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The forging of an enormous 235 ton steel
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ingot was launched by metallurgists in
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late March 2026, marking an important
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milestone in Russia's nuclear energy
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sector. This operation is being
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conducted at one of the world's largest
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automated forging complexes and
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signifies the beginning of production
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for a critical component of the advanced
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Vertoy nuclear reactor.
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The central cylindrical section of the
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reactor pressure vessel for unit 3 of
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the Kursk nuclear power plant two will
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be formed by the forged portion which is
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referred to as the shell.
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This development highlights Russia's
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continued push toward advanced nuclear
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technology through innovation in
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material science, engineering design,
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and industrial manufacturing.
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As Altitude Addicts observes, the Vivver
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TOI reactor represents decades of
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accumulated expertise in nuclear
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engineering. It is a next generation
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pressurized water reactor that combines
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improved efficiency, longer operational
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life, and significantly enhanced safety
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Moving deeper into the process, the
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scale and complexity of nuclear forging
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reveal just how extraordinary this
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achievement truly is. The forging of a
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ingot is not just an industrial
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operation. It is a demonstration of
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precision engineering and metallurgical
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Designed to withstand extreme conditions
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such as long-term radiation exposure,
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immense pressure, and very high
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temperatures. The ingot is made from a
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specially formulated steel. Its internal
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structure and chemical composition must
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be carefully controlled to meet these
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demanding requirements.
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In total, the weight of steel ingots
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required for manufacturing the reactor
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vessel components will exceed 2,150
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tons. Each ingot is cast and processed
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separately with every piece assigned to
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a specific section of the reactor
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However, the largest ingot is reserved
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for the most critical part, the outer
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shell of the reactor core zone.
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What makes this component especially
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unique is its monolithic structure.
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Unlike traditional reactor vessels that
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rely heavily on welded sections, the
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VRTI design eliminates weld seams in the
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core shell. This significantly improves
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structural integrity and reduces the
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risk of long-term defects or failures.
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As we transition into the materials
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behind this engineering feat, the
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importance of advanced metallergy
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becomes even clearer.
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The steel used in the VOI reactor vessel
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is a specialized alloy designed to
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retain its strength and durability under
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extreme reactor conditions. Over decades
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of operation, reactor components face
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neutron irradiation, thermal cycling and
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sustained high pressure environments.
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These factors can cause embritment and
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fatigue in ordinary materials.
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To overcome these challenges, Russian
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engineers developed a steel grade that
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resists radiation damage while
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maintaining toughness.
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This allows the reactor vessel to
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function safely over extended periods
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without significant degradation.
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Because of these innovations, the VVR2i
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reactor is designed to operate for up to
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100 years. Initially, it is licensed for
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60 years with the possibility of
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extending its life by an additional 40
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years through proper inspections and
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upgrades. This dramatically improves
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economic efficiency while reducing the
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need for costly replacements.
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Shifting focus toward engineering and
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manufacturing, several innovations
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further enhance the reactor's
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One of the defining features is the
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reduction of welded joints within the
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reactor vessel. While welding is
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essential in many industries, it
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introduces potential weak points. By
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minimizing welds, engineers have
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improved both reliability and production
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Fewer welds mean faster manufacturing,
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reduced labor, and simpler maintenance.
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Inspection processes also become easier
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as there are fewer critical junctions to
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monitor. This leads to lower operational
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costs and improved overall performance.
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Another major innovation lies in the
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design of the main circulation pump.
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Traditionally, such systems rely on oil
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for lubrication and cooling. However,
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the Verttoi reactor uses water instead.
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This eliminates fire risks and removes
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the possibility of oil leakage, making
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Naturally, this leads us into the safety
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systems that define modern nuclear
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design. Safety remains the highest
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priority, and the VR toy combines both
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active and passive safety mechanisms.
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Active systems require external power
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and control while passive systems
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function automatically using natural
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physical principles like gravity and
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pressure differences.
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One of the most remarkable features is
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the core catcher. This device is
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designed to contain and cool molten
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nuclear fuel in the extremely unlikely
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event of a severe accident. As
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highlighted by Altitude Addicts, this is
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one of the most advanced safety
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technologies currently available in the
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Together, these systems ensure that the
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reactor can withstand a wide range of
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emergency scenarios, including power
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loss, coolant leaks, and external
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impacts. These advancements align with
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international safety standards and
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strengthen trust in nuclear energy.
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Turning now to the broader project, the
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Kursk nuclear power plant 2 plays a
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central role in this transformation.
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It is designed to replace the older
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Kursk plant which operates RBMK 10000
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reactors from the Soviet era. These
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older reactors are gradually being
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phased out. The new facility will
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consist of four power units equipped
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with V or Y reactors. Once completed,
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the station's total power output is
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expected to increase by about 20%
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significantly boosting regional energy
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The first unit has already been
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connected to the grid and has reached
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full power. It is now preparing for full
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commercial operation, marking a major
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step forward in adopting next generation
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At the same time, progress continues
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across multiple units at the site.
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Unit 2 is undergoing preparation for
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safety testing with engineers conducting
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a series of system checks under various
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operating conditions.
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Meanwhile, unit 3, the one linked to
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this massive forging process, is still
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in its early construction phase. The
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first concrete was poured in December
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2025, and work is ongoing to complete
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the foundation. The forging of its
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reactor vessel marks a key step in the
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long manufacturing chain ahead.
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This synchronized progress demonstrates
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the scale and coordination required for
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modern nuclear projects.
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It also reflects the efficiency of
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Russia's integrated nuclear industry
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where design, manufacturing, and
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construction work in close alignment.
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Expanding the perspective further, the
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implications of this development extend
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beyond a single power plant. As
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countries look for cleaner energy
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solutions, nuclear power is increasingly
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seen as a reliable option.
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Russia through its nuclear sector
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continues to position itself as a global
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leader by offering complete solutions
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from reactor construction to fuel supply
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and long-term operation.
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The success of the Viviver TOI could
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strengthen this position even further.
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With its focus on long service life,
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advanced safety, and efficient
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production, this reactor design aligns
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with global trends in sustainable
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energy. As Altitude Addicts concludes,
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such next generation systems could play
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a key role in meeting future energy
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In conclusion, the forging of this
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massive steel ingot represents far more
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than a manufacturing step. It symbolizes
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the evolution of nuclear engineering
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towards safer, more efficient, and
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longerlasting energy systems. As
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construction at Kursk nuclear power
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plant 2 continues, the world will be
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watching closely. If successful, this
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project could set new global standards
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for nuclear power and open the door to a
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new era of reliable and clean energy.
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