Resin loading ¡Ion exchange resin/ HTGR fissile fuel / Nuclear fuel kernels / Uranium loading /Weak-acid resinAbstract Fissile fuel for High-Temperature Gas-Cooled Reactors (HTGRs) is fabricated in the form of small spheres ~300 um in diameter, each containing ~ 70 Mg of highly enriched uranium; the preferred chemical composition is a mixture of oxide and carbide. This report describes a process for loading weakacid ion exchange resin beads with uranium, from which the desired product is then derived by thermal treatment. The resin loading process has a major advantage over alternative, traditional methods because the process steps are relatively simple. This derives primarily from the fact that the resin is commercially available in the form of spherical beads. This factor is of significant benefit under any circumstances but especially in the case of the remote fabrication required for the highly radioactive 2 33 U recycle fuel. The process is based on the exchange of uranyl ion with the acid form of a carboxylate resin. This type and form of resin was chosen because (a) it contains only C, H, and O and is therefore free of other cations and additional undesirable elements such as N, S, or P; (b) it is available with a high enough concentration of exchange sites to achieve the necessary uranium density in the product. This usage differs from the usual applications of ion exchange resins because full loading is required, and the loaded resin itself is the desired product. In order to drive the reaction to essential completion, it is necessary to use acid-deficient uranyl nitrate [i. e., a composition equivalent to UO2(NO 3 ) 1-s (OH) 0 5 ]. This solution composition can be achieved either by extraction of HNOj with an amine in an organic solvent or by reaction with U0 3 . Each of these methods has been demonstrated in both batch and continuous modes. For recycle fuel, where uranyl nitrate solution is the natural product of reprocessing, amine extraction is preferred. For smaller operations, batch loading is the simpler approach; however, for larger operations, a single Higgins-type pulsed column can load 100 kg U per day in a continuous mode.