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DOE OSTI2025

Tantalum Experiments in Fully-Reflected Water-Moderated Triangular-Pitched U(6.90)O 2 Fuel Rod Lattices (1.02 cm Pitch)

The United States (US) Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories (SNL). The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5 % 235 U. The 7uPCX assembly is a water moderated and — reflected array of aluminum-clad U(6.90 %)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMP-THERM 096, LEU- COMP-THERM-097, LEU-COMP-THERM-101, LEU-COMP-THERM-102, and LEU-COMP-THERM-111. Applied interests in neutron-absorbing elements at epithermal and intermediate neutron energy ranges at DOE’s Hanford Site and Savannah River Site were identified through DOE Office of Environmental Management (EM) workshops and needs surveys performed in conjunction with the National Nuclear Security Administration/Nuclear Criticality Safety Program. In response, a team lead by Oak Ridge National Laboratory (ORNL) performed a study evaluating the use of 7uPCX for testing the epithermal cross sections of materials at SNL. This marked the inception of the set of experiments described here. The purpose of these experiments was to measure the effects of tantalum in nearly-critical systems. The tantalum was introduced into the fuel arrays as experiment rods within a central test region. The central test region was designed to target the epithermal neutron energy range by providing a dry cylindrical cavity constructed of aluminum and lined with 0.04 in (0.1016 cm) thick cadmium sheet. The central test region has an outer diameter of 3.75 in (9.525 cm) length of 31 in (78.74 cm) and can hold 85 tantalum rods nominally 0.25 in (0.635 cm) outside diameter and 31.25 in (79.375 cm) long. The critical experiments were done using a set of triangular-pitched grid plates fabricated for these experiments. The grid plate set accommodated a fuel array of a total of 2016 fuel rod positions on a pitch of 0.4 in (1.016 cm) in a series of 21 hexagonal rings positioned around the central test region. The fuel used in these experiments was fabricated using unirradiated 6.90 % enriched UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The eight cases in this experiment series were performed in 2024 in the Sandia Critical Experiments (SCX) at the Sandia Pulsed Reactor Facility by varying the number of fuel rods in the critical assembly. The personnel involved in conducting these experiments included David Ames, Elijah Lutz, Beth Hanson, Patrick Ward, Jason Soares, and Augie Chapa from SNL, as well as Mathieu Dupont and B.J. Marshall from ORNL. Case 1 had no tantalum experiment rods. Case 2 had seven tantalum rods in the center of the central test region. Case 3 had 18 tantalum rods in the third hexagonal ring of the central test region. Case 4 had 19 tantalum rods in the center of the central test region. Case 5 had 30 tantalum rods in the outer most positions of the central test region. Case 6 had 37 tantalum rods in the center of the central test region. Case 7 had 61 tantalum rods in the center of the central test region. Case 8 had 85 tantalum rods filling all positions in the central test region. All eight critical experiments are judged to be acceptable as benchmark experiments.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Automated reactor physics analysis framework of High Flux Isotope Reactor low-enriched uranium silicide dispersion fuel designs

The High Flux Isotope Reactor (HFIR) is a versatile research reactor that provides one of the highest steady-state neutron fluxes of any reactor in the world. The HFIR reactor physics team investigated the conversion of the current 93 wt% highly enriched uranium U 3 O 8 -Al dispersion fuel to a 19.75% low-enriched uranium (LEU) U 3 Si 2 -Al dispersion fuel. The team continuously develops a Python module to streamline the analysis steps required for an LEU core design to ensure reproducible and agile design iteration. The Python module automates the data processing between analysis steps and automates the input perturbation for branch calculations and design changes. The automated framework has proven to significantly increase the efficiency and reproducibility of the reactor physics team to design High Flux Isotope Reactor (HFIR) LEU cores and thoroughly analyze performance metrics, safety metrics, and thermal safety margins. Consequently, the team can now respond rapidly to fuel fabrication engineer and thermal-hydraulic-structural analyst requests. Numerous combinations of LEU fuel designs are explored, of which two LEU fuel designs are presented here in this paper: a low density silicide design, and a high-density silicide design. Results show that both designs meet or exceed safety and performance metrics with exception for minor differences caused by the hardened spectrum from LEU.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Comparing Low Enriched Fuel to Highly Enriched Fuel for use in Nuclear Thermal Propulsion Systems

Low enriched uranium (LEU) is an economically and politically friendly alternative to highly enriched uranium (HEU) that can enable the use of nuclear thermal propulsion (NTP) systems. Historically, only HEU reactors were considered for NTP due to need of minimum mass systems and the common perception that HEU nuclear cores will always make smaller reactors than LEU cores. However, recent studies have shown LEU NTP systems can be created to enable human Mars missions. These studies do not show the performance losses or gains when using an LEU system rather than an HEU system. The goal of this paper is to present four optimized NTP systems designed for the same 16,000 lbs-f thrust, with a combination of minimum mass and high specific impulse. The four designs differ in the nuclear fuel type; two contain a carbide composite fuel that is derived from historical experiments and two contain tungsten cermet fuel which has become a good fuel choice given advances in manufacturing techniques. Within each fuel type, LEU or HEU will be used. The final paper will contain core design details such as fuel dimensions, enrichment profiles, fuel layout and thermal design details including core pressure drops and hydrogen outlet conditions. Similar performances are found between HEU and LEU designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

A Plan to Qualify New Fuel for the High Flux Isotope Reactor for Material Minimization

The High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) is one of five high power research reactors the Office of Material Management and Minimization (M3) Program, Office of Conversion is working to convert from using highly enriched uranium (HEU) fuel to using low-enriched uranium (LEU) fuel. This effort stems from the primary objective within the U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA) to achieve permanent threat reduction by minimizing, and when possible, eliminating weapon-usable nuclear material around the world. Under M3’s Office of Conversion, the U.S. High Performance Research Reactor (USHPRR) Project is pursuing fuel qualification and licensing of LEU fuels to support the high-performance reactors. All high-performance reactors except HFIR will be converted to LEU monolithic uranium-molybdenum alloy fuel. HFIR will be evaluated for conversion to LEU using a uranium silicide fuel, namely, U3Si2-Al dispersion fuel. The mission of the USHPRR Project is to develop the technology needed to reduce, and eventually eliminate, worldwide use of HEU in civilian applications. The goal is to develop the technical means needed to use low enriched uranium (LEU) instead of HEU fuel in research and test reactors without significant penalties in performance, economics, or safety of the reactors. The USHPRR Project has four major elements, called Pillars: Fuel Qualification (FQ) managed at Idaho National Laboratory (INL), Fuel Fabrication (FF) managed at Pacific Northwest National Laboratory (PNNL), Reactor Conversion (RC) managed at Argonne National Laboratory (Argonne), and Cross-Cutting (CC) managed at Savannah River National Laboratory (SRNL). FQ is responsible for the qualification of the fuel type. RC is responsible for supporting reactor conversion analysis and overseeing licensing submittals leading to conversions of domestic reactors to LEU fuel. For the FQ effort, FQ (INL) worked in collaboration with RC (Argonne) and ORNL to develop the plan for the uranium silicide fuel qualification for HFIR. The resulting HFIR Fuel Qualification Plan provides the general approach for the USHPRR team to move the selected uranium silicide fuel design for HFIR conversion through qualification. Authorization and use in HFIR will be approved through the DOE’s Office of Science. Uranium silicide fuel was previously qualified in NUREG-1313 at an approximate maximum heat flux of 1.4 MW/m2 and a maximum fuel section temperature of about 130°C. In addition to the different regulator process utilized by DOE, these upper limits will be exceeded in HFIR; therefore, further testing will be necessary to ensure the fuel can meet HFIR qualification requirements. The HFIR fuel loading may exceed 4.8 gU/cm3 which was determined in the NUREG-1313 safety evaluation to be acceptable for use in non-power NRC-licensed reactors provided there exist no other safety considerations. In addition, the uranium silicide fuel will need to be qualified in a HFIR-specific design. This plan includes the currently available information from the USHPRR Project Functions and Requirements document and expands these requirements to ensure that planned tests have traceable results providing evidence that the requirements have been met. Data collection methods are discussed as well as the process to show that the requirements have been met. This document is designed to provide a pathway for researchers to obtain data necessary and at the appropriate quality level for HFIR fuel qualification

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Impact of U-10Mo HALEU Fuel Element Tolerances on the Massachusetts Institute of Technology Reactor safety and operational performance – Neutronics

The U.S. is coordinating efforts for the conversion of six U.S. high performance research reactors (USHPRR), including one critical assembly from highly enriched uranium (HEU) to low-enriched uranium (LEU). In order to continue the mission of these reactors, including the Massachusetts Institute of Technology Reactor (MITR), and achieve similar performance, high assay low-enriched uranium (HALEU) with a high-density metallic alloy of uranium with 10 wt% molybdenum (U-10Mo) is being considered. Following the preliminary design of the proposed MITR LEU fuel elements using the U-10Mo monolithic alloy, the impact of the fabrication specification was assessed. This work focuses on the analysis of select neutronics characteristics of the MITR LEU core as a function of the variation of the relevant fuel specification parameters (e.g., U-10Mo composition, fuel plate thickness, etc.). A separate article submitted to this journal addresses the impact on the thermal hydraulic performance. The analyses in these works are performed based on an all-LEU conversion management plan identified in previous work, in which only the proposed elements are utilized for achieving the conversion of MITR. The variations of two main neutronics characteristics are assessed as a function of the variability of the specification parameters resulting from the fabrication process: the MITR LEU core reactivity and the fuel cycle length. The main findings of this work show that the MITR core can meet the operational requirements during the LEU transition plan under the limiting fabrication parameter combinations considered. In addition, the analyses show that the dependency of the core neutronics characteristics on the specification parameters is highly linear within the specification tolerances. The rates of variation are reported in detail for each parameter and can serve as a powerful tool for future MITR fuel management in cases such as when HALEU supply is established that may allow additional cycle length or other operational benefits.

Conversion↗

DOE OSTI2016

A reload and startup plan for conversion of the NIST research reactor

The National Institute of Standards and Technology operates a 20 MW research reactor for neutron-based research. The heavy-water moderated and cooled reactor is fueled with high-enriched uranium (HEU) but a program to convert the reactor to low-enriched uranium (LEU) fuel is underway. Among other requirements, a reload and startup test plan must be submitted to the U.S. Nuclear Regulatory Commission (NRC) for their approval. The NRC provides guidance for what should be in the plan to ensure that the licensee has sufficient information to operate the reactor safely. Hence, a plan has been generated consisting of two parts. The reload portion of the plan specifies the fuel management whereby initially only two LEU fuel elements are in the core for eight fuel cycles. This is repeated until a point when the optimum approach is to place four fresh LEU elements into the reactor each cycle. This final transition is repeated and after eight cycles the reactor is completely fueled with LEU. By only adding two LEU fuel elements initially, the plan allows for the consumption of HEU fuel elements that are expected to be in storage at the time of conversion and provides additional qualification of production LEU fuel under actual operating conditions. Because the reload is to take place over many fuel cycles, startup tests will be done at different stages of the conversion. The tests, to be compared with calculations to show that the reactor will operate as planned, are the measurement of critical shim arm position and shim arm and regulating rod reactivity worths. An acceptance criterion for each test is specified based on technical specifications that relate to safe operation. Additional tests are being considered that have less safety significance but may be of interest to bolster the validation of analysis tools.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

A Reload and Startup Plan for and #8233;Conversion of the NIST Research Reactor

The National Institute of Standards and Technology operates a 20 MW research reactor for neutron-based research. The heavy-water moderated and cooled reactor is fueled with high-enriched uranium (HEU) but a program to convert the reactor to low-enriched uranium (LEU) fuel is underway. Among other requirements, a reload and startup test plan must be submitted to the U.S. Nuclear Regulatory Commission (NRC) for their approval. The NRC provides guidance for what should be in the plan to ensure that the licensee has sufficient information to operate the reactor safely. Hence, a plan has been generated consisting of two parts.The reload portion of the plan specifies the fuel management whereby initially only two LEU fuel elements are in the core for eight fuel cycles. This is repeated until a point when the optimum approach is to place four fresh LEU elements into the reactor each cycle. This final transition is repeated and after eight cycles the reactor is completely fueled with LEU. By only adding two LEU fuel elements initially, the plan allows for the consumption of HEU fuel elements that are expected to be in storage at the time of conversion and provides additional qualification of production LEU fuel under actual operating conditions. Because the reload is to take place over many fuel cycles, startup tests will be done at different stages of the conversion. The tests, to be compared with calculations to show that the reactor will operate as planned, are the measurement of critical shim arm position and shim arm and regulating rod reactivity worths. An acceptance criterion for each test is specified based on technical specifications that relate to safe operation. Additional tests are being considered that have less safety significance but may be of interest to bolster the validation of analysis tools.

42 ENGINEERING↗

DOE OSTI2018

Alternate Design Concepts for the High Flux Isotope Reactor using Low-Enriched Uranium Fuel Systems: Scoping Analysis

The Oak Ridge National Laboratory (ORNL) High Flux Isotope Reactor (HFIR) is a multi-mission research reactor dedicated mainly to isotope production, neutron scattering experiments, material irradiation, testing and activation. In the framework of non-proliferation policies, the international community is currently aiming to reduce or even eliminate, when and where possible, the use of Highly Enriched Uranium (HEU: 235 U/U ≥ 20 wt. %) in civilian applications. In that context, most research reactors worldwide still operating with HEU fuel are actively engaged in an effort to convert to Low Enriched Uranium fuel system (LEU: 235 U/U < 20 wt. %). Within the US, the High Performance Research Reactor (USHPRR) fleet (which includes HFIR) is expected to convert to LEU fuel using the UMo “monolithic” fuel system currently under development. ORNL is responsible for the development of a LEU design for HFIR. In the past years, Argonne National Laboratory (ANL) offered technical assistance to the ORNL LEU design team whenever deemed appropriate. Due to their complex nature, acceptable HFIR LEU designs identified so far, all based on the UMo monolithic fuel system, would require a substantial fabrication development effort before being proven commercially viable. In order to mitigate technical risks and reduce cost/schedule uncertainties, it appears appropriate to study alternate design solutions and alternate fuel systems as possible backup options for the HFIR conversion to LEU fuel. In that context, ANL has been exploring alternate design concepts for HFIR. Complementing the ORNL design activities, the goal is to find the best design solution for HFIR in term of cost, performance and safety. The present report summarizes the findings regarding two types of alternate conceptual design: U 3 Si 2 designs and un-contoured UMo design. Based on available tools and methods, preliminary analysis show that both concepts could probably meet performance and steady-state safety requirements but element fabrication would remain complex and would require a non-trivial fabrication development effort.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2019

Safety Analysis of the Mo-99 Production Upgrade to the University of Missouri Research Reactor (MURR) with Highly-Enriched and Low-Enriched Uranium Fuel

The University of Missouri has been working in conjunction with Argonne National Laboratory (ANL) in the National Nuclear Security Administration (NNSA) Material Management and Minimization (M3) Reactor Conversion Program to support conversion of the University of Missouri- Columbia Research Reactor (MURR®) from highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel. MURR is one of five U.S. High Performance Research Reactors (USHPRR) plus a critical facility that plans to convert to the use of LEU fuel. The purpose of this report is to document the safety margins for both HEU and LEU cores with the Mo-99 production upgrade proposed, designated as the 2017-RBM-99 device in this report. In addition to the 2017-RBM-99 device, the neutronics models also include descriptions of the experimental facilities and experiment loading that are currently typical for MURR and which are different from the experiments that were modeled in the analysis performed for the PSAR. Lastly, there have been changes to the LEU fuel element design with regard to the coolant channel thickness tolerances for the innermost and outermost coolant channels based on feedback from the fuel fabricator. This design change did not change the nominal dimensions of the coolant channels/fuel plates or fuel loading of the fuel plates in the element. Thus, for the purpose of the neutronics analysis for the 2017-RBM-99 upgrade, which is based on nominal dimensions and fuel loadings, the components of the LEU element are modeled the same as in the PSAR analysis. However, the design tolerance changes were incorporated in the calculations of the steady-state safety margins for both HEU and LEU. While the use of fewer significant figures has simplified fabrication, yet there were no negative impacts, including on safety margins, since the end channels were not limiting locations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

High Flux Isotope Reactor Low-Enriched Uranium Low Density Silicide Fuel Design Parameters

High Flux Isotope Reactor (HFIR) highly enriched uranium (HEU) to low-enriched uranium (LEU) conversion activities are ongoing as part of the Department of Energy (DOE) National Nuclear Security Administration (NNSA)’s nuclear nonproliferation mission. Design activities studying the conversion of HFIR from HEU to LEU fuel explored different fuel design features and shapes with a low density uranium-silicide dispersion (U 3 Si 2 -Al) fuel, which has a uranium density of 4.8 gU/cm 3 . The goal of these studies is to generate several HFIR LEU fuel designs of varying fuel fabrication complexity that meet the current HEU performance metrics and safety requirements. The documented designs will serve as references for fuel fabrication and qualification activities. Recent advancements in modeling and simulation tools enable quick prototyping of fuel designs. Shift, a Monte Carlo neutron transport and depletion tool optimized for high-performance computing (HPC) architectures, is used for efficient fuel cycle and performance metrics calculations. The HFIR Steady State Heat Transfer Code (HSSHTC) is used to vet the thermal safety margin. Also, a new automation tool that connects all fuel design analysis steps, named Python HFIR Analysis and Measurement Engine (PHAME), has been developed to expedite the design study in an efficient and reproducible manner. Leveraging these tools, several candidate fuel designs were selected for varying fabrication complexity. This report provides design feature details for four selected HFIR LEU low density U 3 Si 2 -Al fuel designs and their corresponding performance and safety metrics. Nominal, best-estimate design parameters and irradiation conditions, including fission rate densities, power densities, heat fluxes, and cumulative fission densities are provided for candidate fuel designs relevant to framing irradiation experiments to support fuel qualification efforts. Simulations show that the low density U 3 Si 2 -Al, with design features to enhance safety, can meet HEU core performance metrics and safety requirements if the reactor power is increased from 85 MW (HEU) to 95 MW (LEU) and if the active fuel length is increased from 50.80 cm (HEU) to 55.88 cm (LEU).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

High Flux Isotope Reactor Low Enriched Uranium U-10Mo Fuel Design Parameters

Activities to convert the HFIR from HEU to LEU are ongoing as part of the US Department of Energy (DOE) National Nuclear Security Administration (NNSA) nuclear nonproliferation mission. Design activities to study the conversion of HFIR from HEU to LEU fuel explored different fuel design features and shapes with a uranium-molybdenum (U-10Mo) monolithic alloy fuel. This high-density alloy contains 90 wt % uranium and 10 wt % molybdenum and has a uranium density of 15.318gU/cm 3 . The goal of these studies is to generate several candidate HFIR LEU fuel designs of varying fuel fabrication complexity that meet the current HEU performance metrics and safety requirements. Recent advancements in modeling and simulation tools and design methods enabled a thorough analysis of the available design space with U-10Mo fuel. A surrogate model used this analysis as training data to quickly determine the performance of a design given specific design parameters. An optimization module used this surrogate model to quickly search this multidimensional search space given specific desired performance characteristics. This approach was made possible by the large available design space with U-10Mo fuel. Shift, a Monte Carlo tool optimized for high-performance computing (HPC) architectures, was used for faster calculation and better data management for reactor physics simulations. Once most of these design studies were complete, a new suite called the Python HFIR Analysis and Measurement Engine (PHAME) was developed to connect all fuel design analysis steps, making design studies more efficient and reproducible. The post-processing capabilities of these new tools are leveraged for the information provided herein. Leveraging these tools, several candidate fuel designs were selected with varying levels of feature complexity and reactor performance. This report provides design feature details for four selected HFIR LEU U-10Mo fuel designs and their corresponding performance and safety metrics. Nominal best-estimate design parameters and irradiation conditions, including fission rate densities, power densities, heat fluxes, and cumulative fission densities, are provided. Simulations show that the high uranium density of U-10Mo fuel provides a large potential design space that enables various LEU designs to meet HEU core performance metrics and safety requirements with a power increase from 85 MW (HEU) to 95 MW or 100 MW (LEU).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Technical Considerations on MURR Control Blade Design Change and Testing using a New Metal Matrix Composite

The University of Missouri Research Reactor (MURR) is one of six research reactors, including a critical facility, that are pursuing conversion as part of a collaboration with the U.S. Department of Energy National Nuclear Security Administration Material Management and Minimization Office of Reactor Conversion and Uranium Supply, under the U.S. High Performance Research Reactors (USHPRR) conversion project. Five of the six USHPRR are planned to convert from highly enriched uranium (HEU) fuel using a low-enriched uranium (LEU) high assay monolithic alloy of uranium-10 wt% molybdenum (U-10Mo). As part of the conversion safety analysis, it is necessary to demonstrate the safety performance of the proposed core fueled with LEU as compared to the current HEU cores. The MURR reactor is planning to switch to a new control blade design that uses a metal matrix composite of boron carbide (B 4 C) and aluminum as the absorber in place of Boral®. Since MURR is expected to adopt the new metal matrix composite control blade design prior to conversion, the impact of the new blade design on the neutronics characteristics of the MURR cores for conversion are analyzed in this work through updates to incorporate the changes to the blade design in conversion models as they directly impact the LEU conversion safety analysis. The quantitative comparison shows that the neutronics and thermal hydraulic behavior of one metal matrix composite blade replacing a Boral blade is comparable for the two example MURR LEU and HEU cores states considered. Geometrical changes in the metal matrix composite blade design, combined with a 4% increase in areal boron density, showed local heating effects up to 20% higher than the Boral design. As expected, the metal matrix composite showed slightly lower heat depositions and absorber region temperatures for the LEU cases compared to HEU. Although this analysis was comparative for a single blade, maximum control blade temperatures for both Boral, metal matrix composite, and HEU/LEU remained below 100 °C, though additional analysis at a core level could differ. A qualitative irradiation behavior assessment concludes that the mechanisms that may drive swelling and blistering in the current Boral design are eased by the adoption of the metal matrix composite design. The work concludes that the two blade designs are essentially equivalent with regards to neutronics, thermal hydraulics, and expected material behavior under irradiation. However, due to the geometrical changes to the blades including redesigned and thinner cladding, new testing and increased surveillance for distortion and swelling are recommended to confirm the performance of the metal matrix composite control blade design. Where testing is completed prior to conversion, the only anticipated impacts on conversion to LEU U-10Mo fuel would be the need for models and safety analysis incorporating the metal matrix composite control blades.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

A Plan to Qualify New Fuel for the High Flux Isotope Reactor for Material Minimization

The High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) is one of five high power research reactors the Office of Material Management and Minimization (M3) Program, Office of Conversion is working to convert from using highly enriched uranium (HEU) fuel to using low-enriched uranium (LEU) fuel. This effort stems from the primary objective within the U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA) to achieve permanent threat reduction by minimizing, and when possible, eliminating weapon-usable nuclear material around the world. Under M3’s Office of Conversion, the U.S. High Performance Research Reactor (USHPRR) Project is pursuing fuel qualification and licensing of the high-performance reactors to operate with LEU fuels. All high-performance reactors except HFIR will be converted to LEU monolithic uranium-molybdenum alloy fuel. HFIR will be evaluated for conversion to LEU using a uranium silicide fuel, namely, U3Si2-Al dispersion fuel.The mission of the USHPRR Project is to develop the technology needed to reduce, and eventually eliminate, worldwide use of HEU in civilian applications. The goal is to develop the technical means needed to use low enriched uranium (LEU) instead of HEU fuel in research and test reactors without significant penalties in performance, economics, or safety of the reactors. The USHPRR Project has four major elements, called Pillars: Fuel Qualification (FQ) managed at Idaho National Laboratory (INL), Fuel Fabrication (FF) managed at Pacific Northwest National Laboratory (PNNL), Reactor Conversion (RC) managed at Argonne National Laboratory (Argonne), and Cross-Cutting (CC) managed at Savannah River National Laboratory (SRNL). FQ is responsible for the qualification of the fuel type. RC is responsible for supporting reactor conversion analysis and overseeing licensing submittals leading to conversions of domestic reactors to LEU fuel. For the FQ effort, FQ (INL) worked in collaboration with RC (Argonne) and ORNL to develop the plan for the uranium silicide fuel qualification for HFIR.The resulting HFIR Fuel Qualification Plan provides the general approach for the USHPRR team to move the selected uranium silicide fuel design for HFIR conversion through qualification. Authorization and use in HFIR will be approved through the DOE’s Office of Science. Uranium silicide fuel was previously qualified in NUREG-1313 at an approximate maximum heat flux of 1.4 MW/m2 and a maximum fuel section temperature of about 130°C. In addition to the different regulator process utilized by DOE, these upper limits will be exceeded in HFIR; therefore, further testing will be necessary to ensure the fuel can meet HFIR qualification requirements. The HFIR fuel loading may exceed 4.8 gU/cm3 which was determined in the NUREG-1313 safety evaluation to be acceptable for use in non-power NRC-regulated reactors provided there exist no other safety considerations. In addition, the uranium silicide fuel will need to be qualified in a HFIR-specific design. This plan includes the currently available information from the USHPRR Project Functions and Requirements document and expands these requirements to ensure that planned tests have traceable results providing evidence that the requirements have been met. Data collection methods are discussed as well as the process to show that the requirements have been met. This document is designed to provide a pathway for researchers to obtain data necessary and at the appropriate quality level for HFIR fuel qualification.

Shokes, Tamara↗

DOE OSTI2023

Predicting Safety Rod Reactivity Insertion in the Advanced Test Reactor

42 ENGINEERING↗

DOE OSTI2024

Californium-252 production at the High Flux Isotope Reactor - II: Comparison between the highly enriched uranium and a proposed low-enriched uranium core

This is the second paper on a 252 Cf production study performed in support of efforts to convert the High Flux Isotope Reactor (HFIR) from highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel. The first paper primarily focuses on validating computational tools and nuclear data. This companion paper evaluates another critical aspect: the 252 Cf production capability with a proposed LEU core. HFIR must maintain its world-class performance and missions following conversion and because 252 Cf is a vital, multipurpose neutron-emitting radioisotope, the ability to efficiently produce 252 Cf must be preserved. In this study, the HFIRCON transport and depletion tool, several nuclear data libraries, and Campaign 78 data were used to compute 252 Cf production, sensitivity, and safety metrics. Further, results indicate the 252 Cf production and production rates are slightly higher with a 95MW th LEU core compared with those obtained with the 85MW th HEU core. Additionally, the target peak fission rate densities, discharge cumulative fission densities, and heat deposition rates with the LEU core are within a few percent of those calculated with the HEU core. The findings suggest HFIR’s 252 Cf production capability can be effectively maintained with an LEU core without adversely affecting the safety metrics.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2019

Transitional cores and fuel cycle analyses in support of MIT reactor low enriched uranium fuel conversion

The Massachusetts Institute of Technology Reactor (MITR) is a research reactor in Cambridge, Massachusetts designed primarily for experiments using neutron beam and in-core irradiation facilities. At 6 MW, it delivers neutron flux and energy spectrum comparable to power light water reactors (LWRs) in a compact core using highly enriched uranium (HEU) fuel. In the framework of non-proliferation policy, research and test reactors have started a program to convert HEU fuel to low enriched uranium (LEU) fuel. A new type of LEU fuel based on a high density alloy of uranium and molybdenum (U-10Mo) is expected to allow conversion of U.S. high performance research reactors (USHPRRs) like the MITR. The Preliminary Safety Analysis Report (PSAR) for the MITR LEU conversion has been submitted and currently under review by the U.S. Nuclear Regulatory Commission (NRC). A transition core plan, from 22 fresh LEU fuel elements (i.e., beginning-of-life) gradually to 24 of them arranged in an equilibrium configuration, is expected to serve as an appendix chapter in the final SAR. The current study reported here presents the fuel cycle development, which eventually leads to the transition core plan. The results confirm the equilibrium state, where both the shim bank movement (i.e., core reactivity) as well as the content of fissile materials stabilize, can be achieved by fixed-pattern fuel management. Fission density has been evaluated for a number of fully discharged LEU fuel elements, using a best-estimate approach. The fuel cycle calculations also generate power profiles at each core state. A steady-state thermal-hydraulic safety analysis has thus been performed, where onset of nucleate boiling (ONB) is considered as the safety criterion. The results confirm significant margin to ONB at all analyzed transition and equilibrium fuel cycle states.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

DIissolution of low enriched uranium from the experimental breeder reactor-II fuel stored at the Idaho National Laboratory

The Idaho National Laboratory (INL) is actively engaged in the development of electrochemical processing technology for the treatment of fast reactor fuels using irradiated fuel from the Experimental Breeder Reactor-II (EBR-II) as the primary test material. The research and development (R&D) activities generate a low enriched uranium (LEU) metal product from the electrorefining of the EBR-II fuel and the subsequent consolidation and removal of chloride salts by the cathode processor. The LEU metal ingots from past R&D activities are currently stored at INL awaiting disposition. One potential disposition pathway is the shipment of the ingots to the Savannah River Site (SRS) for dissolution in H-Canyon. Carbon steel cans containing the LEU metal would be loaded into reusable charging bundles in the H-Canyon Crane Maintenance Area and charged to the 6.4D or 6.1D dissolver. The LEU dissolution would be accomplished as the final charge in a dissolver batch (following the dissolution of multiple charges of spent nuclear fuel (SNF)). The solution would then be purified and the 235 U enrichment downblended to allow use of the U in commercial reactor fuel. To support this potential disposition path, the Savannah River National Laboratory (SRNL) developed a dissolution flowsheet for the LEU using samples of the material received from INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Local Power Impact Experiment Design for a New Fuel Type for use in the Advanced Test Reactor

The Advanced Test Reactor (ATR), and complimentary zero-power ATR Critical (ATRC) reactor, located at Idaho National Labs (INL), are undergoing conversion from Highly Enriched Uranium (HEU) to Low Enriched Uranium (LEU). Both have a variety of testing locations that can receive large variations in flux due to its unique serpentine design, consisting of five lobes (see Figure 1). Initial criticality and power distribution throughout the core are controlled by core-external outer shim control cylinders (OSCCs). Distinct test loops allow for testing at specific temperatures, pressures, and irradiation conditions. The ATR is one of the key nuclear engineering research and testing facilities within the DOE National Laboratory Complex, and the ATRC supports its operation [1]. Currently, the Office of Material Management and Minimization (M3) within the National Nuclear Security Administration of the DOE is working to convert the remaining research reactors, including the ATR, from 93% HEU fuel to 19.75% LEU fuel (LEU) to support non-proliferation [2]. Extensive materials testing at INL and internationally has demonstrated that a high-density uranium molybdenum (U 10Mo) alloy can meet the performance requirements of the remaining high powered research reactors. However, there are many technical challenges to address before the conversion to LEU can be successful, including the accurate characterization of the reactor core physics with LEU fuel. Reactor physics safety evaluations currently use Monte Carlo for the 21st Century (MC21), a continuous-energy Monte Carlo radiation transport code [3]. Existing MC21 models of the ATR and ATRC cores have a validation basis for use in neutronics analyses with HEU fuel. The models are used to support safety analyses that include comparisons to the safety requirements for the reactors. However, the use of the LOWE element in the ATR and ATRC is not currently covered by the current model validation basis. To deploy the new fuel type, extensive computational reactor physics support is necessary to support the use of LOWE in the ATR and ATRC. Therefore, LOWE requires a rigorous validation basis, aligned with that of HEU fuel, that takes advantage of the existing software tools and processes currently used for the ATR and ATRC. The experiment to validate of the MC21 models for determining power, the Power Impact Validation Experiment, will consist of two flux runs in the ATRC, one with fully HEU loading and one with a single LOWE element. Both flux runs will be instrumented with 20 sets of azimuthal fission wires and 3 sets of axial fission wires, as shown in Figure 4. Standard flux run methodology will be used [4]. Power Impact Validation Experiment data will be compared against MC21 calculated data, both for absolute fission rate accuracy and to determine the relative change in fission rates between the two runs. The results of the Power Impact Validation Experiment and subsequent evaluations will provide the validation basis for MC21 for use with LOWE elements. Key features of the Power Impact Validation Experiment include: (1) Two flux runs to allow for LOWE perturbed measurements to be compared to already validated measurements taken from a full core of HEU fuel, (2) Optimization of instrumentation to balance analytical needs with practical considerations (e.g., limited time window to count beta particles from fission products), and (3) Standard ATRC core loading, including both driver positions and flux traps, to minimize cost while remaining representative of typical ATR core loading.

42 ENGINEERING↗