Development of an Initial UK National R & D Programme

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Development of an Initial UK National R & D Programme.

A PROPOSAL FOR DECC

NNL REFERENCE: 07003

Date: 30 August 2012

National Nuclear Laboratory Limited (Company number 3857752) Registered in England and Wales.

Registered office: 5th Floor, Chadwick House, Warrington Road, Birchwood Park, Warrington, WA3 6AE NNL Commercial

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Contents

Contents ...... 2

Executive Summary ...... 4

1. Introduction ...... 5

1.1. The National Nuclear Laboratory ...... 5

1.2. The Dalton Nuclear Institute at The University of Manchester ...... 7

2. Background to the Opportunity ...... 9

2.1. Placement of the work with the NNL and the Dalton Nuclear Institute at The University of Manchester (DNI) – “Sole Source Justification” ...... 9

3. Scope of Work ...... 14

3.1. Programme Area: Strategic Assessment...... 14

3.1.1. Objective ...... 14

3.1.2. Scope ...... 14

3.1.3. Facilities and People ...... 14

3.1.4. Output ...... 15

3.1.5. Urgency ...... 15

3.1.6. Leverage ...... 15

3.2. Programme Area: Fuels...... 17

3.2.1. Objective ...... 17

3.2.2. Scope ...... 17

3.2.3. Output ...... 18

3.2.4. Facilities and people ...... 18

3.2.5. Urgency ...... 19

3.2.6. Leverage ...... 19

3.3. Programme Area: Reactors...... 21

3.3.1. Objective ...... 21

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3.3.2. Scope ...... 21

3.3.3. Facilities and People ...... 21

3.3.4. Urgency ...... 22

3.3.5. Outputs ...... 22

3.3.6. Leverage ...... 23

3.4. Programme Area: Recycle...... 24

3.4.1. Objective ...... 24

3.4.2. Scope ...... 24

3.4.3. People and Facilities ...... 24

3.4.4. Urgency ...... 25

3.4.5. Output ...... 25

3.4.6. Leverage ...... 26

4. Our Delivery Team ...... 27

5. Proposal Deliverables ...... 30

6. Commercial ...... 31

6.1. Price ...... 31

6.2. Timescales and Invoicing ...... 31

6.3. Validity ...... 31

Table 1 – task 1 milestones ...... 32

Table 2 - task 2 Milestones ...... 32

Table 3 - task 3 Milestones ...... 33

Table 4 - task 4 Milestones ...... 33

Appendix 1 – Proposed Components of a National R&D Programme ...... 34

National Nuclear Laboratory Limited (Company number 3857752) Registered in England and Wales. Commercial-in-Confidence Registered office: 5th Floor, Chadwick House, Warrington Road, Birchwood Park, Warrington, WA3 6AE

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Executive Summary

The UK Government has made a commitment to reduce Our proposal offers:enables: greenhouse gas emissions by 80 % from 1990 levels by 2050. This may involve a significant expansion of nuclear StateLeverage of the of art power to as much as 75 GWe beyond 2050. In order to facilities.international R&D maintain the option to deliver such a strategy, a significant funds. national R & D programme will be required to underpin future Provides the energy decisions. It is anticipated that such a national opportunityAccess to over for 11,000 programme would be developed by the Government’s leverageyears of experienceof European recently-established Research Advisory Board, and will be in andwhilst UK using Research state of line with the UK’s future energy policy, and may include key Councilthe art facilities.funds. programme areas are set out in Appendix 1. SustainsSkills maintenance existing skills. in Prior to this national R&D programme being fully established, areas where industrial there is a requirement to carry out some preliminary R&D to programmesUnderpins gaps are within no underpin gaps associated with higher energy scenarios (i.e. longerexisting in scenarios. place. up to 75 GWe) together with maintaining key R&D skill base areas in the short term where no other funding is in place to UnderpinningUtilises consortiums of gaps sustain this. withinexisting existing extensive energy scenarios.networks of To address this short term requirement, the NNL together interactions across the with the Dalton Nuclear Institute at The University of UKA “Hub and andEuropean Spoke” Manchester (DNI), propose to lead an initial R&D nuclearapproach industry. to create and programme which will address these issues. The sustain strategic consortium led by the NNL believes that there is an urgent relationshipsOver 11,000 yearsessential of requirement to commence a programme of work on fission forcombined R&D across experience. the fuel research and development. An Executive Steering Group cycle. Detailed programme to will be established, made up of industry experts. The results support individual of the work will be shared with this group and will be widely Talent creation using programme areas. published. extensive consortium experience and Use of existing “Hub The following proposal presents the key elements of this enabling the skills and Spoke” model will initial programme together with our understanding on why pipeline of bringing create strategic the work should be carried out at this time and why our young talent into relationships across the consortium will provide the best value. industry. UK nuclear industry. This initial programme is based on four main areas : Executive Steering GroupExtensive to advise experience and of Strategic Assessment. directconsortium strategy facilitating Fuels. enabling young talent Reactors. Availability/into industrial Recycle. transparencyplacements. of results

Details of the individual programme areas are provided in Section 3.

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1. Introduction

1.1. The National Nuclear Laboratory

On July 23rd 2008 the UK Secretary of State for Business Enterprise and Regulatory Reform announced the establishment of a National Nuclear Laboratory (NNL) bringing together a world-class nuclear research capability operating as a Government-owned, and contractor-operated business. NNL was established out of the former BNFL Nuclear Sciences and Technology Services, which in turn was formed from the Research and Technology division of BNFL and encompassed the Research and Technology activities of BNFL, Magnox Electric and the Nuclear Science business of AEA Technology. The National Nuclear Laboratory is therefore able to offer a range of technical skills that is representative of this pedigree.

The National Nuclear Laboratory is a unique resource constituting the bulk of the UK’s remaining national nuclear research capability and all of the civil nuclear research facilities. The company comprises approximately 650 highly qualified staff based at six locations around the United Kingdom, operates both active and non-active research facilities and provides specialist technical and consulting services to a range of UK and overseas customers including the IAEA, Department of Energy and Climate Change (DECC), Nuclear Decommissioning Authority (NDA), MoD, UKAEA, EdF, Magnox Electric Ltd, Sellafield Ltd and other commercial organisations.

The National Nuclear Laboratory provides a range of independent technology services to support operating nuclear plants as well as decommissioning and clean-up activities and scientific research organisations. These services include the ability to accommodate and conduct both active and inactive work at its facilities.

The mission that has been set for the NNL includes the following:

To become an international centre of excellence in nuclear research and development, playing a vital role in cleaning up the UK's nuclear waste legacy and contributing to the programme of nuclear new build. To create a platform for UK and internationally funded R&D; To safeguard the UK's high-tech nuclear expertise, facilities and skills. To support the UK’s strategic nuclear research and development requirements; To operate world class facilities that underpin nuclear research undertaken by UK and international customers; To safeguard and enhance key skills that are essential to deliver the UK’s nuclear policy;

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To deliver value for customers through the provision of first class science-based research and technical solutions; To spin out commercial operations to assist in the development of the market for the provision of nuclear research; The National Nuclear Laboratory operates an Integrated Management System which is accredited to both ISO9001:2008 and ISO14001:2004 as well as the security management standard ISO 27001:2005.

The NNL is very proud of its safety performance, for which we have been awarded the Royal Society for the Protection of Accidents (ROSPA) R&D sector award for Occupational Health and Safety excellence for five successive years, an unprecedented feat. The ROSPA Sector Awards identify and reward the best health and safety performance in each industrial category. In order to win these awards we have demonstrated that we have maintained consistently excellent or continuously improving health and safety performance and approaches to health and safety management.

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1.2. The Dalton Nuclear Institute at The University of Manchester

The Dalton Nuclear Institute at The University of Manchester is internationally renowned for its nuclear research capability, skills development programmes and strategic links with the nuclear sector. Its mission is to address the urgent skills and research needs associated with low carbon emissions and secure nuclear energy for the benefit of society both now and in the future. This encompasses reactor operations, nuclear fuel cycles, nuclear new build, nuclear safety, non- proliferation, decommissioning and radioactive waste management, with Institute staff providing expertise around the world. The Institute is strategically important to the UK and its international partners and works across three primary areas that comprise the development of research and development (R&D), a skilled workforce, and socio-economic impact. In 2012 the Dalton Nuclear Institute received a Diamond Jubilee Queen’s Anniversary Prize for its ‘internationally- renowned research and skills training for the nuclear industry’. The Prizes are awarded biennially, as part of the honours system, to UK universities and colleges in respect of innovative work of outstanding quality which is producing transformational impact and benefits. It is the highest form of national recognition for work done by higher and further education sectors.

The Institute has enabled a significant and positive change to the national and international nuclear landscape across three primary areas:

Leading-edge nuclear research capability and capacity have increased, leading to new knowledge and leading-edge technology that enable challenging nuclear issues to be addressed.

Skills development programmes have been launched resulting in hundreds of students developing knowledge of nuclear science and engineering.

Socio-economic development through collaboration leading to an increase in human capital, an expansion in knowledge transfer, and input to public policy.

With over ninety academic staff engaged in nuclear research, 150 PhD students and fifty post doctoral researchers, the Dalton Nuclear Institute is playing a leading role in establishing a nuclear research capability that is able to address nuclear research challenges. This has meant attracting internationally leading experts to the University, training younger staff with nuclear interests, and expanding nuclear research facilities such as the £20M Dalton Cumbrian Facility near Sellafield. Our research turnover has grown by a factor of five over the previous six years, the number of nuclear publications increased by over 60%, and we have achieved the highest impact of nuclear publications globally and stimulated over 15 long-term collaborations with industry and academia. The Institute has attracted leading nuclear researchers to the University and has built major research facilities to target research on the most challenging nuclear

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issues. DNI collaborates with universities and industry to establish a national nuclear capability that is increasingly sought out by international players for partnership, research and skills development. Technology transfer has facilitated the application of new understanding to address nuclear issues of safety, security and radioactive waste management.

The Institute has played a leading role in establishing new undergraduate, postgraduate and Continual Professional Development (CPD) programmes to meet the nuclear skills challenge. DNI provides an ever-increasing flow of graduates into the nuclear sector and a major growth in strategic collaborations with nuclear stakeholders and the immediate supply chain. We established a broad range of nuclear programmes that encompass outreach to widen participation, undergraduate teaching and postgraduate research to enable hundreds of students to develop their scientific and engineering skills, and CPD modules that enable career development in the nuclear industry.

The Institute has played a leading role in engaging strategically with nuclear stakeholders in the UK and overseas to help realise the economic benefit of nuclear through skills development, research collaboration, and technology transfer in areas such as fuel design, manufacturing technology, materials performance, nuclear security, nuclear facility decommissioning and radioactive waste management. We have provided expert advice to government, the regulator, and industry to help shape public policy, maintain the safety of nuclear plant, and focus public/private R&D and knowledge transfer. The Institute is a partner with the Battelle Memorial Institute and Serco in the National Nuclear Laboratory (NNL) management consortium and is an integral part of Britain’s Energy Coast plan.

In addition, the Institute has been engaged in public policy development, expert consultancy and studies by learned societies, delivering independent, authoritative advice on nuclear matters. We engage with large companies, as well as small and medium-sized enterprises, in order to transfer our knowledge and know-how and this has facilitated economic growth. We provide the portal for academics to access the new NNL nuclear research facilities in West Cumbria and this is contributing to the socio-economic development of the region through the Britain’s Energy Coast plan.

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2. Background to the Opportunity

The UK Government has made a commitment to reduce greenhouse gas emissions by at least 80% on 1990 levels by 2050. One of the ways in which this commitment could be met is through a significant expansion of the role of nuclear power in meeting energy needs. A range of scenarios have been postulated which include expanding nuclear energy generating capacity to up to 75 GWe (compared to the current nuclear generating capacity of about 10 GWe). An expansion which goes beyond the immediate target of 16 GWe is likely to require a significant change in nuclear strategy. For example a sustainable approach to deliver a larger nuclear generating capacity is unlikely to rely solely on Light Water Reactors operating an open fuel cycle. It is likely to involve some use of fuel recycling and the construction and operation of fast reactors.

In order to deliver a sustainable expansion in nuclear generating capacity to (for example) 40 GWe or more by the year 2050 it would be necessary to initiate a national R&D programme. Appendix 1 presents a summary of the main components which are likely to need to be incorporated into a comprehensive national programme. It is anticipated that such a national programme would be developed by the Government’s recently-established Research Advisory Board, once Government has updated its nuclear strategy. However there are a series of specific circumstances in which a case can be made to commission a limited scope of R&D before the Research Advisory Board has reached its full conclusions.

2.1. Placement of the work with the NNL and the Dalton Nuclear Institute at The University of Manchester (DNI) – “Sole Source Justification”

To address this policy initiative the NNL and the Dalton Nuclear Institute at The University of Manchester (DNI) propose to jointly lead this work programme which will provide an understanding of the challenges facing a high level scenario of 75 GW. This consortium approach will bring in experts from other UK universities and centres of nuclear R&D excellence and will aim to establish collaboration opportunities with international organisations with whom NNL and DNI have existing links. The consortium will seek synergies with existing, associated R&D programmes and hence ensure that the benefits to the UK programme are maximised. The proposal utilises NNL and DNI facilities and draws on the benefits of the University access agreement to NNL’s active facilities.

There is an urgent requirement to commence a programme of work on fission research and development. A national UK R & D programme is required to support the decision on credible options for nuclear energy scenarios. In the short term underpinning is required for the roadmap and other UK Government requirements. A combined approach using an NNL / DNI consortium provides the only option to deliver the first component of a national R & D programme, and is achievable in the short term.

The rationale for DECC to chose this contracting route is detailed below against the three categories of urgency of requirement, rationale for short term solution and rationale for using NNL/ DNI as the only credible provider.

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Urgency: -

Leverage of available funding: There are a number of European and UK Research Council funding grants that are available this financial year. The NNL and DNI have an intimate knowledge of the funding mechanism which is typically based on a three year cycle. An inability to secure applications in the current financial year will result the loss of opportunity in this current funding cycle. The ability to provide leverage into these programmes will enable the UK to ensure maximum value for money through a significant increase in gearing of any funding obtained, and this is detailed in each of the summary sections of the appended programme documents. It is estimated that leveraged funding to two or three times the value may be achieved.

Skills maintenance: There is an urgent need to sustain existing skills which may be at risk in the short term as a result of other R&D being curtailed. With the closure of the Sellafield MOX Plant (SMP) those skills associated with its technical and manufacturing capability will be lost. There is clearly a short term need to sustain skills specifically in relation to fuel manufacture and performance, as this will form a fundamental part of any UK led advanced fuel R & D programme. Primarily this work is based on an overall skills maintenance programme, it should be noted that there will be an urgent requirement to incorporate post doctoral experience at an early stage in this process.

New Fuel Cycle Facilities Return on Investment: The NNL and DNI have an extensive portfolio of facilities which are used to support the fuel cycle for its UK and export customers. The availability of these facilities will see a return on investment in the very short term by providing short term support to commercially funded work and support to the longer term development needs of the UK. The facilities, any enhancements to them made as part of this project will facilitate significant improvements in the progress of future programmes.

Short term solution:-

Initial Programme Required: This will support short term strategy work and shape the requirements for a future long term programme. The NNL and DNI have taken the opportunity to provide more extensive details of each programme area below. These details address the objectives of each area, identify the scope of the work to be carried out and provide the inputs and outputs of each. An estimate of costs and the likely leverage is also included. Roadmap: This programme will fill gaps within the existing scenarios within the UK Government Roadmap. Given the time needed to establish the programme and the urgent need to put in place the necessary requirements, the NNL and DNI have established a partnership that will set out a new national nuclear R&D programme, deliver the initial (urgent) phase of work, and facilitate procurement of the longer-term programme.

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Existing networks: The consortium will draw on existing experience and knowledge through current networks. The NNL as part of the former BNFL Group of companies can demonstrate an extensive series of networks across the UK and worldwide, and its management company which incorporates the U.S. based Battelle, can facilitate “reach back” into the USA. This approach will enable the immediate access to an extensive portfolio of existing programmes of work and key expertise, whilst leveraging existing funds to enhance value. The outcomes of the work will be published and made widely available.

The programme will provide the flexibility to deal with different mechanisms for leverage and this will be addressed at the individual programme level.

One feasible provider:-

Hub and Spoke model: The consortium will use a hub and spoke model to enable access to the full spectrum of fuel cycle R & D both nationally and internationally; whilst providing a clear route for contracting and engagement. The consortium has operated this model successfully for a number of years and used it to create strategic relationships, for example the NNL has used this model in its work with NDA on University interactions which provide extensive strategic and supportive links. This has enabled the integration of key industrial and academic organisations with the right skills and expertise to solve specific nuclear industry challenges. Additionally, we have experience in creating and running centres of excellence through industrialised operations and through this initial work we can provide an insight into how the programmes will be run, managed and coordinated.

To facilitate the promulgation of the outcomes of this work an Executive Steering Group will manage the strategic direction of the work. The work packages presented have been developed to provide a short term response to existing needs, as the process develops the Steering Group will assess the direction, and value provided by the outcomes of the work. The group is likely to be drawn up from industry experts such as EdF, AMEC, The Research Advisory Board, DECC, the EPSRC Nuclear Champion, as well as representatives of the NNL and the University of Manchester.

Joint Appointments: NNL and the University of Manchester have created a number of academic / laboratory joint appointments which bring an integrated approach to solving site and national fuel cycle challenges. This forms a unique combination of expertise in both technical consultancy and research and development that provides an ideal basis to provide support to this work. With our supportive research at a number of universities we have an extensive track record of enabling young talent to gain experience on key industry challenges with a view to creating a pipeline of talent into industry.

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This has been facilitated by the procurement of placements at a number of Universities around the UK, and has included work in our own facilities.

Joint Investment: NNL and DNI are creating opportunities through the Britain’s Energy Coast. A joint investment programme in place already where the NNL and DNI are leveraging existing funds to create new innovative technologies.

Experience: NNL and DCI bring a combined 11,000 man-years of experience across the programme areas covering both breadth and depth of expertise and ranging from academic underpinning to applied development. Our partnership covers fundamental research prior to industrial deployment covering the totality of the TRL levels. We have experience of supporting the industrialised and commercial operations of all aspects of the fuel cycle, this has included adding significant value to existing technical processes to establish better operational efficiencies, which has include work on commercial recycle operations e.g. THORP flowsheet on the Sellafield site, and the technical underpinning of SMP fuel manufacturing operations.

National Facilities: The concept of establishing a National User Facility is at the core of this programme and we can enhance the benefits of this concept with the UK R&D programme. We can offer a suite of experimental facilities and these provide unique capabilities in the U.K. Through a combination of our facilities we will be able to access laboratories to carry out priority R&D which will enhance the return on investment.

The NNL offers a unique and comprehensive range of experimental facilities including caves or hot cells which are used to handle highly radioactive materials such as whole irradiated fuel assemblies. Some of the facilities offer capabilities which are unique in the UK. The facilities available from the NNL include:

- The Central Laboratory, situated on the Sellafield licensed site, is the nucleus of a world leading research and development complex, providing the complete range of facilities to support all disciplines and radioactive levels of nuclear research. These include a suite of gloveboxes which are unique in the UK civil sector and are used to safely carry out research on the separation and recycle of plutonium and minor actinides. The central laboratory also includes a separate alpha suite which contains equipment necessary to produce mixed oxide fuel powders and to fabricate these into fuel pellets and fuel pins.

- The NNL Preston Laboratory is a purpose built state-of-the-art nuclear research facility, situated on the Springfields licensed site, designed to service the needs of businesses in low-activity uranium research and development. The Preston Laboratory incorporates a range of uranium-active facilities including specialist equipment

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required not only to produce the uranium oxide powders required for fuel manufacture, but also to manufacture and carry out all of the necessary Quality Assurance measurements on uranium oxide fuel pellets.

The University of Manchester, Dalton Cumbrian Facility (DCF) is a state of the art complex for the Dalton Nuclear Institute where academia and industry from the UK and overseas can carry out world-leading research and deliver dedicated skills development programmes. DCF provides universities and industry from the UK and overseas with a facility designed to support research and knowledge transfer in the areas of radiation chemistry, physics and radiation damage to materials, nuclear engineering decommissioning and the management of radioactive waste.

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3. Scope of Work

3.1. Programme Area: Strategic Assessment.

3.1.1. Objective

The primary objective of this programme area will be to evaluate the use of a range of reactor systems and associated fuel cycles to determine which are most suited to meeting the UK’s strategic needs. The programme will consider energy security, sustainability, meeting future greenhouse gas emissions targets, for example, amongst others in a 75 GWe scenario. It will provide underpinning information regarding systems and fuel cycles for the subsequent definition of assumptions and scenarios required to underpin a DECC roadmap.

These scenarios are anticipated to compare both low and high generating capacity scenarios and would enable the selection of a limited number of fuel cycles and advanced reactor systems of interest with clearly understood reasons on why these systems could be selected and why others can be rejected. Future work on scenarios can progress with a sound basis for down selection. The UK needs a consistent set of objectives for the nuclear fleet (for example, 75 GWe capacity, sustainable, role beyond electricity). To define fuel cycles which will achieve these objectives, it will be necessary to develop a fuel cycle model for this scenario. Defining a consistent, agreed methodology for these assessments and applying it fairly to all systems is imperative.

3.1.2. Scope

Many candidate future reactor designs and fuel cycles have been proposed and it is important to have high quality information in relation to which of these systems and fuel cycles are most likely to meet the objectives of this work.

The scope will involve the development and implementation of the necessary framework and methodologies needed to assess new nuclear energy technologies and fuel cycle technologies against economic, environmental, proliferation resistance, safety and sustainability factors. The associated fuel cycle facilities will be assessed with a view to specifying recovery and separation targets from fuel recycle and measure the effects of variation of these targets on: the repository (GDF); reactor sustainability and economics of recycle. The fuel cycle assessment will also specify the range and type of facilities which will be required to implement a sustainable nuclear fuel cycle from 2050 onwards.

3.1.3. Facilities and People

Strategic assessment will use existing capability from within the consortium and utilise the output developed by NNL on previous road mapping exercises.

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3.1.4. Output

The output of this programme area will be a report detailing the basis of the technologies, the criteria under which selection can be made and clear statements as to the benefits offered with respect to the strategic criteria.

This enhanced understanding can then be used to define the technology in the scenarios needed to underpin the DECC road mapping exercise by:

Analysing the tipping point(s) where the UK moves from an open to a closed fuel cycle.

Providing a definition of criteria to assess nuclear energy technologies suitable for a range of generating scenarios between 16 and 75 GWe within 3 months of contract initiation.

Assessing nuclear energy technologies against generation, recovery and separation targets from fuel recycle and measuring the effects of variation of these targets on: the repository (GDF); reactor sustainability and economics of recycle, environmental, proliferation resistance and safety factors.

The outcomes of the work will be published in journals and on web sites, as appropriate and will be provided to DECC, to the Research Advisory Board and to members of the Steering Group.

3.1.5. Urgency

Strategic assessment will drive the whole programme scope and will provide an important input to defining the long term R&D programme and will build on current road mapping activities. The overall benefit will be to underpin UK strategic studies on the deployment of Gen IV systems by: fully developing the technology assumptions which underpin the scenarios used for the UK Nuclear Fission Technology Roadmap; determining the impact on GDF footprint; determining the effect of phase-out strategies and clarifying the technical performance specifications for a Gen IV system for the UK.

3.1.6. Leverage

It is envisaged that this task will build on current work and compliment other studies. A number of fuel cycle scenarios have been modelled for an earlier R&D road mapping exercise. The results generated within this programme will supplement those earlier scenarios and will feed into both the drafting of the current R&D Roadmap, which is being produced for the Research Advisory Board and the redrafting of the Government’s nuclear strategy. Although the primary focus will be on the quantification of one or more fuel cycle scenarios it will also take into account the work reported by the Smith School of Enterprise and the

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Environment at the University of Oxford [1,2], which carried out economic assessments of the use of nuclear materials in fuel. This work noted that a window of opportunity exists to determine the UK’s strategic approach to how its stockpiles of separated plutonium, uranium and un-reprocessed spent fuel might be managed within the context of a new-build programme. A main conclusion of the work was that the current structure of the UK nuclear industry, which has been designed to address the rundown of nuclear power in the UK, is not necessarily well suited to a situation involving new nuclear build and an expanded UK nuclear generating capacity. It is also clear that, in the UK, there is now an opportunity to develop an holistic approach to nuclear power - combining the assessment of backend legacy materials with the opportunities offered by new- build development. The intention is to engage Professor Gregg Butler, one of the main authors of the Smith School reports, in this part of the programme.

A key challenge facing the UK is to seize the opportunity, to maximise value for the UK, create jobs, reduce proliferation risk, reduce carbon emissions, increase energy security, and address the long term management of nuclear materials and spent nuclear fuel. This R & D programme will generate information which can be used to inform strategy development and support those aims.

1 A low carbon nuclear future: Economic assessment of nuclear materials and spent nuclear fuel management in the UK, Smith School of Enterprise and the Environment, University of Oxford, March 2011

2 Towards a low carbon pathway for the UK, Smith School of Enterprise and the Environment, University of Oxford, March 2012

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3.2. Programme Area: Fuels.

3.2.1. Objective

Work on plutonium (Pu) based fuel technology is currently not supported by the existing UK commercial infrastructure and R&D is no longer carried out industrially at the Sellafield site following the recent closure of the Sellafield MOX Plant. Consequently the availability of important skills in MOX fuel fabrication are in jeopardy. Pu based fuels in the form of MOX are likely to be the basis for a sustainable fuel cycle beyond the 16GWe scenario, and therefore in order to retain knowledge and understanding of these scenarios and their implications, the skills in Pu fuel fabrication technology and fuel performance are desperately required to be retained.

A secondary aspect of this work is to engage with a potentially influential European Framework programme, which will provide significant leverage in the fundamental understanding of fuel behaviour and whilst this work is provided on a competitive basis, the UK's involvement is currently open to the NNL for a limited time only.

3.2.2. Scope

A state of the art review and technology readiness level assessment of advanced fuels, cladding and associated manufacturing technology, for use in new build and fast reactor programmes, will be undertaken. The review will assess evolutionary new build fuels, Generation III fuels and advanced Generation IV fuels.

The most common fuel type currently used is based on low enriched uranium dioxide and the associated industrial fuel manufacturing processes currently operate in standard oxygen content environments. However, some innovative fuels require fabrication in low oxygen environments. Such fabrication techniques give a greater scope for development of fuels to achieve transmutation or proliferation resistant recycle flowsheets or for fast or Small Modular Reactors (SMR). As there are no proven fuel fabrication flow sheets available to make low oxygen fuel, an initial comparison of contrasting fuel production processes will be prepared. The work will complement existing EU funded programmes researching carbide and nitride fuel fabrication (ASGARD and GoFastR), in which the NNL is already involved. Preparation for initial R&D towards underpinning these flow sheets with practical trials will also facilitate industrially funded opportunities to make low oxygen content test fuel (e.g. test fuel for lead cooled research reactors).

The [text redacted] FP7 programme relates to safety research for the Generation IV prototype Astrid. This provides a valuable opportunity to assess fuel properties with respect to reactor safety performance and focus experimental work on properties of greatest impact, such as the margin to melt of fuel and the risk of clad failure. This programme was recently evaluated very highly in most respects by the European Commission, but has not been supported as a result of a single, fairly minor technicality. This single issue can easily be addressed and it is proposed that the project proposal should be resubmitted with amendments to

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address the outstanding issue in the final Framework 7 call which will close in November 2012.

3.2.3. Output

Output from this work package will be in the form of a series of reports. Technology Readiness Level assessment of advanced fuels, cladding and associated manufacturing technology.

Assessment of the manufacturing QA techniques required for evolutionary and revolutionary fuel in terms of quality assurance, operational dose, technology maturity, throughput, and cost.

Exploratory flow sheets for innovative fuel.

Confirmation on NNL participation in a resubmitted [text redacted] FP7 project.

The outcomes of the work will be published in journals and on web sites, as appropriate, and will be provided to DECC, to the Research Advisory Board and to members of the Steering Group.

3.2.4. Facilities and people

The NNL and DNI consortium have the existing facilities to undertake R&D in fuel technology, although skills in this area are a key risk due to lack of current UK programmes.

Following closure of SMP, the NNL operates the only UK facilities capable of developing both Uranium and Plutonium active test fuels for reactor scale test irradiations. Further, the NNL Central Laboratory experimental capabilities enable the integration of recycle and fuel fabrication technology to underpin the various Pu disposition options possible for the UK stockpile, including options to burn Pu as MOX fuel within a sustainable fuel cycle. The NNL Fuel Manufacturing Facility at Preston is also able to produce and characterise pilot-scale quantities of U- bearing fuels. As an example of disappearing resources, the NNL is currently in the process of securing strategic items of plant used in the research and development of MOX fuels, which are currently in the ownership of Sellafield Limited. Overall, this work will provide a short term programme which will ensure that the option remains available to develop a longer term strategy. Without the proposed work much of this skill base and equipment will be lost and the time and cost required to re-establish the capability would increase substantially.

There is also a Third Party Access Agreement which provides a means for academic access to the Central Laboratory thus enabling University led research and development programmes to link with fundamental research undertaken at DNI facilities.

NNL has expertise at risk associated with Pu based fuel manufacture totalling [text redacted]. SL has further related expertise in MOX manufacture totalling

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around 3 key experts. Dalton Nuclear Institute has a number of key individual experts in fuel technology and programmes of research work which will provide input.

It is proposed that a leading specialist in powder handling at the University of Leeds will be engaged in the delivery of this part of the programme.

The programme will make use of the powder preparation facilities available at the NNL Preston Laboratory, which have previously been used in SMP support programmes.

3.2.5. Urgency

This work is urgently required in order to retain UK expertise in MOX fuel technology and fuel performance following closure of the Sellafield MOX Plant. MOX fuel fabrication and performance skills in the UK (NNL and SL) are otherwise likely to be redeployed leading to fragmentation and dispersal of these skills and it may take around 10 years to subsequently develop equivalent subject matter experts.

There is also an opportunity to engage with proposed European Framework R&D programmes (e.g. [text redacted]) which are open to UK involvement for a limited time in the current 3 year EU funding round. This opportunity offers significant leverage in the area of fundamental understanding of fuel behaviour.

3.2.6. Leverage

This programme will engage with proposed and existing internationally funded R&D programmes and commercially funded projects. The benefits of engagement include leverage of new technology developments, IP from experimental programmes, knowledge retention, skills development and commercially funded commissioning of R&D facilities.

Leverage opportunities in fuels include:

EU funded GoFastR and ASGARD programmes (total programme value of around £10M, UK involvement estimated at £1M ) in which the NNL is currently a participant.

US lab, Next Generation Nuclear Plant (NGNP) projects (accident resilient and advanced fuels) funded by USDoE (total programme value is estimated at $10 Millions, no direct UK involvement). Idaho National Laboratory have expressed an interest in UK involvement if we have a relevant R&D programme to engage with.

World Nuclear Association fuel technology working group (NNL involvement through 1 key expert).

NNL’s self funded R&D programme in fuels associated with revolutionary fuel and cladding technology (estimated at £200K).

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Leverage into these programmes will enable collaboration with UK universities on fuels including Imperial, UoM and EU joint research centres in France, Germany, Holland, Sweden, Switzerland, Romania and Poland. Participation in the existing projects ensures access to data which will enable this programme to be completed more quickly and at much lower cost to DECC than would otherwise be possible.

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3.3. Programme Area: Reactors.

3.3.1. Objective

The primary objective of this work is to ensure that the R&D skills and capabilities are in place to underpin the evaluation of potential future UK exploitation of advanced reactor system technologies, including Generation-IV systems and advanced Light Water Reactors including small and modular reactors (SMRs). This work is also important for current UK light water reactor requirements, including the need to ensure the continuing safe operation of existing reactor plant including, where appropriate, life-time extension; and the licensing and operation of new build systems such as the EPR. The aim will be to meet these objectives by leveraging access to existing and planned new EU and international research programmes on Gen-IV and SMRs in order to maximise the value of the research investment.

3.3.2. Scope

The work will be conducted in the thematic areas already identified by the international Gen-IV programme, namely: Materials, Analytical Methods, Safety, System Integration, and Fuel and Fuel Cycle (although this latter theme will largely be covered by the Fuels Programme Area). The Gen-IV programme has identified six candidate reactor systems, all of which are currently the subject of varying levels of international research interest, although most countries focus their efforts onto the development of two or three of these systems. The UK has previously been active in the Gen-IV programme (broadly from 2000-2006), and identified three priority systems for UK interest: the Sodium Fast Reactor (SFR), the Very High Temperature Reactor (VHTR) and, to a lesser extent, the Gas- cooled Fast Reactor (GFR). One key aspect of the proposed programme will be to critically review the basis for the selection of the priority systems for the UK, in order to ensure that the available research resources are focused on technology areas best match the longer-term needs of the country. In addition to these Gen- IV systems, a modest effort will be directed towards investigating the potential for SMRs to offer benefits to the UK infrastructure. This study will be conducted with a view to establishing the extent to which such systems may be attractive to the UK, and the corresponding research needs to support any future deployment.

3.3.3. Facilities and People

The University of Manchester’s Dalton Nuclear Institute and the NNL, together with key collaborators from across UK industry and academia, are able to offer unrivalled capabilities to deliver the proposed research programme. Some examples of key facilities are:

The Dalton Cumbria Facility (ion-beam and gamma irradiation; materials characterisation).

The Nuclear Manufacturing Technology Research Laboratory (laser joining and cutting; electro-discharge machining, TIG and hybrid welding and

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cladding, high-temperature creep and creep-fatigue testing, refreshed autoclave testing under PWR and gas-cooled primary circuit conditions).

Active Fuels and Graphite Laboratories (equipped with state-of-the-art thermo-physical and thermo-chemical characterisation equipment, and able to handle low active irradiated samples).

Materials Science Centre (extensive suite of advanced electron-optic instruments including TEMs, FEG-SEMs. environmental SEM, FIBs, x-ray tomography, residual stress measurement, and materials properties characterisation for complete material characterisation and in-situ testing/analysis).

Thermal-hydraulic testing capabilities (a wide range of flow test loops).

NNL facilities for the examination of irradiated materials.

These facilities are complemented by formidable expertise across a range of disciplines crucial to the delivery of a Reactor Technology programme, including expertise in: core physics and thermal-hydraulics, coolant chemistry, radiation damage, nuclear fuel, cladding and coatings, structural integrity, materials characterisation and testing, corrosion, and nuclear manufacturing.

This programme will result in an increase in the skill base in this area through the recruitment of Post Doctoral Researchers at the University of Manchester. It will also contribute to the continued use of specialist powder handling and pellet production facilities at the NNL Preston Lab.

3.3.4. Urgency

As already highlighted, opportunities for participation in new EU and international research programmes are foreseen over the next 6-9 months. Such opportunities (including opportunities from Research Councils) are, at best, periodic, and may not occur again for another 2-3 years. In order to maximise the opportunity to leverage research funding, it would be opportune to launch proposals for new programmes over the next 6 months, such that funding can be secured from current budgetary provisions.

Maintenance of existing UK expertise in the area of reactor systems technology is also a key consideration. Several internationally-leading experts are approaching retirement over the next several years, and the availability of a modest forward programme would offer a timely opportunity to capture their knowledge and to transfer it to newly educated personnel. At the same time, current doctoral training programmes are producing over 50 PhD students each year, and if challenging nuclear-oriented research programmes are not in place, then the sector risks losing these high-value individuals to other fields.

3.3.5. Outputs

Output from this Programme Area will be in the form of a series of reports:

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(1) Technology Readiness Level and Technology Risk assessments of the Generation-IV and SMR systems, including their likely applicability to addressing future UK energy needs and fit with UK technical capabilities.

(2) Following from (1) above, development of a recommended strategy and programme for the UK to re-engage with international research programmes in the area of the priority Gen-IV and SMR systems.

(3) Assessment of the potential advantages and research needs associated with advanced reactor components, materials and chemistry.

The outcomes of the work will be published in journals and on web sites, as appropriate, and will be provided to DECC, to the Research Advisory Board and to members of the Steering Group.

3.3.6. Leverage

The programme of work will leverage NNL and The Dalton Nuclear Institute’s involvement in existing research collaborations, as well as drawing value from their extensive network of national and international collaborators including industry and academia. Existing research programmes include EPSRC nuclear programme grants in Nuclear Fuel, Nuclear Graphite, Nuclear Materials, Radiochemistry, and New Nuclear Manufacturing; and EU programmes including F-BRIDGE, ARCHER.

NNL and the Dalton Nuclear Institute have an established network of UK and international collaborators, mostly underpinned by Collaboration Agreements. These include: Rolls-Royce, EDF, Areva, Westinghouse, AMEC, Serco, Battelle, Idaho National Laboratory, Oak Ridge National Laboratory, CEA, IRSN, NRG, PSI, VTT, and KAERI. In addition, the Dalton Nuclear Institute has a network of academic collaborators through various Research Council programmes and industrial research, and is a partner in the international Expert Group on Innovative Structural Materials, which is significantly focused on materials requirements for future reactor designs.

The involvement of both the Dalton Nuclear Institute and the NNL in the programmes described will ensure that the programme can be delivered more quickly and at much lower cost to DECC than would otherwise be possible.

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3.4. Programme Area: Recycle.

3.4.1. Objective

The scenarios involving a high generating capacity are likely to rely on recycling nuclear materials and the concept of burning minor actinides in fast reactors; the “closed fuel cycle”. Recycle or reprocessing will be required to deliver this closure of the fuel cycle. The technology options available for recycle of materials are many and varied and include aqueous, as well as pyrochemical (non-aqueous) options. It is currently difficult to make an informed decision on the best technology to apply for a recycling plant which may be built in the future as, there is unequal maturity between aqueous and non-aqueous processes;. The objective of this work package will be to raise the overall technical maturity of both aqueous and non-aqueous recycling technologies. This work is needed now to take advantage of the opportunity to leverage work being undertaken currently on EU programmes regarding various recycle options for future fuel cycle.

3.4.2. Scope

Three initial tasks are proposed. The first is an experimental task to further develop and test one of the aqueous separation technologies and the second is a smaller review task aimed at non-aqueous technologies, with a third task aimed at defining the waste streams and likely candidate processes that can be used for treatment.

Exploratory testing of NNL’s modified version of the GANEX process. Performance can be compared against the more sophisticated “Co- stripping” process flowsheet being developed under the ACSEPT project.

State of the art review and technology readiness level assessment of non- aqueous processing technologies.

State of the art review and technology readiness level assessment of high and intermediate level waste processing technology and their application to fast reactor recycle.

3.4.3. People and Facilities

The programme will use NNL’s extensive range of expertise which has been, built up over decades of research initially funded through BNFL corporate programmes and more recently EU FP7 programmes such as EUROPART, ACSEPT and now ASGARD. The programme will also make use of the Central Laboratory gloveboxes, which are unique in the UK civil nuclear sector and can handle larger quantities of plutonium and minor actinides than is possible in any University laboratory. Academic contribution will be provided through:

The NNL- DNI and the MBASE consortia to contribute to the design and implementation of GANEX process experiments, and determine the implications of results obtained. Experiments to be performed in NNL Central Laboratory.

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The consortium and key expertise from the REFINE consortium (as determined by the REFINE Principal Investigator) will contribute to the review and assessment of non-aqueous processing technologies.

The consortium and key expertise from the DIAMOND consortium (as determined by the DIAMOND Principal Investigator) will contribute to the review and assessment of ILW and HLW processing technology.

This will involving seeking inputs from key academics involved in each of these programmes. In addition to researchers from the University of Manchester experts from the University of Lancaster, the University of Reading, The University of Leeds, The University of Edinburgh, the University of Sheffield and Imperial College will be involved.

3.4.4. Urgency

This work will proceed on an urgent basis as:

International competitors (e.g. [text redacted]) are in the midst of testing their own versions of the GANEX process. By completing the technical development, the UK will have the opportunity to position ourselves to build a demonstrator plant which would have significant financial incentives for the nation that hosts such a plant.

The REFINE consortium addresses the research aspect of non-aqueous reprocessing but a complementary development programme needs to be immediately implemented to address the inequality between the TRLs of hydrometallurgical and pyrochemical processes. A review in the area will quickly address the requirements such a programme needs to deliver.

The DIAMOND consortium has to a limited extent addressed the research aspect of future waste forms but a complementary development programme and research on a wider range of waste, specifically linked to a closed fuel cycle, needs to be immediately implemented. A review in the area will quickly address the requirements such a programme needs to deliver.

3.4.5. Output

Output from this work package will be in the form of a series of reports.

Reporting of results from exploratory testing of the GANEX process.

State of the art review of non-aqueous processing.

State of the art review of high and intermediate level waste processing technology. The outcomes of the work will be published in journals and on web sites, as appropriate, and will be provided to DECC, to the Research Advisory Board and to members of the Steering Group.

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3.4.6. Leverage

Current direct financial leverage is estimated at around £3.6 M against existing programmes on ACSEPT, REFINE, DIAMOND, MBASE and ASGARD.

Future direct financial leverage is estimated to be £20 M through future EU programmes (SACSESS) and EPSRC Centres for Doctoral Training (successor to Nuclear FiRST).

Aspects of intellectual leverage from networking with nine UK universities and 14 international research organisations spread across eleven countries should also be considered.

The involvement of the NNL, the Dalton Nuclear Institute, and the other academics listed will ensure that the programme can be delivered more quickly and at much lower cost to DECC than would otherwise be possible.

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4. Our Delivery Team

The NNL/DNI will utilise a number of key experts on this programme who have significant fuel cycle experience. Examples of this fuel cycle expertise include the following people:

[Text Redacted]

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[text redacted]

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[text redacted]

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5. Proposal Deliverables

The NNL have identified the following deliverables with the associated costs and dates for completion.

Task Name Cost / £k Reference Task1: D1.1 Scenario analysis of the tipping point(s) from open

to closed cycle Task1: D1.2 Definition of key assessment criteria and their application to nuclear energy technologies Task 2: D 2.1 Technology Readiness Level assessment of advanced fuels, cladding and associated manufacturing technology Task 2: D 2.2 Assessment of the manufacturing techniques required for evolutionary and revolutionary fuel in terms of quality assurance, operational dose,

throughput, and cost Task 2: D 2.3 Preliminary flow sheets for innovative fuel Cost Task 2: D 2.4 Confirmation of NNL participation in [text redacted] breakdown Task 3: D3.1 Technology Readiness Level &Technology Readiness redacted Assessment of Gen IV & SMR systems Task 3: D3.2 Determine recommended strategy for the UK to re- engage with international R&D programmes Task 3: D3.3 Assessment of potential advantages & research needs associated with advanced reactor components, materials & chemistry Task 4: D4.1 Report on exploratory testing of the GANEX process Task 4: D4.2 Review of state of the art non-aqueous processing technologies Task 4: D4.3 Review of state of the art high & intermediate level waste processing technology Total

The dates for completion are based on an assumed start date of September 1st 2012. A later start date may result in later delivery dates. No costs are included for deliverable 2.4 under task 3.

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6. Commercial

6.1. Price

The NNL’s price, on a fixed price basis for the work defined in Section 3 above is:

£ 1,256,600 excluding VAT

(One million two hundred and fifty six thousand six hundred pounds excluding VAT)

PROGRAMME AREA PRICE £K

Strategic Assessment.

Fuels. Cost breakdown Reactors. redacted

Recycle.

TOTAL * £1,256.6

* includes ~ £ 300 k of capital expenditure.

6.2. Timescales and Invoicing

Work will commence upon the agreement of terms and conditions.

Invoicing will take place against achievement of the milestones listed in Tables 1 to 4.

6.3. Validity

This proposal is valid until 30 September 2012.

If you have any queries on this or any other issue please do not hesitate to contact Dr. Fiona Rayment, Director, Fuel Cycle Solutions on 01925 289 869 or email address [email protected]

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Table 1 – task 1 milestones

Task Name Date for Cost / £k Reference Completion D1.1 Scenario analysis of the tipping point(s) 28/03/13 from open to closed cycle Cost D1.2 Definition of key assessment criteria and 30/11/12 breakdown their application to nuclear energy redacted technologies Total

Table 2 - task 2 Milestones

Task Name Date for Cost / £k Reference Completion D 2.1 , M1 Complete literature search and review of 21/12/12 worldwide operations D 2.1 , M2 Issue report on Technology Readiness 15/02/13 Level assessment of advanced, cladding and manufacturing technology D 2.1 , M3 Issue updated report incorporating client 28/03/13 comments D 2.2 , M1 Complete review of process technology 21/12/12 for evolutionary / revolutionary fuels D 2.2 , M2 Issue report of the status of the 15/02/13 manufacturing techniques required for Cost evolutionary and revolutionary fuel in breakdown terms of quality assurance, operational redacted dose, throughput, and cost D 2.2 , M3 Issue updated report incorporating client 28/03/13 comments D 2.3 , M1 Complete safety cases for experimental 21/12/12 work D 2.3 , M2 Take delivery of equipment 31/01/13 D 2.3 , M3 Complete experimental work 30/04/13 D 2.3 , M4 Issue report on preliminary flow sheets 31/05/13 for innovative fuel D 2.4 Confirmation of NNL participation in [text 28/03/13 redacted] Total

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Table 3 - task 3 Milestones

Task Name Date for Cost / £k Reference Completion D3.1 , M1 Interim report presenting an initial 30/11/12 assessment of technology readiness level, taking into account the effects of future energy scenarios D3.1 , M2 Issue report assessing the Technology 28/03/13 Readiness Level & Technology Readiness Assessment of Gen IV & SMR systems D3.2 , M1 Interim report assessing potential re- 01/02/13 engagement strategy Cost D3.2 , M2 Determine recommended strategy for 28/03/13 breakdown the UK to re-engage with international redacted R&D programmes D3.3, M1 Interim report assessing potential 28/02/13 research needs associated with advanced reactor components & chemistry D3.3 , M2 Assessment of potential advantages & 26/04/13 research needs associated with advanced reactor components, materials & chemistry Total Table 4 - task 4 Milestones

Task Name Date for Cost / £k Reference Completion D4.1 , M1 Complete safety cases for GANEX 22/02/13 experimental work D4.1 , M2 Complete GANEX rig trials 28/03/13 D4.1 , M3 Complete analysis of samples from rig 26/04/13 trials D4.1 , M4 Issue report on experimental testing of 31/05/13 GANEX trials D4.2 , M1 Confirm pyro-processing technologies to 18/01/13 Cost be assessed breakdown D4.2 , M2 Confirm other non-aqueous technologies 18/01/13 redacted to be assessed D4.2 , M3 Issue review on the state of the art of 28/03/13 non-aqueous processing technologies D4.3 , M1 Confirm the state of the art HLW and 22/02/13 ILW processing technologies to be reviewed D4.3 , M2 Issue report assessing the state of the 28/03/13 art HLW and ILW processing technologies Total

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Appendix 1 – Proposed Components of a National R&D Programme

It is anticipated that a national R&D programme would ultimately need to cover 9 broad areas, as follows:

1. Strategic Assessment – this area will assess the effect of technological development and provide an overall picture of the advantages and disadvantages against a range of factors of interest to Government, Industry and the Public; economic, environmental, proliferation resistance, safety and sustainability.

2. Fuels – this area will focus on the development of new fuels for new and existing reactor systems.

3. Reactors – this area will focus on the GenIV reactor systems that have been proposed, as well as Small Modular Reactors (SMR), which may have an application in the UK.

4. Transport & Storage – this area will focus on transport and storage requirements for new fuels between station and management facilities.

5. Recycle – as part of a sustainable nuclear energy, recycle of materials will be required. The technology options available are many and varied and this area will focus on these options. It will include aqueous, as well as pyrochemical options.

6. Decommissioning– it is probable that facilities for new reactor and recycle technologies will present different challenges for decommissioning than those currently being addressed in the UK’s legacy programmes. This area will focus on identifying these challenges.

7. Waste Management & Disposal– the implementation of new reactor and recycle technologies will require new wasteforms to be developed that will be compatible with existing plans for low, intermediate and high level waste disposal in the UK. This area will focus on the development of these new wasteforms.

8. Safeguards & Security – metrics to assess proliferation resistance of future nuclear technologies will be developed and applied in area 1; this area will focus on the development of technologies that can be implemented into future facilities to track and monitor fissile materials.

9. Programme Integration – this area will focus on ensuring that activities across the overall programme are managed, co-ordinated and link into the any proposed governance structures.

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Confidentiality, Copyright and Reproduction

This document has been prepared in response to a specific request for information and is submitted on the basis of strict confidentiality. It may not be used for any other purposes, reproduced in whole or in part, nor passed to any organisation or person without the specific permission in writing of the Strategic Business Development Director, National Nuclear Laboratory.