US Kairos Power and BWX Technologies (BWXT) have agreed to collaboratively explore technical and process opportunities to optimise commercial production of TRISO nuclear fuel to supply Kairos Power’s planned reactor fleet and other potential customers. The arrangement will bring together Kairos Power’s established capabilities in annular graphite pebble production with BWXT’s more than 20 years of experience in TRISO fuel manufacturing.
TRISO (TRi-structural ISOtropic) particle fuel is a proven technology developed by the US Department of Energy (DOE). Each TRISO particle is made up of a uranium, carbon, and oxygen fuel kernel encapsulated by three layers of carbon- and ceramic-based materials that prevent the release of radioactive fission products.
In 2023, the US Nuclear Regulatory Commission (NRC) issued a construction permit for Kairos Power’s Hermes demonstration reactor – the first non-water-cooled reactor to be approved for construction in the US in more than 50 years.
The Hermes design is for a 35 MWt non-power version of the company’s fluoride salt-cooled high temperature reactor design, the KP-HFR. Kairos has also submitted a construction permit application for Hermes 2, a proposed two-unit demonstration plant that would build on the experience of Hermes and would produce electricity and demonstrate the complete architecture of future commercial plants. Hermes will use TRISO pebble bed fuel.
Under the collaboration agreement, Kairos and BWXT will consider possible paths to deliver fuel for the Hermes 2 Demonstration Plant and subsequent Kairos Power reactor deployments. The joint team will explore opportunities to utilise the state-of-the-art TRISO Development Lab (TDL) at Kairos Power’s Albuquerque campus, the BWXT Innovation Campus in Lynchburg, Virginia, and BWXT’s existing TRISO production line to optimise TRISO fuel manufacturing and process automation.
The companies have also agreed to explore opportunities to jointly develop a TRISO fuel fabrication facility, which would incorporate this experience and knowledge, along with newly developed technology for commercial fuel production. Kairos said the combined fuel manufacturing knowledge and expertise creates the opportunity to develop efficient and cost-effective mass-produced TRISO coated particle fuel to support Kairos Power’s commercial scale-up and lower fuel costs for the advanced reactor industry.
“This collaboration between Kairos Power and BWXT is an opportunity to develop a secure pathway to produce the fuel we need for Hermes 2 and beyond,” said Ed Blandford, Kairos Chief Technology Officer and co-founder. “Commercial TRISO fuel production is the next step in the development of Kairos Power’s fuel supply chain. With BWXT as a trusted strategic partner, we have a clear path to produce the high-quality fuel products that will unlock advanced nuclear energy’s potential.”
Micah Hackett, Kairos Vice President for Fuels & Materials, noted: “Kairos Power sees an opportunity with BWXT to accelerate innovation in TRISO fuel manufacturing processes and more quickly realize gains in production, automation, and process efficiency that will reduce future commercial fuel costs. As Kairos and other vendors announce firm reactor deployment plans, investing in TRISO fuel manufacturing capabilities today will ensure a cost-competitive product to fuel the advanced reactor fleet of tomorrow.”
According to Josh Parker, Senior Director at BWXT Advanced Fuels, the collaboration between BWXT and Kairos creates an industry-leading TRISO development and manufacturing team. “Together, we believe we have the opportunity and skills to speed up the development process and provide more economical TRISO fuel that ensures supply for Kairos, BWXT, and the wider advanced reactor community.”
