Straight-chain halocarbon forming fluids for TRISO fuel kernel production – Tests with yttria-stabilized zirconia microspheres

Highlights: • YSZ TRISO kernels formed in three alternative, non-hazardous forming fluids. • Kernels characterized for size, shape, pore/grain size, density, and composition. • Bromotetradecane is suitable for further investigation with uranium-based precursor. - Abstract: Current methods of TRISO fuel kernel production in the United States use a sol–gel process with trichloroethylene (TCE) as the forming fluid. After contact with radioactive materials, the spent TCE becomes a mixed hazardous waste, and high costs are associated with its recycling or disposal. Reducing or eliminating this mixed waste stream would not only benefit the environment, but would also enhance the economics of kernel production. Previous research yielded three candidates for testing as alternatives to TCE: 1-bromotetradecane, 1-chlorooctadecane, and 1-iodododecane. This study considers the production of yttria-stabilized zirconia (YSZ) kernels in silicone oil and the three chosen alternative formation fluids, with subsequent characterization of the produced kernels and used forming fluid. Kernels formed in silicone oil and bromotetradecane were comparable to those produced by previous kernel production efforts, while those produced in chlorooctadecane and iodododecane experienced gelation issues leading to poor kernel formation and geometry