United States Revives Shuttered Nuclear Plants to Meet Energy Demand

Newcleo has opened its EUR10 million (USD11 million) advanced nuclear fuel engineering, testing, and training center in Chusclan, located in the Gard department of southern France. This facility, named FASTER (Fuel process Assembly Storage Training and Enhanced Reality), is designed to support the development and manufacturing of mixed uranium/plutonium oxide (MOX) fuel for Newcleo's small modular lead-cooled fast reactors.

The FASTER facility provides advanced engineering, prototype testing, and immersive training capabilities for Newcleo’s fuel team, which consists of approximately 100 engineers and specialists. The center operates on a "test and learn" approach, translating concepts into prototypes and test mock-ups for refinement and industrial deployment. Seven test facilities are currently operational, with more under development.

MOX Fuel Manufacturing and Recycling

The facilities at FASTER address various stages of MOX fuel manufacturing, including powder dosing optimization, glovebox ergonomics, pellet handling, fuel pin assembly and decontamination, pellet inspection, and helium filling. Newcleo plans to fabricate MOX nuclear fuel, which is produced using a mixture of uranium and plutonium oxides, to power its lead-cooled fast reactors and potentially other third-party off-takers.

MOX fuel, when used in fast reactors, enables the multi-recycling of nuclear fuel in a closed fuel cycle. This circular approach aims to extract more energy from natural uranium compared to traditional once-through fuel cycles in thermal reactors, while also reducing the volume and radioactivity of nuclear waste.

Regulatory Submissions and Investment

In December 2024, Newcleo submitted its Safety Options File to the Autorité de Sûreté Nucléaire et de Radioprotection (ASNR) for its proposed mixed-oxide fuel assembly facility. The ASNR's official opinion on these safety options will contribute to the authorization application for the facility's construction. In July, ASNR issued an opinion on Newcleo's proposed safety features, deeming the company's safety approach satisfactory at that stage.

Newcleo intends to directly invest in a MOX plant to fuel its small modular lead-cooled fast reactors. The company has proposed deploying an advanced MOX fuel fabrication facility in the Aube department of France, near Nogent-sur-Seine, to manufacture fuel for its future European reactors. This project represents an initial investment of EUR1.8 billion (USD2.1 billion) and could eventually include three production lines. An additional investment of EUR3.2 billion by 2040 could enable the creation of two more lines.

Newcleo's roadmap includes the first non-nuclear precursor prototype of its lead-cooled fast neutron reactor being ready this year in Italy, with the first reactor operational in France as early as 2032. The final investment decision for the first commercial power plant is anticipated around 2029.

Uranium Procurement and Fuel Development

Bluecore Energy has acquired uranium hexafluoride (UF6) enriched to 4.95% U-235 from WMC. This material is currently stored at a U.S. nuclear fuel facility as Bluecore Energy develops its plans for future fuel fabrication, testing, and validation. This acquisition marks a step in transitioning the company's technology from engineering and non-fueled hardware development towards fuel-related processes and eventual deployment.

Regulatory and Classification Progress

The company is simultaneously developing its safety, regulatory, and maritime classification pathways. In August, Bluecore Energy initiated pre-application engagement with the U.S. Nuclear Regulatory Commission (NRC) under 10CFR50, presenting its design overview and regulatory strategy. The U.S. Coast Guard also participated in this meeting.

A memorandum of understanding (MOU) signed in June between the NRC and the U.S. Coast Guard establishes a framework for coordinating requirements and processes for civilian maritime nuclear projects. This MOU is crucial for addressing the lack of a specific regulatory framework for siting floating nuclear power plants in U.S. harbors, potentially streamlining regulatory processes where both agencies have jurisdiction.

In addition to U.S. regulatory compliance, Bluecore Energy is working with the American Bureau of Shipping (ABS) for marine vessel classification, hull structural integrity, and maritime engineering safety. The company emphasizes that its systems are designed for deployment on floating maritime platforms, offering flexibility for future operations in various maritime locations, including potential offshore deployments to support ports, AI data centers, and coastal infrastructure.

Reactor Design and Testing

Bluecore Energy's reactor is a 10 MW PWR that will utilize nuclear fuel enriched to 4.95% U-235. The company plans to deploy these reactors on multiple tethered floating barges, branded as the Nautilus Floating Nuclear Power Plant (FNPP). The reactor's primary coolant system operates at approximately 315°C (599°F) under high pressure, with the primary loop designed to isolate radioactive inventory. Heat rejection will use closed-circuit cooling systems that interface with maritime water loops or ambient heat sinks without releasing irradiated water.

A non-nuclear, non-fueled prototype hull and an electrically heated test pressure vessel are under construction at the company's headquarters in the Port of Long Beach. These prototypes will be used to test hydrodynamic water-flow behavior, sea-motion dynamics, and thermal hydraulics. The barges are designed to withstand harbor conditions, including wave action, tidal drift, seismic shocks, and collision risks, incorporating compartmentalized marine collision bulkheads and passive containment barriers. The entire nuclear island, turbine train, containment shell, and balance of plant are intended to be pre-integrated in a shipyard environment, bypassing traditional on-site civil concrete construction.