First-of-a-kind boron-based component adds a safety layer to 77 MW small reactor

US nuclear technology firm NuScale Power has fabricated the first boron-oxide pellets designed for the passive emergency cooling system of its small modular reactor, marking a manufacturing milestone for a component intended to help keep the reactor core stable during an emergency. The pellets were produced with advanced nuclear materials manufacturer MillenniTEK as NuScale works to move its reactor technology closer to commercial deployment. The companies say the work demonstrates a production process for a specialized component of NuScale’s emergency core cooling system (ECCS). The pellets are designed to become part of the reactor’s safety response without requiring operators to intervene. If the ECCS is activated, the boron-oxide material dissolves into the reactor coolant, helping control the reactor’s core reactivity and keep it within safe limits. NuScale says the manufacturing milestone also helps establish the supply chain and production capabilities needed to build components for its planned reactor deployments. The company is developing its technology for applications ranging from electricity generation to data centers and industrial heat. Boron pellets add passive safety The boron-oxide pellets are part of a safety system designed around NuScale’s small modular reactor architecture. Rather than relying solely on active equipment or operator action, the ECCS is designed to respond automatically when required. Boron is widely used in nuclear systems because it can absorb neutrons. By introducing the boron-containing material into the reactor coolant during an emergency, the system is designed to reduce the number of neutrons available to sustain the nuclear reaction. That makes the pellets a relatively small component with an important role in controlling reactor behavior during abnormal conditions. “This first-of-a-kind fabrication milestone demonstrates MillenniTEK’s ability to support the advanced manufacturing needs of next-generation nuclear technologies,” said Steve Getley, MillenniTEK President. For NuScale, the work is also about demonstrating that specialized reactor components can be manufactured at the quality and consistency required for commercial nuclear projects. “NuScale’s technology is built on a commitment to safety, simplicity, and deployability, and this milestone reflects the continued progress we are making to prepare our technology and supply chain for commercial deployment in the near-term,” said John Hopkins, NuScale President and Chief Executive Officer. Scaling components for deployment NuScale’s reactor technology is based on the NuScale Power Module, a pressurized water reactor designed to generate 77 megawatts of electricity per module. Multiple modules can be combined into larger power plants, with the company’s current configuration scaling to as much as 924 MW across 12 modules. The company says its SMR design is the first and only one to have received design certification from the US Nuclear Regulatory Commission. It is targeting the technology for electricity generation as well as applications such as data centers, district heating, desalination and hydrogen production. MillenniTEK’s role highlights another part of the SMR challenge: manufacturing the specialized materials and components required to move reactor designs from regulatory approval toward physical deployment. The company manufactures technical ceramic components by converting powdered materials into solid parts and also develops prototype components for SMR, microreactor, and space reactor applications.The first boron-oxide pellets therefore represent more than a single component entering production. They are part of NuScale’s effort to establish repeatable manufacturing processes and a supply chain capable of supporting its reactors as it moves toward commercial customers.Get the latest in engineering, tech, space & science - delivered daily to your inbox.With over a decade-long career in journalism, Neetika Walter has worked with The Economic Times, ANI, and Hindustan Times, covering politics, business, technology, and the clean energy sector. Passionate about contemporary culture, books, poetry, and storytelling, she brings depth and insight to her writing. When she isn’t chasing stories, she’s likely lost in a book or enjoying the company of her dogs.