Synthesis, Purification, and Characterization of Molten Salt Fuel for the SALIENT-03 Irradiation Experiment

This work presents the synthesis, purification, and characterization of a molten salt fuel for the irradiation experiment SALIENT-03 (SALt Irradiation ExperimeNT), a collaborative effort between the Nuclear Research and Consultancy Group and the Joint Research Centre, European Commission. The primary objective of the project is to investigate the corrosion behavior of selected Ni-alloy based structural materials which are being considered for the construction of fluoride molten salt reactors. During the test, these materials will be exposed to selected liquid molten fuel salts under irradiation in the High Flux Reactor in Petten, the Netherlands. In addition, the properties and distribution of the fission products formed in the fuel salt during burn-up will be studied by various post irradiation examinations. In the SALIENT-03 fuel, U and Pu fluorides, as fissile material, are dissolved in a carrier melt based on a 78⁷LiF-22ThF₄ eutectic mixture to form fuel salts with four different compositions, containing PuF₃, UF₄, UF₃, and CrF₃. This article comprehensively describes all the steps of this fuel synthesis process: the synthesis of the required pure fluoride powders (⁷LiF, ThF₄, UF₄, UF₃, and PuF₃); the mixing, melting, and purification of the different fuel salt compositions; and the fabrication of solid ingots to be loaded into the irradiation capsules. The characterization of the intermediate and final products is also carried out, following a rigorous quality assurance protocol. The quality assurance is achieved using an analytical scheme consisting of mass balance-based conversion efficiency evaluation, X-ray diffraction, and differential scanning calorimetry analyses. All experimental goals were successfully achieved, highlighting promising prospects for advancing future research and development regarding fuel production methods for fluoride-based molten salt reactors.