Pyroprocessing: the integral fast reactor waste fiasco

Nuclear Monitor # 849, 25 Aug 2017, ‘Pyroprocessing: the integral fast reactor waste fiasco’,

In theory, integral fast reactors (IFRs) would gobble up nuclear waste and convert it into low-carbon electricity. In practice, the IFR R&D program in Idaho has left a legacy of troublesome waste. This saga is detailed in a recent article1 and a longer report2 by the Union of Concerned Scientists’ senior scientist Ed Lyman.

Lyman notes that the IFR concept “has attracted numerous staunch advocates” but their “interest has been driven largely by idealized studies on paper and not by facts derived from actual experience.”1 He discusses the IFR prototype built at Idaho ‒ the Experimental Breeder Reactor-II (EBR-II), which ceased operation in 1994 ‒ and subsequent efforts by the Department of Energy (DOE) to treat 26 metric tons of “sodium-bonded” metallic spent fuel from the EBR-II reactor with pyroprocessing, ostensibly to convert the waste to forms that would be safer for disposal in a geological repository. A secondary goal was to demonstrate the viability of pyroprocessing ‒ but the program has instead demonstrated the serious shortcomings of this technology.

Lyman writes:1

“Pyroprocessing is a form of spent fuel reprocessing that dissolves metal-based spent fuel in a molten salt bath (as distinguished from conventional reprocessing, which dissolves spent fuel in water-based acid solutions). Understandably, given all its problems, DOE has been reluctant to release public information on this program, which has largely operated under the radar since 2000.

“The FOIA [Freedom of Information Act] documents we obtained have revealed yet another DOE tale of vast sums of public money being wasted on an unproven technology that has fallen far short of the unrealistic projections that DOE used to sell the project to Congress, the state of Idaho and the public. However, it is not too late to pull the plug on this program, and potentially save taxpayers hundreds of millions of dollars. …

“Pyroprocessing was billed as a simpler, cheaper and more compact alternative to the conventional aqueous reprocessing plants that have been operated in France, the United Kingdom, Japan and other countries.

“Although DOE shut down the EBR-II in 1994 (the reactor part of the IFR program), it allowed work at the pyroprocessing facility to proceed. It justified this by asserting that the leftover spent fuel from the EBR-II could not be directly disposed of in the planned Yucca Mountain repository because of the potential safety issues associated with presence of metallic sodium in the spent fuel elements, which was used to “bond” the fuel to the metallic cladding that encased it. (Metallic sodium reacts violently with water and air.)

“Pyroprocessing would separate the sodium from other spent fuel constituents and neutralize it. DOE decided in 2000 to use pyroprocessing for the entire inventory of leftover EBR-II spent fuel – both “driver” and “blanket” fuel – even though it acknowledged that there were simpler methods to remove the sodium from the lightly irradiated blanket fuel, which constituted nearly 90% of the inventory.

“However, as the FOIA documents reveal in detail, the pyroprocessing technology simply has not worked well and has fallen far short of initial predictions. Although DOE initially claimed that the entire inventory would be processed by 2007, as of the end of Fiscal Year 2016, only about 15% of the roughly 26 metric tons of spent fuel had been processed. Over $210 million has been spent, at an average cost of over $60,000 per kilogram of fuel treated. At this rate, it will take until the end of the century to complete pyroprocessing of the entire inventory, at an additional cost of over $1 billion.

“But even that assumes, unrealistically, that the equipment will continue to be usable for this extended time period. Moreover, there is a significant fraction of spent fuel in storage that has degraded and may not be a candidate for pyroprocessing in any event. …

“What exactly is the pyroprocessing of this fuel accomplishing? Instead of making management and disposal of the spent fuel simpler and safer, it has created an even bigger mess. …

“[P]yroprocessing has taken one potentially difficult form of nuclear waste and converted it into multiple challenging forms of nuclear waste. DOE has spent hundreds of millions of dollars only to magnify, rather than simplify, the waste problem. This is especially outrageous in light of other FOIA documents that indicate that DOE never definitively concluded that the sodium-bonded spent fuel was unsafe to directly dispose of in the first place. But it insisted on pursuing pyroprocessing rather than conducting studies that might have shown it was unnecessary.

“Everyone with an interest in pyroprocessing should reassess their views given the real-world problems experienced in implementing the technology over the last 20 years at INL. They should also note that the variant of the process being used to treat the EBR-II spent fuel is less complex than the process that would be needed to extract plutonium and other actinides to produce fresh fuel for fast reactors. In other words, the technology is a long way from being demonstrated as a practical approach for electricity production.”


1. Ed Lyman / Union of Concerned Scientists, 12 Aug 2017, ‘The Pyroprocessing Files’,

2. Edwin Lyman, 2017, ‘External Assessment of the U.S. Sodium-Bonded Spent Fuel Treatment Program’,