Nuclear Fuel Cycle

The Nuclear Fuel Cycle supporting the nuclear power programme covers exploration, mining, fuel fabrication, heavy water production, fuel reprocessing and waste management. Following were the activities of DAE in this programme sector :

Exploration and research relating to atomic minerals needed for the Nuclear Power Programme of the country are carried out by the Atomic Minerals Directorate for Exploration and Research (AMD).

AMD established continuity of ore grade mineralisation at Gogi, Gulbarga district, Karnataka and Rohil-Ghateshwar, Sikar district, Rajasthan. Widespread uranium mineralisation associated with Gulcheru quartzite was located along Gandi - Kannampalle tract, Cuddapah district, Andhra Pradesh.

Additional uranium resources at Wahkyn, West Khasi Hills district, Meghalaya and Koppunuru area, Guntur district, Andhra Pradesh, and additional reserves of xenotime bearing polymineralic concentrate and columbite-tantalite in parts of Bihar, Orissa & Gujarat were estimated.

The Directorate carried out airborne Gamma Ray Spectrometric (AGRS) and Aero-Magnetic (AM) surveys over 19,000 line km in parts of Madhya Pradesh and Orissa.

Uranium and thorium are the resource minerals for the Nuclear Power Programme. The Public Sector Undertakings of DAE, responsible for mining and processing of uranium ore and minerals sands (which contain thorium and rare earth elements), the Uranium Corporation of India Ltd. (UCIL) and the Indian Rare Earths Ltd. respectively showed marked improvements in their performance.

The Heavy Water Board runs seven of the eight heavy water plants installed in the country to meet the heavy water requirements of the Indian reactors.

The performance and safety record of all the operating heavy water plants was very good. As a result of stable operation and continuous run of the plants, the cumulative production of heavy water achieved, far exceeded the target set for the period. In October, 2000, 16 MT of heavy water was exported to South Korea.

Modifications for sustaining operation of the Heavy Water Plant, Baroda and commissioning of the R & D Pilot Plant Facility at Talcher for production of Di-2-ethyl hexyl phosphoric acid (D2EHPA) were the major developments.

Board’s focus on energy conservation and manpower training aspects resulted in energy conservation, cost reduction, and high capacity utilisation in all the operating plants.

The Nuclear Fuel Complex (NFC) at Hyderabad meets the fuel and zircaloy requirements of all the nuclear power reactors in the country. In addition, NFC manufactures stainless steel tubes for industrial applications.

During the year 2000-01, NFC met its annual production targets. For natural uranium oxide PHWR fuel, hafnium free zirconium oxide and special materials (in particular tantalum penta-oxide powder), the production and sales far exceeded the targets. On September 9, 2000, NFC crossed a milestone of manufacturing 2 lakh natural uranium oxide fuel bundles for PHWRs. Components for PFBR such as Control & Safety Rod and Sheath subassembly, and D9 material for fuel pin components were successfully developed. New schemes namely, the 37 Element PHWR Fuel Project for TAPS-3&4 (PHWR 500 MWe), Replacement and Augmentation of Zirconium Sponge Plant and Advanced Materials Processing and Characterisation Facilities progressed satisfactorily. Also, NFC obtained ISO 9002 certification.

The fuels for the research reactors were fabricated at BARC which also continued its pursuit of the development of new fuels for advanced reactors.

Progressive introduction of MOX fuel in the atomic power reactors at Tarapur continued and performance of the fuel in the reactor was as per the design. Construction of a new shielded hot cell facility, revamping and augmentation of Fuel Fabrication Facility at Tarapur continued.

Development of PFBR fuel and plutonium based fuels and their characterization made further progress at Trombay and high-density thorium oxide fuel pellets for flux flattening of all the new PHWRs were fabricated.

At IGCAR, studies were conducted for the development of fast reactor fuels and cladding materials. Here, a laboratory scale facility was commissioned for the preparation of uranium oxide microspheres by sol-gel method.

The Fuel Reprocessing Programme of BARC is focused on the recovery of fertile material from spent fuel after it is discharged from the research/power reactors, and safe management of the radioactive wastes from nuclear facilities.

Construction activities related to revamping of Tarapur Reprocessing Plant of BARC progressed.

At IGCAR, the Lead Mini Cell for reprocessing of the carbide fuel of FBTR on laboratory scale, was safety-reviewed by SARCOP ( Safety Review Committee for Operating Plants) of AERB. The facility will be commissioned shortly.

Most of the vessels and equipment for the Fast Reactor Fuel Reprocessing Plant (FRFRP) at Kalpakkam were ready for erection.

The Waste Management Facilities (WMF) for treatment and disposal of low and intermediate level waste streams, operated safely at Trombay, Tarapur, Rawatbhata and Kalpakkam. The radioactivity discharge was well below the authorized limits.

Waste Immobilization Plant at Trombay for treatment and immobilization of high level waste from the reprocessing plant at Trombay is getting ready for commissioning. The civil construction of Waste Immobilization Plant at Kalpakkam and the procurement and installation activity of process and other equipment made good progress. A suitable glass matrix for managing high level waste from thorium cycle, was successfully developed by BARC.

Efforts towards the indigenisation of equipment used in waste management led to the development of stainless steel (304L) plates and pipes for reprocessing and waste management applications, and the filter canisters for use by the nuclear power plant workers. Development of a process for separation of yttrium from high level waste was a spin off. Yttrium has wide applications in medical field.

The safety performance of the nuclear power stations continued to be excellent. The radioactive releases to the environment and the occupational doses were kept much below the prescribed limits. Off-site emergency exercises were also carried out at various sites to ensure emergency preparedness.

NPCIL-Safety Review Committee (NPC-SRC) continued to conduct appropriate interdisciplinary reviews of all safety related events and safety submissions. Internal safety reviews and audits were conducted for assurance of health & safety aspects in the operating stations and in the projects under construction.

The epidemiological surveys conducted by the Tata Memorial Centre observed no increase in cancer prevalence in the radiation workers of NAPS and RAPS as compared with the non-radiation workers. Similar surveys conducted at MAPS and Kaiga, were under finalisation.

RAPS won the Industrial Safety Awards of AERB and NPCIL, RAPP 3&4 won the AERB Fire Safety award, and TAPP 3&4 won the award for construction sites.

BARC continued to work on the development of safety related technologies for PHWRs. These included catalytic recombiners, vibration diagnostic techniques, and garter spring repositioning system.

Environment surveillance and monitoring at all the nuclear facilities is a continuing programme. Radiological Safety Programme was strengthened with the procurement of equipment for a mobile laboratory, aerial gamma monitoring, Environment Survey Laboratories and Site Emergency Control Centre.

Health Physics Units of BARC at the nuclear power plants, fuel reprocessing plants, and waste management facilities continued their safety related functions. The civil work of the Radiological Protection Training and Information Centre, being set up by BARC, was completed.

The safety related studies at IGCAR focused on the safety features of PFBR. Under the Core Disruptive Accident (CDA) scenario the primary containment of PFBR and major internals were analysed for structural integrity, and sodium fire consequences for the reactor containment building of PFBR were estimated; Structural integrity assessment of primary sodium pipe was demonstrated, and Safety analysis and shielding codes & data were validated. Probabilistic Safety Analysis of Shutdown System and Decay Heat Removal System of PFBR continued. For structural response studies under cyclonic wind conditions, three meteorological towers were installed at Kalpakkam.

BARC continued with its environment and meteorological survey programme around nuclear power plant sites. The levels of the radioactivity around the sites were found to be insignificant. As a part of the preoperational survey, samples from Kudankulam sites were analysed.

Under the Personnel Monitoring Programme, whole body counting of around 2500 personnel for internal contamination was carried out by BARC.

The Environmental Survey Laboratory (ESL) at Trombay participated in the intercomparison studies conducted by IAEA and International Reference Centre of WHO. The ESL-Kaiga was recognized by the Mangalore University as a centre for pursuing research in radiation physics and environment chemistry.

On-line weekly environmental monitoring of the Kalpakkam site found the radiation field well within limits.

TAPS & KAPS obtained Environmental Management System Certification under ISO 14001.

Heavy Water Plant at Thal, Maharas-htra, won the "AERB Green Site Award".