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The main objective of the Depleted UO{sub 2} Kernels Production Task at Oak Ridge National Laboratory (ORNL) was to conduct two small-scale production campaigns to produce 2 kg of UO{sub 2} kernels with diameters of 500 {+-} 20 {micro}m and 3.5 kg of UO{sub 2} kernels with diameters of 350 {+-} 10 {micro}m for the U.S. Department of Energy Advanced Fuel Cycle Initiative Program. The final acceptance requirements for the UO{sub 2} kernels are provided in the first section of this report. The kernels were prepared for use by the ORNL Metals and Ceramics Division in a development study to perfect the triisotropic (TRISO) coating process. It was important that the kernels be strong and near theoretical density, with excellent sphericity, minimal surface roughness, and no cracking. This report gives a detailed description of the production efforts and results as well as an in-depth description of the internal gelation process and its chemistry. It describes the laboratory-scale gel-forming apparatus, optimum broth formulation and operating conditions, preparation of the acid-deficient uranyl nitrate stock solution, the system used to provide uniform broth droplet formation and control, and the process of calcining and sintering UO{sub 3} {center_dot} 2H{sub 2}O microspheres to form dense UO{sub 2} kernels. The report also describes improvements and best past practices for uranium kernel formation via the internal gelation process, which utilizes hexamethylenetetramine and urea. Improvements were made in broth formulation and broth droplet formation and control that made it possible in many of the runs in the campaign to produce the desired 350 {+-} 10-{micro}m-diameter kernels, and to obtain very high yields

Production of Depleted UO<sub>2</sub>Kernels for the Advanced Gas-Cooled Reactor Program for Use in TRISO Coating Development