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In the U.S., that huge task would take place at an aging plutonium factory in South Carolina called the Savannah River Site. From the 1950s to the 1980s, the 310-square-mile facility had churned out about 36 tons of weapons-grade plutonium for nuclear warheads. Now, the plant would turn those same warheads into fuel rods. The Department of Energy initially estimated it would cost about $1 billion to convert the plant. Construction began in August 2007, with an expected completion date of 2016.

The U.S. government even had a ready customer for the rods. Charlotte-based Duke Energy (DUK), one of the largest nuclear power companies in the U.S., signed on as a buyer. From 2005 to 2008, the company ran tests of MOX fuel the Department of Energy got from France. The fuel worked fine. Everything was going according to plan.

Almost seven years after construction began, the MOX plant is now 60 percent built. But it’s looking increasingly likely that it won’t ever be completed….The MOX plant in South Carolina requires 85 miles of pipe, 23,000 instruments, and 3.6 million linear feet of power cables. The project is vastly over budget: The Department of Energy has sunk about $5 billion into it so far and estimates it will cost an additional $6 billion to $7 billion to finish the plant, plus an additional $20 billion or so to turn the plutonium into fuel over 15 years. In its 2015 budget request released in March, the Department of Energy announced it will place the MOX project on “cold standby,” effectively mothballing the project for the foreseeable future. “It’s a major fiasco,” says Edwin Lyman, a senior scientist at the Union of Concerned Scientists. “Billions of taxpayer dollars have been wasted. It’s a classic boondoggle.”

The MOX plant is the latest blunder for the Department of Energy, which has a reputation for mismanaging big, complicated projects, particularly those related to nuclear energy. Costs for a nuclear waste treatment plant in Washington State have nearly tripled to $13 billion. A uranium processing facility in Tennessee once estimated to cost around $1 billion is now tipping the scales at around $11 billion, according to an Army Corps of Engineers study. It’s also running about 20 years behind schedule. A Department of Energy spokesman declined to comment for this article…….http://www.businessweek.com/articles/2014-04-24/u-dot-s-dot-botches-plan-to-turn-nuclear-warheads-into-fuel