Argonne National Laboratory (ANL) is advancing next-generation nuclear fuel recycling technologies to reduce the long-term radiotoxicity of used nuclear fuel. A pilot-scale pyroprocessing facility plays a critical role in this effort, supporting research on electro-refining-based processes that can significantly reduce the time radioactive waste remains hazardous while allowing for more sustainable management of nuclear materials from commercial light-water reactors.

Merrick partnered with ANL to develop a conceptual design report, establishing a credible foundation for cost estimation, safety, and safeguards while supporting future scalability. The design accommodates initial operations at 100 metric tonnes per year and allows for expansion up to 400 metric tonnes per year. We shaped the facility’s overall process flow, focusing on five core pyroprocessing functions—fuel preparation, oxide-to-metal conversion, actinide and fission product separation, material recycling, and waste treatment.

Designing a nuclear processing facility requires rigorous attention to safety, security, and system integration. Merrick’s deep nuclear systems engineering expertise allowed us to integrate robust safety and security features throughout the facility, accounting for both routine operations and severe-scenario conditions. The resulting concept provides ANL with a flexible, forward-looking platform to advance nuclear fuel recycling research while managing radiological risks with precision and care.