Rosatom Automates Nuclear Fuel Manufacturing Using AI and Digital Twins
Rosatom’s fuel division (TVEL) is running more than 200 AI-driven digital projects for nuclear fuel production, aiming to reach “dark factory” automation levels with minimal permanent human presence.
The Core of the Transformation
TVEL integrates artificial intelligence into nuclear fuel manufacturing, spanning more than 200 initiatives ranging from predictive maintenance to full-scale digital twins. Rosatom as a whole is transitioning toward an Industry 5.0 model, in which over two hundred digital initiatives cover the entire nuclear fuel lifecycle – from fuel matrix design to final quality control.
Artificial intelligence predicts equipment failures, digital twins of workshops simulate operational scenarios in virtual environments, and autonomous robots handle logistics and assembly at facilities in Novosibirsk, Angarsk, and Zarechny.
The division’s leadership is explicitly targeting “dark factories,” where robots and AI replace human operators in routine processes, freeing personnel for innovation. TVEL supplies nuclear fuel to around 70% of the world’s reactor fleet, reinforcing its global position through large-scale digitalization.
A Retrospective of Implementation
Digitalization at TVEL began gaining momentum in the early 2020s, when Rosatom launched pilot digital twin projects for complex assemblies, including reactor components. By 2022, a predictive maintenance platform was deployed, linking data from hundreds of machines and significantly reducing accident rates across production sites.
By 2025, the portfolio expanded to more than 200 projects, including autonomous warehouses and AI systems for fuel matrix design. This development is part of Rosatom’s broader Industry 5.0 strategy, with TVEL acting as the flagship within the nuclear segment.
Economic Momentum
The introduction of AI is expected to free up thousands of working hours, redirecting specialists toward high-tech tasks such as developing fuel for fast neutron reactors. The division could reduce operating costs by 10–15% by shifting routine work to algorithms, strengthening the group’s competitiveness in export markets across Asia and Europe.
Russian IT companies are also set to benefit, gaining contracts for customized “dark factory” solutions and forming a technology cluster around TVEL with projected turnover in the billions of rubles.
Scaling Prospects
Experts forecast that the global AI-for-energy market could reach $20 billion by 2030. By that point, TVEL plans to shift roughly 80% of its production to unmanned operation, integrating AI with quantum computing to achieve ultra-precise modeling of neutron fluxes. “Dark factories” are expected to become the industry standard, with Russian-developed models exported to partner countries within BRICS, where similar projects are anticipated in China and India.
Synergy with other Rosatom divisions will accelerate digitalization across the entire nuclear value chain – from uranium mining to waste management. This opens new niches for Russian software in the global energy sector, where AI is already being applied to decarbonization challenges.
Future Horizons
TVEL’s digital transformation is poised to set the pace for the entire nuclear industry, making fuel production fully autonomous and export-oriented. “Dark factories” are expected to secure Russia’s leadership in green energy, with AI minimizing risks and maximizing operational efficiency.
The project will strengthen technological sovereignty by opening export channels for Russian algorithms. Nuclear fuel is set to become cheaper and more reliable, contributing to the global transition toward net-zero emissions.
