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Overview of System Integration Analysis Activities for Integrated Waste Management

Spent nuclear fuel (SNF) generated by the current fleet of commercial nuclear reactors is being stored at reactor sites in spent fuel pools (SFPs) and in dry independent spent fuel storage installations (ISFSIs). The U.S. Department of Energy Office of Nuclear Energy (DOE-NE) Integrated Waste Management (IWM) program is examining a suite of IWM system options and conducting supporting analyses to enable future informed choices. The IWM program is currently organized into the following four major areas: (1) IWM facilities and equipment concepts and development, (2) transportation capability analysis and support, (3) information technology solutions and support, and (4) system integration analysis and support. This paper focuses on the activities ongoing in the IWM system integration analysis and support area. Two main research activities in this area are: data and tools development, validation, and maintenance; and special studies, analyses, and assessments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Development of Cable Aging Acceptance Criteria for Nuclear Facilities

The aging of nuclear power plant electrical cables has been the subject of substantial research and development (R&D) projects in the nuclear industry, national and international laboratories, universities, and vendor organizations for several years. More specifically, these R&D efforts were conducted to develop equipment and techniques for assessing age-related degradation of in-service cables in nuclear facilities including power plants, research reactors, waste facilities and fuel fabrication plants. In recent years, cable R&D efforts in the nuclear arena have also included work to develop new cables for the next generation of reactors. Over time, exposure to harsh environmental conditions such as elevated temperatures, radiation, and humidity in nuclear installations can result in age-related degradation and failure of cables. In the current fleet of nuclear reactors, there are thousands of miles of cabling installed in each plant and many of these cables are exposed to these harsh environmental conditions. For these cables, the jacket and insulation polymers harden and become brittle over time, making them more susceptible to crack formation and growth, moisture intrusion, and other mechanisms that can lead to cable failure. Moreover, the existing U.S. fleet of 98 nuclear reactors has an average operating age of 38 years. Many of these nuclear power plants have applied for and almost all have been granted regulatory approval for license renewals to operate for 60 years, 20 years beyond their original 40-year life. Further, subsequent license renewals (SLRs) are underway with a few commercial nuclear power sites already approved to operate up to 80 years. As these reactors pursue operating life extensions, utilities must find a way to address issues associated with age-related degradation of cables. Designers of small modular reactors are also in need of technologies to evaluate the performance of cables that will be installed in harsher environments (e.g. higher temperatures, radiation doses, dose rates, etc.) than those present in current-generation reactors. Today, a variety of cable condition monitoring (CM) techniques have been developed and successfully used in nuclear facilities. These techniques are used to identify age-related degradation and assess the condition of cables to determine if their performance characteristics have changed with age. However, objective criteria must be developed for these CM tests to help quantify cable condition and thereby develop repair and replacement schedules. With operating life extending to 80 years and more SLRs on the horizon, both nuclear facilities and regulators need an objective means to determine the aged condition of cables.

36 MATERIALS SCIENCE↗

Development of Cable Aging Acceptance Criteria for Nuclear Facilities

The aging of nuclear power plant electrical cables has been the subject of substantial research and development (R&D) projects in the nuclear industry, national and international laboratories, universities, and vendor organizations for several years. More specifically, these R&D efforts were conducted to develop equipment and techniques for assessing age-related degradation of in-service cables in nuclear facilities including power plants, research reactors, waste facilities and fuel fabrication plants. In recent years, cable R&D efforts in the nuclear arena have also included work to develop new cables for the next generation of reactors. Over time, exposure to harsh environmental conditions such as elevated temperatures, radiation, and humidity in nuclear installations can result in age-related degradation and failure of cables. In the current fleet of nuclear reactors, there are thousands of miles of cabling installed in each plant and many of these cables are exposed to these harsh environmental conditions. For these cables, the jacket and insulation polymers harden and become brittle over time, making them more susceptible to crack formation and growth, moisture intrusion, and other mechanisms that can lead to cable failure. Moreover, the existing U.S. fleet of 98 nuclear reactors has an average operating age of 38 years. Many of these nuclear power plants have applied for and almost all have been granted regulatory approval for license renewals to operate for 60 years, 20 years beyond their original 40-year life. Further, subsequent license renewals (SLRs) are underway with a few commercial nuclear power sites already approved to operate up to 80 years. As these reactors pursue operating life extensions, utilities must find a way to address issues associated with age-related degradation of cables. Designers of small modular reactors are also in need of technologies to evaluate the performance of cables that will be installed in harsher environments (e.g. higher temperatures, radiation doses, dose rates, etc.) than those present in current-generation reactors. Today, a variety of cable condition monitoring (CM) techniques have been developed and successfully used in nuclear facilities. These techniques are used to identify age-related degradation and assess the condition of cables to determine if their performance characteristics have changed with age. However, objective criteria must be developed for these CM tests to help quantify cable condition and thereby develop repair and replacement schedules. With operating life extending to 80 years and more SLRs on the horizon, both nuclear facilities and regulators need an objective means to determine the aged condition of cables.

36 MATERIALS SCIENCE↗

Evaluated Nuclear Data Library, with ENDL2009.5-direct (2009.5 Rev.)

LLNL’s Nuclear Data and Theory Group have created a 2009.5 revised release of the Evaluated Nuclear Data Library (ENDL2009.5). This library is designed to support LLNL’s current and future nuclear data needs and will be employed in nuclear reactor, nuclear security and stockpile stewardship simulations with ASC codes. The ENDL2009 database was the most complete nuclear database for Monte Carlo and deterministic transport of neutrons and charged particles. It was assembled with strong support from the ASC PEM and Attribution programs, leveraged with support from Campaign 4 and the DOE/Office of Science’s US Nuclear Data Program. This document lists the revisions and fixes made in a new release called ENDL2009.5, by comparing with the existing data in the previous releases ENDL2009.3 and ENDL2009.4. In addition to the legacy library ENDL2009.5 from ENDL-format files generated by Fete, an ENDL2009.5-direct library is also released, in which ENDF6-formatted sources are used wherever possible to avoid possible translation errors from Fete.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Overview of System Integration Analysis Activities for Integrated Waste Management

Spent nuclear fuel (SNF) generated by the current fleet of commercial nuclear reactors is being stored at the reactor sites in spent fuel pools (SFPs) and in dry independent spent fuel storage installations (ISFSIs). The US Department of Energy Office of Nuclear Energy (DOE-NE) is developing an Integrated Waste Management Program (IWMP) comprising a suite of options and supporting analyses to enable future informed choices. The IWMP is organized into the following five major areas: 1) Consent-Based Siting, 2) IWM Facilities and Equipment Concepts and Development, 3) Transportation Capability Analysis and Support, 4) Information Technology Solutions and Support, and 5) System Integration Analysis and Support. This paper discusses the activities ongoing in the IWMP System Integration Analysis and Support area. Two main areas of research in system integration are data and tools development, as well as system analysis assessments. One of the tools being developed in the system integration area is the Used Nuclear Fuel-Storage, Transportation & Disposal Analysis Resource and Data System (UNF-ST&DARDS) tool. It is being developed as a foundational resource for DOE-NE to manage SNF data, along with several compatible analysis tools for time-dependent characterization of SNF and related systems. UNF-ST&DARDS has the unparalleled ability to track SNF through the entire back end of the fuel cycle—from the time the fuel is discharged from a reactor through its disposal in a geological repository. UNF ST&DARDS interfaces with the SCALE code system for nuclear analysis and COBRA-SFS for thermal analysis. Another main tool being developed is the Next Generation System Analysis Model (NGSAM). NGSAM is an agent-based simulation software tool expressly designed to be capable of modeling the waste management system. NGSAM has been developed to enable informed decision-making by providing the capability of analyzing various potential system options for the management of SNF and HLW. Using NGSAM, system architecture analyses are being conducted to support the future deployment of a comprehensive nuclear waste management system that considers all major back-end aspects of the nuclear fuel cycle (i.e., transportation, storage, and disposal). System analysis assessments may investigate the implications of various strategies such as different acceptance rates, acceptance queues, facility capacities and options, standardized canisters, and different assumed system operation start dates. Recently, some system analysis effort has begun to look at how the waste management system might operate for advanced reactor fuel cycles.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Advanced Fuels Campaign Time-at-Temperature Irradiation Campaign and Post-Irradiation Examination Plan

With increasing per capita energy consumption and rapidly growing energy consumption predicted for data centers, the US faces challenges in meeting projected energy demands. The current administration is attempting to accelerate the deployment of new nuclear construction by providing significant investments in advanced nuclear and by modernizing regulatory approaches for the licensing new reactors. However, enabling extended power uprates (EPUs) for the current nuclear reactor fleet would provide a shorter-term solution to better calibrate near-term energy generation capacity to the ever-growing energy demands of the modern era. One pathway to achieve power uprates is to increase the operational window by reassessing fuel safety limits around anticipated transients. Existing light-water reactors (LWRs) utilize a targeted operational window with well-defined operational efficiencies, yet this window is also often bound by conservative safety limits that result in suboptimal operational performance. For example, the operation of the existing fleet is highly constrained by safeguards to operation related to anticipated operational occurrences (AOOs), which are moderate-frequency transients expected with a frequency greater than 0.01 per reactor-year. These AOOs include temperature excursions where the critical heat flux for the system is exceeded, resulting in a departure from nucleate boiling (DNB) at the cladding surface. This DNB event is a thermohydraulic condition that, with current conservative fuel safety limits, results in the fuel rods being classified as “failed,” meaning that the cladding may not be returned to service.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Advanced Fuels Campaign Time-at-Temperature Irradiation Campaign and Post-Irradiation Examination Plan

With increasing per capita energy consumption and rapidly growing energy consumption predicted for data centers, the US faces challenges in meeting projected energy demands. The current administration is attempting to accelerate the deployment of new nuclear construction by providing significant investments in advanced nuclear and by modernizing regulatory approaches for the licensing new reactors. However, enabling extended power uprates (EPUs) for the current nuclear reactor fleet would provide a shorter-term solution to better calibrate near-term energy generation capacity to the ever-growing energy demands of the modern era. One pathway to achieve power uprates is to increase the operational window by reassessing fuel safety limits around anticipated transients. Existing light-water reactors (LWRs) utilize a targeted operational window with well-defined operational efficiencies, yet this window is also often bound by conservative safety limits that result in suboptimal operational performance. For example, the operation of the existing fleet is highly constrained by safeguards to operation related to anticipated operational occurrences (AOOs), which are moderate-frequency transients expected with a frequency greater than 0.01 per reactor-year. These AOOs include temperature excursions where the critical heat flux for the system is exceeded, resulting in a departure from nucleate boiling (DNB) at the cladding surface. This DNB event is a thermohydraulic condition that, with current conservative fuel safety limits, results in the fuel rods being classified as “failed,” meaning that the cladding may not be returned to service.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

The MUSIC Critical Benchmark and Nuclear Data

The Measurement of Uranium Subcritical and Critical (MUSIC) experiment was a series of measurements of critical and subcritical configurations of bare highly enriched uranium. The goal was to compare measurement methods, analysis techniques, and simulation methods across regimes of criticality and to provide high-quality validation of 235 U nuclear data. A benchmark evaluation of the two critical configurations of the MUSIC experiments will soon be published in the release of the International Criticality Safety Benchmark Evaluation Project Handbook. The recent execution of the experiment aids in proper quantification of model simplifications and all uncertainties associated with the experiment. Historical benchmark evaluations are heavily relied on for uranium nuclear data validation despite the fact that the same level of documentation and comparable uncertainty analysis may not be present. The MUSIC evaluation is less likely to include “unknown unknowns” that could impede accurately modeling the system. Presented are both highly detailed and very simplified models, which represent the experimental configurations accurately, aiding the users of the benchmark for nuclear data or transport code validation. The sensitivities of k eff to nuclear data and nuclear data–related uncertainties are very similar between this experiment and previous bare uranium sphere experiments. In addition, the nuclear data uncertainties to any nuclides other than 235 U are small. For all these reasons, the recently evaluated MUSIC benchmark critical configurations could prove very useful for 235 U nuclear data validation. Currently, major libraries have good agreement with the experimental results, within 200 pcm for all nuclear data libraries, and within one standard deviation of the experimental result for most. Suggested nuclear data adjustments based on MUSIC and Lady Godiva are also presented, with posterior improvements to both the agreement in k eff and the uncertainty associated with the nuclear data.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NUCLEI (SciDAC-4) effort at The University of Tennessee, Knoxville

This Report summarizes the accomplishments of NUCLEI researchers at The University of Tennessee, Knoxville (UTK) and those supported via subcontracts at the University of North Carolina at Chapel Hill (UNC) and Iowa State University (ISU). The SciDAC-4 NUCLEI collaboration had the goal to advance the computation of atomic nuclei and to make reliable predictions including uncertainty estimates for observables of interest. These goals were achieved by developing improved nuclear interactions and currents that are input to the computations, and by advancing the algorithms and techniques used for computing nuclear observables of interest. The computed results advanced our understanding of how nuclei work; they helped to guide and interpret experiments at existing low-energy nuclear physics facilities, the Facility for Rare Isotope Beams, Jefferson Laboratory, and neutrino experiments. In addition, predictions were made that await confrontation with experimental results.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Performance of Pulsed Thermal Tomography Imaging with Machine Learning-Based Classification of Defects in Additively Manufactured Structures

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of complex topology nuclear reactor parts from high-strength corrosion resistance alloys, such as stainless steel and Inconel. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process. Some of the challenges with using LPBF method for nuclear manufacturing include the possibility of introducing pores into metallic structures. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures in high temperature nuclear reactor environment. Currently, there exist limited capabilities to evaluate actual AM structures non-destructively. Pulsed Thermal Tomography Imaging (PTT) provides a capability for non-destructive evaluation (NDE) of subsurface defects in arbitrary size structures. The PTT method is based on recording material surface temperature transients with infrared (IR) camera following thermal pulse delivered on material surface with flash light. The PTT method has advantages for NDE of actual AM structures because the method involves one-sided non-contact measurements and fast processing of large sample areas captured in one image. Following initial qualification of an AM component for deployment in a nuclear reactor, a PTT system can also be used for in-service nondestructive evaluation (NDE) applications. In this report, we describe recent progress in enhancing PTT capabilities in detecting and visualizing microscopic defects in metallic specimens. The thermal tomography (TT) algorithm obtains depth reconstructions of spatial effusivity from the data cube of sequentially recorded surface temperatures. However, interpretation of TT images is non-trivial because of blurring of images with increasing depth. To address this challenge, we have developed a deep learning convolutional neural network (CNN) to classify size and orientation subsurface defects in simulated TT images. CNN is trained on a database of TT images created for a set of simulated metallic structures with elliptical subsurface voids. Test of CNN performance demonstrate the ability to classify radii and angular orientation of subsurface defects in TT images. In addition, we have shown that CNN trained on elliptical defects is capable of classifying irregular-shaped defects obtained from scanning electron microscopy (SEM) of stainless steel sections printed with LPBF.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

FY23 ION Based Approaches to Address Labor and Knowledge Retention

This study will seek to outline the current problem facing the nuclear industry related to staffing, training, and retaining the necessary workforce for long-term sustainability. A review of published reports and knowledge gained by working in the nuclear energy sector will form the basis for this scoping study. This study will not seek to draw any conclusions regarding the underlying causes of these personnel issues but will attempt to ask questions and help outline future research. The Integrated Operations for Nuclear business model provides opportunities to partially mitigate some of the current issues facing staffing the nuclear fleet. Upgrading safety and control systems from analog to digital as advocated by the Integrated Operations for Nuclear process allows the nuclear facility to compete for the best and brightest candidates and offers them a broad and sustainable career path where their skills can be valued and utilized in the broader industrial sectors. This study will seek to identify the primary reasons that the nuclear industry is facing this labor crisis and seek to identify possible solutions that will be fully evaluated in future research.

42 ENGINEERING↗

Charge radii of exotic potassium isotopes challenge nuclear theory and the magic character of N = 32

Nuclear charge radii are sensitive probes of different aspects of the nucleon–nucleon interaction and the bulk properties of nuclear matter, providing a stringent test and challenge for nuclear theory. Experimental evidence suggested a new magic neutron number at N = 32 in the calcium region, whereas the unexpectedly large increases in the charge radii open new questions about the evolution of nuclear size in neutron-rich systems. By combining the collinear resonance ionization spectroscopy method with β-decay detection, we were able to extend charge radii measurements of potassium isotopes beyond N = 32. Here we provide a charge radius measurement of 52 K. It does not show a signature of magic behaviour at N = 32 in potassium. The results are interpreted with two state-of-the-art nuclear theories. The coupled cluster theory reproduces the odd–even variations in charge radii but not the notable increase beyond N = 28. This rise is well captured by Fayans nuclear density functional theory, which, however, overestimates the odd–even staggering effect in charge radii. These findings highlight our limited understanding of the nuclear size of neutron-rich systems, and expose problems that are present in some of the best current models of nuclear theory.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Complete Evaluation of ION Cost Reduction Opportunities for LWRS Pathways

The Light Water Reactor Sustainability (LWRS) Program, sponsored by the U.S. Department of Energy (DOE), plays a pivotal role in enhancing the sustainability, safety, and economic viability of the nation's fleet of nuclear power plants. This program collaborates extensively with industry, vendors, suppliers, regulatory agencies, and research and development organizations within the nuclear energy sector. The overarching goals of the LWRS program are twofold: to provide innovative science and technology-based solutions to the nuclear industry, surpassing current performance models, and to manage the aging of systems, structures, and components (SSCs) to extend the operational lifetimes of nuclear power plants safely, efficiently, and economically. The program focuses on five research and development pathways: Plant Modernization: This pathway seeks to enhance the economic viability of nuclear power plants in evolving energy markets through innovation, efficiency improvements, and digital transformation. The integration of digital technologies into plant operations is a central theme, aiming to create a seamless digital environment that improves plant economics and safety. Flexible Plant Operation and Generation: Research efforts in this pathway explore opportunities for light-water reactors (LWRs) to directly supply energy to industrial processes, diversifying revenue generation approaches and improving economic sustainability.

42 ENGINEERING↗

Demonstration of the Human and Technology Integration Guidance for the Design of Plant-Specific Advanced Automation and Data Visualization Techniques

Nuclear power continues to be a safe, reliable, and carbon-free electricity generating source for the United States, though the cost of operating and maintaining the current United States nuclear power plant fleet has become uncompetitive with other sources. This gap is attributed to the advent of new digital instrumentation and control technologies that other electricity generating industries are currently leveraging to streamline work and greatly reduce operating, maintenance, and support costs. Digital instrumentation and control systems and control room modernization offers significant opportunities to reduce operating and maintenance costs to ensure the continued operation of the existing United States light-water reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Design and Prototyping of Advanced Control Systems for Advanced Reactors Operating in the Future Electric Grid (Final Report)

Despite its significant advantages as a baseload, low-carbon energy source, the U.S. nuclear power industry has faced increasing difficulties in maintaining economic competitiveness in a rapidly evolving energy market. The economic conditions faced by the current fleet of nuclear power plants (NPPs) in the U.S. deregulated electricity market require a concerted effort to mitigate specific cost factors. Many units are struggling to stay competitive, and some premature shutdowns have occurred. Besides, in response to the large penetration of renewable energy sources, the role of nuclear power plants as pure baseload units needs to be reconsidered. Based on these experiences, operational flexibility is considered a fundamental requirement for the next generation of nuclear reactors to be competitive in the future energy market. The deployment of advanced reactors capable of operating within a new power grid paradigm, known as the Integrated Energy System (IES) was investigated. This approach combines new reactor designs with Thermal Energy Storage (TES) technologies, allowing the nuclear reactor to maintain a steady power output without the need for constant adjustments in response to load demand fluctuations. With this configuration, the reactor operates as a baseload unit, experiencing only very gradual power transients, while the energy storage facility within the power conversion cycle acts as a peaking unit.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Preliminary Feasibility of Printing, Microstructure Analysis and Mechanical Performance of a Down Selected Ni Alloy

This report is submitted as completion of a Milestone 3 deliverable under work package ORNL CT-23OR1304051 in support of the Advanced Materials and Manufacturing Technologies (AMMT) program. The AMMT program is aiming at the faster incorporation of new materials and manufacturing technologies into complex nuclear-related systems. An integrated approach, combining advanced characterization, high-throughput and accelerated testing, modeling and simulation including machine learning and artificial intelligence will be employed. While 316H (Fe-16-18Cr-10-14Ni-2-3Mo-0.04-0.1C) has been identified as a key alloy to be integrated into the AMMT accelerated alloy qualification approach due its relevance for many current and future nuclear energy reactors, many other alloys could be considered for the advanced fabrication of innovate high-performance nuclear components. ANL, INL, ORNL and PNNL are collaborating on identifying the most promising alloy candidates relevant for the AMMT program. A selection criteria matrix was established to evaluate the alloys considering their relative importance and technological readiness levels for nuclear energy applications, with a focus on laser powder bed fusion (LPBF). Due to the broad range of potential candidate alloys, ORNL and INL focused on Ni-based alloys, while ANL and PNNL mainly evaluated Fe-based alloys. PNNL previously published materials scorecards reports on several key alloys and this report is providing a broader overview of Ni-based candidate alloys, expending beyond alloys well-known to the nuclear community. Of particular interest are alloys that are currently commercially available in powder form due to the growing demand from other industries that have invested heavily in additive manufacturing. Among these alloys, Haynes 282 (Fe-20Cr-20Co-8Mo) was selected due to its superior strength at high temperature compared to the code-qualified alloy 617 (Ni-20-24Cr-10-15Co-8-10Mo). To assess the integration of this new alloy into the AMMT digital manufacturing framework, we performed the rapid optimization of alloy 282 printing parameters on a Renishaw 250 machine, the fabrication of sufficient materials for extensive characterization and mechanical testing both at ORNL and INL, and added the printing data into the digital platform via the Peregrine software. A detailed analysis of the LPBF 718 alloy was also conducted, with creep specimens being tested at 600-650°C and characterized by advanced electron microscopy. The alloy superior mechanical strength and great printability associated with the extensive database that has already been generated highlight the promising potential of LPBF 718 as a candidate alloy for the AMMT program. INL, ANL and PNNL have generated similar reports and all the information will be compiled into a final M2 milestone report to provide the AMMT leadership team with clear recommendations on the down selection of reactor materials, as well as establish a roadmap for the qualification of these selected alloys.

36 MATERIALS SCIENCE↗