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Sphericity Control of UO₂ Fuel Kernels Through Gelling Media Coupling with Multi-Field Washing.

Laiyao Geng¹, Hui Jing², Yanli Zhao¹

¹State Key Laboratory of Advanced Nuclear Energy Technology, Nuclear Power Institute of China, Chengdu 610213, China.

Materials (Basel, Switzerland)

|May 4, 2026

Summary

Achieving high sphericity in nuclear fuel kernels is vital for advanced reactors. This study introduces a sol-gel method optimizing gelling and washing, significantly improving fuel kernel quality and manufacturing efficiency.

Keywords:

UO2 sphericity silicone oil sol–gel static washing

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Area of Science:

Nuclear Engineering
Materials Science
Chemical Engineering

Background:

Nuclear energy is key for energy security and carbon neutrality, demanding efficient and safe fuel elements.
Silicon carbide layers in coated fuel particles are validated for fission product retention in high-temperature reactors.
Precise sphericity of uranium dioxide (UO2) fuel kernels is essential for tristructural isotropic (TRISO) fuel performance and Generation IV reactors.

Purpose of the Study:

To develop a sphericity control strategy for large-sized UO2 fuel kernels using sol-gel processing.
To enhance tristructural isotropic (TRISO) fuel particle performance for advanced nuclear power plants.
To establish a theoretical and engineering basis for precision manufacturing of high-performance nuclear fuels.

Main Methods:

Integrated sol-gel processing with physicochemical regulation of gelling media.
Multi-field washing flow field optimization, including silicone oil-mediated interfacial tension gradient control.
Innovative three-phase sequential washing: kerosene washing, anhydrous ethanol interfacial transition, and ammonia solution replacement.

Main Results:

Achieved 99.8% kernel sphericity qualification, a significant improvement in quality.
Reduced washing solution consumption by 79%, enhancing process efficiency.
Attained an average sphericity of 1.03 for the fuel kernels.

Conclusions:

The integrated approach effectively suppresses gel sphere destabilization and revolutionizes microsphere washing.
Established a coupling mechanism between gelling media and washing processes, highlighting synergistic effects.
Provides a robust foundation for the precision manufacturing of advanced nuclear fuels.