, oil & gas and industrial sectors. Design certification is anticipated by 2027, followed by site specific licensing and construction on the first unit toward the end of the decade. 

Westinghouse has named Dr. Rita Baranwal, currently Chief Technology Officer, to Senior Vice President in the Energy Services business, to lead the team developing the AP300 SMR. Baranwal is the former Assistant Secretary of Nuclear Energy at the U.S. Department of Energy, with experience as director of the Gateway for Accelerated Innovation in Nuclear (GAIN) initiative at Idaho National Lab.

Microreactor

In February, Westinghouse filed a Notice of Intent to submit licensing reports for its eVinci microreactor to the U.S. Nuclear Regulatory Commission (NRC) and the Canadian Nuclear Safety Commission for joint review. 

The two agencies signed a Memorandum of Cooperation in 2019 to facilitate such technical reviews of advanced nuclear technologies.

Last fall, we visited the Westinghouse research and development facility near Pittsburgh and produced this report on the technology and what we saw.

The report topics for joint review include a common set of key requirements for the classification of systems, structures and components for the eVinci microreactor. This approach is expected to enable deployment of a standard design in both countries. Other topics for review are defining the necessary transportation requirements for shipment of the eVinci microreactor across the border and factory safety testing and inspection programs.

The two agencies signed a Memorandum of Cooperation in 2019 to facilitate such technical reviews of advanced nuclear technologies.

Last fall, we visited the Westinghouse research and development facility near Pittsburgh and produced this report on the technology and what we saw.

The report topics for joint review include a common set of key requirements for the classification of systems, structures and components for the eVinci microreactor. This approach is expected to enable deployment of a standard design in both countries. Other topics for review are defining the necessary transportation requirements for shipment of the eVinci microreactor across the border and factory safety testing and inspection programs.

Westinghouse said the first two topical reports for formal NRC review were delivered in December, ahead of schedule. The topical reports are created in an effort to gain early NRC approval on critical aspects of the technology and design.

The eVinci Microreactor is designed to provide around 5 MW of electricity for more than eight years without refueling, and is expected to be factory built and assembled before it is shipped in a container.

Westinghouse was awarded a grant from the United Kingdom’s Department for Business, Energy and Industrial Strategy to support the development of advanced nuclear fuel.

The nuclear power giant is partnering with Urenco to complete a pre-front end engineering design (FEED) study regarding TRISO fuel production to support potential high-temperature gas-cooled reactors that are under development.

The work will occur at Westinghouse’s Springfields fuels facility in Preston, Lancashire.

“This award is an important step in creating commercial-scale advanced fuel production in the UK at our Springfields facility for the reactors of tomorrow,” said Patrick Fragman, Westinghouse President and CEO.

TRISO, or Tri-structural Isotropic, is made up of a poppy seed-sized carbon and oxygen fuel kernel. The kernel is encapsulated by three layers of carbon- and ceramic-based materials that prevent the release of radioactive fission products, according to the U.S. Department of Energy (DOE). The small kernels are considered to have very “robust” energy capabilities and be very flexible in application.

TRISO fuel is intended to be tough enough handle the higher operating temperatures of advanced reactors.

Westinghouse will also receive support on this study from TRISO-X, a subsidiary of X-energy. Maryland-based X-energy is working to develop its Xe-100 high-temperature gas-cooled reactor design and TRISO-X particle fuel.

X-energy now plans to try to license the reactor through the Nuclear Regulatory Commission (NRC). The goal is to have a unit operational by 2028, starting with a 320 MW four-unit Xe-100 power plant in Washington state.

X-energy also recently broke ground on a pilot-scale nuclear fuel facility at Oak Ridge to further develop its TRISO-X fuel and support the Xe-100 design.

The U.S. Department of Energy (DOE) said the fuel fabrication facility has the capacity to produce eight metric tons per year of TRISO pebble fuel, enough to power 12 of X-energy’s proposed Xe-100 SMRs. The facility would also be capable of manufacturing TRISO fuel for other advanced reactor designs. X-energy said it plans to double its fuel production by the 2030s.

Cameco and Brookfield Renewable Partners announced an agreement to acquire Westinghouse Electric for close to $7.9 billion, yet another sign of the increasing interest in nuclear.

The deal brings Westinghouse’s reactors under Cameco, one of the world’s largest suppliers of uranium fuel; and Brookfield Renewable, one of the world’s largest clean energy investors.

“Every credible net-zero pathway relies on significant growth in nuclear power,” said Mark Carney, Brookfield vice-chair and head of Transition Investing.

“We’re witnessing some of the best market fundamentals we’ve ever seen in the nuclear energy sector,” added Tim Gitzel, president and CEO of Cameco.

Westinghouse Electric emerged from Chapter 11 bankruptcy four years ago, and makes technology used in close to half of the world’s nuclear power plants.

The total enterprise value for Westinghouse is $7.875 billion. The company’s existing debt structure will remain in place, leaving an estimated $4.5 billion equity cost to the consortium, subject to closing adjustments.

Brookfield Renewable and its institutional partners will own a 51% interest in Westinghouse and Cameco will own 49%. The acquisition is expected to close in the second half of 2023 and is subject to closing conditions and approvals.

Nuclear power needs to play a significant role in helping meet net-zero goals globally, according to a June 2022 report by the International Energy Agency (IEA).

IEA says nuclear can reduce reliance on fossil fuels, cut carbon dioxide emissions and provide flexibility in energy systems that continue to integrate higher shares of renewables.

Push for a micro reactor

Westinghouse is currently developing the eVinci micro reactor and recently signed an agreement with the Canadian Nuclear Safety Commission initiating a technical design assessment for the technology.

The eVinci micro reactor could serve in several applications: Electricity and heating for remote communities and islands, industrial sites, data centers, universities, defense facilities, marine propulsion, hydrogen generation and water purification.

Westinghouse touts the micro reactor’s solid core and advanced heat pipes, which enable passive core heat extraction and allow for autonomous operation and load following capabilities. The reactor is designed to deliver combined heat and power – 5 MWe and up to 13MWt.

According to the company, other benefits of eVinci include an easily transportable generator; a 40-year design life with three-plus year refueling interval; and a target of less than 30 days of on-site installation.

Westinghouse signed supplier agreements with 22 companies allowing for cooperation on the potential construction of its AP1000 reactors in Poland.

The company previously announced MOU agreements with ten companies toward the same goal in January 2022.

Westinghouse is competing with France’s state-owned power company EDF and South Korea’s Korea Hydro and Nuclear Power to build Poland’s first nuclear power plant, according to Reuters.

The country wants to build 6-9 GW of nuclear capacity to reduce its carbon emissions and gradually phase out coal while remaining energy independent.

Reuters also reported that the U.S. recently made an offer on how the countries can cooperate on building nuclear energy projects in Poland. In 2021 the U.S. Trade and Development Agency provided a grant for Westinghouse and Bechtel to conduct a front-end engineering design (FEED) study for a nuclear plant in Poland using AP1000 reactors.

“The involvement of the Polish industry in the creation of the nuclear industry in the country and its first power plant is absolutely crucial,” said Mirosław Kowalik, President of Westinghouse Poland.

The memoranda announced Sept. 22 establish cooperation with the following companies:

Kersten Sp. z o.o. – world leader in bending steel and aluminum components.

Famur Famak S.A. – global supplier of complete bulk material handling and storage systems and individual machines.

Mostostal Puławy S.A. – company specializing in manufacturing and installation of steel structures.

Sefako S.A. – boiler manufacturer.

ZPUE S.A. – manufacturer of advanced solutions for the electric power industry, primary and secondary power distribution and generation equipment.

Grupa Powen-Wafapomop S.A. – manufacturer of pumps and services provider.

Emerson Automation Solutions – provider of technologies and services that help businesses measure, analyze, control, automate and optimize manufacturing, processing, and distribution

Monta Materials Handling Sp. z o.o. – company specializing in assemblies of industrial equipment and installations.

GL Steel Sp. z o.o. – installation, maintenance, and servicing of static devices.

Bureau Veritas Polska Sp. z o.o. – certification of systems, products and persons, technical assessments and inspections in various industries, certification of suppliers and technology and environmental assessments.

Prochem S.A. – design company, implementing industrial investments and public facilities. It also deals extensively with environmental protection. It specializes in the design and implementation of construction projects.

ZRE Katowice S.A. – comprehensive services for energy and industry. Modernization, design, production, repair, service, assembly, and diagnostics.

Energoprojekt Katowice S.A. – comprehensive service of investments in the field of design, consulting, expertise and technical analysis, construction supervision, and general contracting.

APS Energia S.A. – specialists in testing, inspection, and certification.

TÜV NORD Polska Sp. z o.o. – certification of systems, products, and persons, technical assessments and inspections in various industries, certification of suppliers and technology, and environmental assessments.

Izotechnik Sp z o.o. – manufacture and installation of equipment and entire industrial installations, as well as their repair and modernization.

Grafton Recruitment Sp. z o.o – recruitment company.

Bireta Professional Translations Sp.J. – translation services.

Ecol Sp. z o.o. – maintenance services for industrial machinery and equipment.

Mostostal Kraków Sp. z o.o. – provides services in the fabrication and assembly of steel structures and equipment installation.

Eaton Electric Sp. z o.o – manufacturer of devices and equipment that support electricity management.

ENEGOMONTAŻ-PÓŁNOC-BEŁCHATÓW S.A. – implementation of energy and industrial construction facilities.

The U.S. Nuclear Regulatory Commission (NRC) has renewed the operating license for Westinghouse’s Columbia Fuel Fabrication Facility in Hopkins, South Carolina.

The Columbia facility produces nuclear fuel for use in commercial nuclear reactors.

The action authorizes the facility to continue operating through Sept. 12, 2062. Renewal follows completion of NRC staff’s safety and environmental reviews of the facility. The final environmental recorded “small” impacts on most resources, and “small to moderate” impacts on groundwater and waste generation during decommissioning. Overall, staff did not identify new processes or technologies that might introduce new safety concerns.

The Columbia facility’s license was first issued by the Atomic Energy Commission in 1969 and was last renewed by the NRC in 2007.

The site houses fuel manufacturing facilities, product engineering and testing laboratories, as well as fuel marketing and contract administration. It covers 1,155 acres that include 550,000 square feet of manufacturing and office space.