Across the United States, nuclear reactors generate vast amounts of electricity and a significant amount of used nuclear fuel. While this material is often treated as waste, more than 95% of its energy potential remains untapped. Now, with support from the Department of Energy (DOE), scientists at Argonne National Laboratory are partnering with private industry to bring the promise of nuclear fuel recycling into reality. This innovative approach to energy reuse could reshape how the US manages its nuclear resources, reducing radioactive waste and extracting more energy from existing fuel sources.
At the heart of this project are centrifugal contactors – high-speed spinning devices designed to separate mixed liquids based on density. These compact, efficient machines make the recycling process safer, faster, and more adaptable to industrial needs. The collaboration bridges laboratory research with practical application, aiming to create a process that nuclear energy producers can adopt without excessive cost or complexity.
Recycling used nuclear fuel isn’t simple. The material is highly radioactive and continues to emit heat long after leaving the reactor. This means it must be stored and cooled for years before it’s safe to handle. Even then, recycling facilities must be equipped with shielding systems and radiation management tools to protect workers and the environment. Security is another major concern. Every step of the recycling process – from storage to separation – must be designed with safeguards to prevent unauthorised access or misuse. By applying ‘safeguards by design,’ Argonne’s researchers embed security features directly into the technology from the start, ensuring compliance with national and international standards.
Beyond the technical aspects, nuclear fuel recycling must also make economic sense. The process must yield materials that have real commercial value. Fortunately, some recycled products – like specific radioisotopes – can be used in advanced reactors, space exploration, or even medical diagnostics. For example, isotopes recovered during nuclear fuel recycling could power deep-space missions or assist in life-saving imaging technologies. If demand for these byproducts grows, the economics of recycling become more favourable, encouraging investment in new facilities.
Not all reactors are created equal. Future nuclear plants – especially next-generation designs – will use fuel in different ways, requiring recycling methods that are tailored to specific materials. Argonne’s experts are uniquely positioned to anticipate these needs. By modelling how fuel behaves in different reactor types, they can adjust their recycling strategies to fit evolving energy technologies. This kind of foresight is essential. Today’s research lays the groundwork for facilities that could one day recycle fuel from advanced modular reactors, helping the US achieve its clean energy goals.
Leading the charge is Peter Tkac, a nuclear chemist at Argonne, whose team is pioneering small-scale tests that replicate the harsh environments of real-world nuclear fuel recycling. Using a Van de Graaff accelerator – a type of particle accelerator – they generate low levels of radioactivity to study how chemicals behave under radiation. This controlled environment allows for rapid development without the risks or costs of working directly with spent nuclear fuel. Tkac’s group also leverages 3D printing to rapidly prototype and test new parts for the centrifugal contactors. This flexibility not only accelerates development but also ensures the designs can be easily adapted for industrial use.
This isn’t Argonne and SHINE’s first collaboration. Previously, the two worked together to improve the production of medical isotopes, leading to life-saving innovations in diagnostics and therapy. Now, they’re bringing that same expertise to the nuclear energy sector. By refining and scaling up nuclear fuel recycling technology, this partnership is tackling one of the key obstacles to expanding nuclear power in the US – long-term waste management. If successful, the project could drastically reduce the volume of radioactive waste and extend the utility of existing fuel, helping ensure an abundant and cleaner energy supply for generations to come.