725MW US nuclear plant recovers tilted fuel assembly with device built in two weeks

A shuttered nuclear power plant in the US has overcome a major challenge ahead of its planned restart after engineers successfully recovered a tilted fuel assembly from its reactor.

The demanding operation was carried out at the Palisades Nuclear Power Plant in Michigan. Florida-based energy technology firm, Holtec International announced its successful completion Wednesday, October 21.

For the procedure, the company used a specially designed Fuel Movement Device (FMD), which it developed, manufactured, and delivered in just two weeks. According to Holtec, the feat brings the nuclear plant closer to restarting operations.

The facility could become the first permanently shut-down US commercial nuclear plant to return to power generation. The fuel recovery was reportedly carried out safely and without errors. “When we encounter a challenge, what matters is how we respond,” Fadi Diya, Holtec International chief nuclear officer, said.

Rapid device development

The facility’s restart preparations were temporarily disrupted on August 30, 2026, after a fuel bundle unexpectedly tilted at a 30-degree angle inside the reactor. Its bottom remained in position H-1, and its top leaned against the core shroud. The Nuclear Regulatory Commission (NRC), confirmed that the incident caused no radiation release or worker injuries.

However, recovering the tilted fuel assembly required a specialized engineering solution. To address the challenge, Holtec developed a custom Fuel Movement Device and a specially engineered fuel transfer canister to safely lift, secure, and relocate the assembly.

Fuel assembly is moved through the equipment hatch using Holtec’s Fuel Transfer Canister for storage in the spent fuel pool. Credit: Holtec International

The equipment was developed in Camden, New Jersey, while the specialized parts were produced in Pittsburgh, Pennsylvania. At the same time, Palisades personnel handled the regulatory preparations, equipment testing, training, as well as the recovery operation.

Once the equipment was ready technical crews lifted the tilted fuel assembly from the reactor and placed it in a specially designed container. The team then secured the lid and moved the container to the plant’s spent fuel pool. Holtec stated that the recovered assembly is now safely stored in the pool.

Restart efforts continue

The NRC approved the recovery procedure through a license amendment. “Our team approached this recovery with the same commitment to safety, technical rigor, and teamwork that has guided our work throughout the restart,” Diya said.

The Michigan plant previously ceased operations in 2022 and is now undergoing preparations to return to commercial electricity generation. Its restart would be the first of its kind in US nuclear history.

Holtec’s specially-designed Fuel Movement Device staged above the reactor to undertake fuel recovery. Credit: Holtec International

However, the reactor is not ready yet. Workers still need to complete fuel loading, inspections, and safety tests. Holtec must also meet federal regulations. The firm said its experience with nuclear fuel supported the recovery.

“We developed a solution, executed it safely and error-free, and demonstrated the depth of expertise across our organization,” Diya shared in a press release. “I’m proud of this team and grateful for the dedication they bring to Palisades every day.”

Source: https://interestingengineering.com/energy/us-nuclear-plant-recovers-tilted-fuel-assembly-2-weeks