Review Materials development and corrosion problems in nuclear fuel reprocessing plants Baldev Raj * , U. Kamachi Mudali Indira Gandhi Centre for Atomic Research, Kalpakkam 603 102, India Received 30 January 2005; received in revised form 20 July 2005; accepted 20 July 2005 Abstract A broad based materials development programme has been in progress worldwide towards the development of materials for applications in spent nuclear fuel reprocessing plants. International efforts have resulted in the development of advanced materials like nitric acid grade (NAG) special austenitic stainless steels, Ti–5% Ta, Ti–5% Ta–1.8% Nb, Cr–W–Si, Nb–W, zirconium based alloys etc. for highly corrosive nitric acid environments. A critical review of performance of current and promising materials and their associated fabrication technologies for manufacturing is attempted. All-titanium electrolytic dissolver, electrode materials for electrochemical processes, dissimilar joints of titanium-type 304L stainless steel (SS), and double oxide coating on titanium for reconditioning (DOCTOR) have been developed at Indira Gandhi Centre for Atomic Research (IGCAR) based on systematic interdisciplinary R&D efforts. Dynamic nitric acid loop, a unique testing facility built at IGCAR is been described. Directions in materials and components developments, corrosion assessment and challenges ahead are also discussed. q 2005 Elsevier Ltd. All rights reserved. Keywords: Materials; Manufacturing; Coatings; Corrosion; Reprocessing plants; Nitric acid; Advanced materials 1. Introduction Reprocessing, refabrication and management of radioactive waste are the three major areas of activities that have attracted focused efforts to achieve successes in the back-end of nuclear fuel cycle (Anil Kakodkar, 2000). The integrity and availability of nuclear fuel reprocessing plants for uninterrupted operation depends on the quality and performance of critical engineering components, vessels and piping. Any failure of the component of reprocessing unit processes would lead to the leakage of radioactivity, and slowing down the production of useful fissile material required for sustained operation of power plants. Materials selection, fabrication, operation, maintenance and inspection of various components of different unit processes of reprocessing plants are of paramount importance in meeting the requirements of uninterrupted and safe operation of reprocessing plants (Baldev et al., 2000). This demand poses and dictates many challenges with respect to the reprocessing plants, particularly of fast breeder reactors (FBRs) as they handle high plutonium content fuels with various fission products (FPs) and transuranium (TRUs) elements due to significant high burn ups in fast breeder reactors. The plants are designed with the objective of zero incident failures such as leakages in pipes, vessels and equipment since, the repair and maintenance in high activity area is never a planned activity. High Pu content and higher burn up of the fuel (O100,000 MWd/ton) also Progress in Nuclear Energy 48 (2006) 283–313 www.elsevier.com/locate/pnucene 0149-1970/$ - see front matter q 2005 Elsevier Ltd. All rights reserved. doi:10.1016/j.pnucene.2005.07.001 * Corressponding author. Tel.: C91 44 27480260; fax: C91 44 27480060. E-mail addresses: dir@igcar.ernet (B. Raj), dirsec@igcar.ernet.in (B. Raj).