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At least 235 records · Page 13

Design, Fabrication and Integration of a NaK-Cooled Circuit

The Early Flight Fission Test Facilities (EFF-TF) team has been tasked by the NASA Marshall Space Flight Center Nuclear Systems Office to design, fabricate, and test an actively pumped alkali metal flow circuit. The system, which was originally designed for use with a eutectic mixture of sodium potassium (NaK), was redesigned to for use with lithium. Due to a shi$ in focus, it is once again being prepared for use with NaK. Changes made to the actively pumped, high temperature circuit include the replacement of the expansion reservoir, addition of remotely operated valves, and modification of the support table. Basic circuit components include: reactor segment, NaK to gas heat exchanger, electromagnetic (EM) liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and a spill reservoir. A 37-pin partial-array core (pin and flow path dimensions are the same as those in a fill design) was selected for fabrication and test. This paper summarizes the integration and preparations for the fill of the pumped liquid metal NaK flow circuit.

Garber, Anne↗

Nuclear Physics Made Very, Very Easy

The fundamental approach to nuclear physics was prepared to introduce basic reactor principles to various groups of non-nuclear technical personnel associated with NERVA Test Operations. NERVA Test Operations functions as the field test group for the Nuclear Rocket Engine Program. Nuclear Engine for Rocket Vehicle Application (NERVA) program is the combined efforts of Aerojet-General Corporation as prime contractor, and Westinghouse Astronuclear Laboratory as the major subcontractor, for the assembly and testing of nuclear rocket engines. Development of the NERVA Program is under the direction of the Space Nuclear Propulsion Office, a joint agency of the U. S. Atomic Energy Commission and the National Aeronautics and Space Administration. This report is being reprinted for use in the U. S. Atomic Energy Commission and National Aeronautics and Space Administration educational and technology utilization programs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

A Small Fission Power System for NASA Planetary Science Missions

In March 2010, the Decadal Survey Giant Planets Panel (GPP) requested a short-turnaround study to evaluate the feasibility of a small Fission Power System (FPS) for future unspecified National Aeronautics and Space Administration (NASA) science missions. FPS technology was considered a potential option for power levels that might not be achievable with radioisotope power systems. A study plan was generated and a joint NASA and Department of Energy (DOE) study team was formed. The team developed a set of notional requirements that included 1-kW electrical output, 15-year design life, and 2020 launch availability. After completing a short round of concept screening studies, the team selected a single concept for concentrated study and analysis. The selected concept is a solid block uranium-molybdenum reactor core with heat pipe cooling and distributed thermoelectric power converters directly coupled to aluminum radiator fins. This paper presents the preliminary configuration, mass summary, and proposed development program.

Mason, Lee↗

Design, fabrication, and operation of capsules for the irradiation testing of candidate advanced space reactor fuel pins

Fuel irradiation experiments were designed, built, and operated to test uranium mononitride (UN) fuel clad in tungsten-lined T-111 and uranium dioxide fuel clad in both tungsten-lined T-111 and tungsten-lined Nb-1% Zr. A total of nine fuel pins was irradiated at average cladding temperatures ranging from 931 to 1015 C. The UN experiments, capsules UN-4 and -5, operated for 10,480 and 10,037 hr, respectively, at an average linear heat generation rate of 10 kW/ft. The UO2 experiment, capsule UN-6, operated for 8333 hr at an average linear heat generation rate of approximately 5 kW/ft. Following irradiation, the nine fuel pins were removed from their capsules, externally examined, and sent to the NASA Plum Brook Facility for more detailed postirradiation examination. During visual examination, it was discovered that the cladding of the fuel pin containing dense UN in each of capsules UN-4 and -5 had failed, exposing the UN fuel to the NaK in which the pins were submerged and permitting the release of fission gas from the failed pins. A rough analysis of the fission gas seen in samples of the gas in the fuel pin region indicated fission gas release-to-birth rates from these fuel pins in the range of .00001.

Thoms, K. R.↗

Technical Assessment of Off-Gas System Technologies for Potential Use in Molten Salt Reactors

Molten salt reactors (MSRs) are a class of Generation IV advanced reactor technologies aimed to enhance and improve the safety, fuel utilization and cost-effectiveness of nuclear power generation. MSR concepts are based on using a molten salt mixture as a primary nuclear reactor coolant, while the fuel can be either directly dissolved in the coolant (i.e., fluid-fueled) or can be in a separate solid form (i.e., salt-cooled solid-fueled). MSRs can be operated in either thermal or fast neutron spectra, as simple fissile convertors, or breeder reactors (e.g., utilizing both fissile and fertile fuels), as well as accelerator-driven sub-critical reactors or transuranic element burners. Operation of MSRs will necessitate management and treatment of the off-gas streams released to the headspace of the reactor where, in some designs, a cover gas can be circulated to remove certain fission products and maintain an inert atmosphere. An inert MSR cover gas swept over or sparged into the salt will confine radionuclides emerging from the free surface, including radioactive noble and non-noble gases, aerosols, and volatile species. The elements and compounds of these species will have a wide range of thermochemical and physical properties, some of which will decay to different products in the off-gas stream. Therefore, system components used to manage and treat MSR off-gas streams will need to be robust under dynamic reactor and chemistry conditions to support adequate reactor performance by managing the composition and species in the salt coolant and cover gas space. Off-gas system components would perform as a radionuclide boundary to the reactor vessel and a primary means for preventing radionuclide release; therefore, they are of high safety significance for MSR operations. This report reviews various technologies and materials for potential implementation in the design of an MSR off-gas system per a general conceptual framework. The reviewed technologies operate based on scrubbing, capture, delay, or separation of species in the off-gas stream. These include molten hydroxide scrubbers, solid sorbents, delay off-gas systems, particle traps, and cryogenic distillation. Since aspects of an off-gas system will be design-specific, the approach is to provide general discussions on attributes of these technologies and materials, including target off-gas stream species, operational parameters and conditions of importance to decontamination factors, implementation maturity, system component monitoring, potential off-normal conditions and considerations for waste products. The information aims to support the U.S. Nuclear Regulatory Commission in their safety evaluations for MSR designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Phase 1 Space Fission Propulsion Energy Source Design

Fission technology can enable rapid, affordable access to any point in the solar system. If fission propulsion systems are to be developed to their full potential; however, near-term customers must be identified and initial fission systems successfully developed, launched, and operated. Studies conducted in fiscal year 2001 (IISTP, 2001) show that fission electric propulsion (FEP) systems with a specific mass at or below 50 kg/kWjet could enhance or enable numerous robotic outer solar system missions of interest. At the required specific mass, it is possible to develop safe, affordable systems that meet mission requirements. To help select the system design to pursue, eight evaluation criteria were identified: system integration, safety, reliability, testability, specific mass, cost, schedule, and programmatic risk. A top-level comparison of four potential concepts was performed: a Testable, Passive, Redundant Reactor (TPRR), a Testable Multi-Cell In-Core Thermionic Reactor (TMCT), a Direct Gas Cooled Reactor (DGCR), and a Pumped Liquid Metal Reactor.(PLMR). Development of any of the four systems appears feasible. However, for power levels up to at least 500 kWt (enabling electric power levels of 125-175 kWe, given 25-35% power conversion efficiency) the TPRR has advantages related to several criteria and is competitive with respect to all. Hardware-based research and development has further increased confidence in the TPRR approach. Successful development and utilization of a "Phase I" fission electric propulsion system will enable advanced Phase 2 and Phase 3 systems capable of providing rapid, affordable access to any point in the solar system.

Houts, Mike↗

Fission Surface Power System Initial Concept Definition

Under the NASA Exploration Technology Development Program (ETDP) and in partnership with the Department of Energy (DOE), NASA has embarked on a project to develop Fission Surface Power (FSP) technology. The primary goals of the project are to 1) develop FSP concepts that meet expected surface power requirements at reasonable cost with added benefits over other options, 2) establish a hardwarebased technical foundation for FSP design concepts and reduce overall development risk, 3) reduce the cost uncertainties for FSP and establish greater credibility for flight system cost estimates, and 4) generate the key products to allow NASA decision-makers to consider FSP as a preferred option for flight development. The FSP project was initiated in 2006 as the Prometheus Program and the Jupiter Icy Moons Orbiter (JIMO) mission were phased-out. As a first step, NASA Headquarters commissioned the Affordable Fission Surface Power System Study to evaluate the potential for an affordable FSP development approach. With a cost-effective FSP strategy identified, the FSP team evaluated design options and selected a Preliminary Reference Concept to guide technology development. Since then, the FSP Preliminary Reference Concept has served as a point-of-departure for several NASA mission architecture studies examining the use of nuclear power and has provided the foundation for a series of "Pathfinder" hardware tests. The long-term technology goal is a Technology Demonstration Unit (TDU) integrated system test using full-scale components and a non-nuclear reactor simulator. The FSP team consists of Glenn Research Center (GRC), Marshall Space Flight Center (MSFC) and the DOE National Laboratories at Los Alamos (LANL), Idaho (INL), Oak Ridge (ORNL), and Sandia (SNL). The project is organized into two main elements: Concept Definition and Risk Reduction. Under Concept Definition, the team performs trade studies, develops analytical tools, and formulates system concepts. Under Risk Reduction the team develops hardware prototypes and conducts laboratory-based testing.

Source record↗

Fission Surface Power for the Exploration and Colonization of Mars

The colonization of Mars will require abundant energy. One potential energy source is nuclear fission. Terrestrial fission systems are highly developed and have the demonstrated ability to safely produce tremendous amounts of energy. In space, fission systems not only have the potential to safely generate tremendous amounts of energy, but could also potentially be used on missions where alternatives are not practical. Programmatic risks such as cost and schedule are potential concerns with fission surface power (FSP) systems. To be mission enabling, FSP systems must be affordable and programmatic risk must be kept acceptably low to avoid jeopardizing exploration efforts that may rely on FSP. Initial FSP systems on Mars could be "workhorse" units sized to enable the establishment of a Mars base and the early growth of a colony. These systems could be nearly identical to FSP systems used on the moon. The systems could be designed to be safe, reliable, and have low development and recurring costs. Systems could also be designed to fit on relatively small landers. One potential option for an early Mars FSP system would be a 100 kWt class, NaK cooled system analogous to space reactors developed and flown under the U.S. "SNAP" program or those developed and flown by the former Soviet Union ("BUK" reactor). The systems could use highly developed fuel and materials. Water and Martian soil could be used to provide shielding. A modern, high-efficiency power conversion subsystem could be used to reduce required reactor thermal power. This, in turn, would reduce fuel burnup and radiation damage .effects by reducing "nuclear" fuels and materials development costs. A realistic, non-nuclear heated and fully integrated technology demonstration unit (TDU) could be used to reduce cost and programmatic uncertainties prior to initiating a flight program.

Houts, Mike↗

Examination of UC-ZrC after long term irradiation at thermionic temperature

Two fluoride tungsten clad UC-ZrC fueled capsules, designated as V-2C and V-2D, were examined a hot cell after irradiation in NASA Plum Brook Reactor at a maximum cladding temperature of 1930 K for 11,089 and 12,031 hours to burnups of 3.0 x 10 to the 20th power and 2.1 x 10 to the 20th power fission/c.c. respectively. Percentage of fission gas release from the fuel material was measured by radiochemical means. Cladding deformation, fuel-cladding interaction and microstructures of fuel, cladding, and fuel-cladding interface were studied metallographically. Compositions of dispersions in fuel, fuel matrix and fuel-cladding interaction layer were analyzed by electron microprobe techniques. Axial and radial distributions of burnup were determined by gamma-scan, autoradiography and isotopic burnup analysis. The results are presented and discussed in conjunction with the requirements of thermionic fuel elements for space power application.

Yang, L.↗

Testing of Liquid Metal Components for Nuclear Surface Power Systems

The capability to perform testing at both the module/component level and in near prototypic reactor configurations using a non-nuclear test methodology allowed for evaluation of two components critical to the development of a potential nuclear fission power system for the lunar surface. A pair of 1 kW Stirling power convertors, similar to the type that would be used in a reactor system to convert heat to electricity, were integrated into a reactor simulator system to determine their performance using pumped NaK as the hot side working fluid. The performance in the pumped-NaK system met or exceed the baseline performance measurements where the converters were electrically heated. At the maximum hot-side temperature of 550 C the maximum output power was 2375 watts. A specially-designed test apparatus was fabricated and used to quantify the performance of an annular linear induction pump that is similar to the type that could be used to circulate liquid metal through the core of a space reactor system. The errors on the measurements were generally much smaller than the magnitude of the measurements, permitting accurate performance evaluation over a wide range of operating conditions. The pump produced flow rates spanning roughly 0.16 to 5.7 l/s (2.5 to 90 GPM), and delta p levels from less than 1 kPa to 90 kPa (greater than 0.145 psi to roughly 13 psi). At the nominal FSP system operating temperature of 525 C the maximum efficiency was just over 4%.

Polzin, K. A.↗

Status of Kilowatt-Class Stirling Power Conversion Using a Pumped NaK Loop for Thermal Input

Free-piston Stirling power conversion has been identified as a viable option for potential Fission Surface Power (FSP) systems on the Moon and Mars. Proposed systems consist of two or more Stirling convertors, in a dual-opposed configuration, coupled to a low-temperature uranium-dioxide-fueled, liquid-metal-cooled reactor. To reduce developmental risks associated with liquid-metal loop integration, a test rig has been built to evaluate the performance of a pair of 1-kW free-piston Stirling convertors using a pumped sodium-potassium (NaK) loop for thermal energy input. Baseline performance maps have been generated at the Glenn Research Center (GRC) for these 1-kW convertors operating with an electric heat source. Each convertor was then retrofitted with a custom-made NaK heater head and integrated into a pumped NaK system at the Marshall Space Flight Center (MSFC). This paper documents baseline testing at GRC as well as the progress made in integrating the Stirling convertors into the pumped NaK loop.

Briggs, Maxwell H.↗

Stirling Power Conversion for Lunar Applications

NASA is developing Stirling power convertors for use in nuclear power systems that would provide electricity to users on the lunar surface. NASA’s Radioisotope Power Systems (RPS) Program is maturing advanced dynamic convertor technologies that would increase the efficiency beyond the heritage systems for missions to the Moon and other solar system bodies of interest. Development efforts have focus on Stirling and Brayton designs that meet reliability and robustness requirements for operation in the lunar environment. GRC is also maturing low power convertors in the range of 1-40 watts to power micro-spacecraft or a network of distributed probes and include basic demonstration of in-house designs for convertors and controllers. In addition to RPS applications, conceptual fission systems have been demonstrated using Stirling convertors in multiple electrically heated tests and one test heated by a nuclear reactor. The Stirling convertors used in these fission system concepts include 100 We convertors to enable a 1 kWe system, 1 kWe convertors to enable a 10 kWe system, and 6 kWe convertors to enable a 40 kWe system. The maturation of Stirling power convertors for nuclear applications includes verification of performance in relevant environments and validation of the design with a focus on high reliability and robustness. Over 1 million hours of testing has been accumulated on dozens of convertors since 1999 in the Stirling Research Laboratory at the NASA Glenn Research Center located in Cleveland Ohio, where the longest running convertor is the work record holder at 137,000 hours, or 15.5 years. These maturation efforts have been instrumental in increasing the technology readiness level of Stirling technologies for space applications.

S. Wilson↗

Closeout Report for the Refractory Metal Accelerated Heat Pipe Life Test Activity

With the selection of a gas-cooled reactor, this heat pipe accelerated life test activity was closed out and its resources redirected. The scope of this project was to establish the long-term aging effects on Mo-44.5%Re sodium heat pipes when subjected to space reactor temperature and mass fluences. To date, investigators have demonstrated heat pipe life tests of alkali metal systems up to .50,000 hours. Unfortunately, resources have not been available to examine the effect of temperature, mass fluence, or impurity level on corrosion or to conduct post-test forensic examination of heat pipes. The key objective of this effort was to establish a cost/time effective method to systematically test alkali metal heat pipes with both practical and theoretical benefits. During execution of the project, a heat pipe design was established, a majority of the laboratory test equipment systems specified, and operating and test procedures developed. Procurements for the heat pipe units and all major test components were underway at the time the stop work order was issued. An extremely important outcome was the successful fabrication of an annular wick from Mo-5%Re screen (the single, most difficult component to manufacture) using a hot isostatic pressing technique. This Technical Publication (TP) includes specifics regarding the heat pipe calorimeter water-cooling system, vendor design for the radio frequency heating system, possible alternative calorimeter designs, and progress on the vanadium equilibration technique. The methods provided in this TP and preceding project documentation would serve as a good starting point to rapidly implement an accelerated life test. Relevant test data can become available within months, not years, and destructive examination of the first life test heat pipe might begin within 6 months of test initiation. Final conclusions could be drawn in less than a quarter of the mission duration for a long-lived, fission-powered, deep space probe.

Martin, J.↗

Overview of Non-nuclear Testing of the Safe, Affordable 30-kW Fission Engine, Including End-to-End Demonstrator Testing

Successful development of space fission systems will require an extensive program of affordable and realistic testing. In addition to tests related to design/development of the fission system, realistic testing of the actual flight unit must also be performed. At the power levels under consideration (3-300 kW electric power), almost all technical issues are thermal or stress related and will not be strongly affected by the radiation environment. These issues can be resolved more thoroughly, less expensively, and in a more timely fashing with nonnuclear testing, provided it is prototypic of the system in question. This approach was used for the safe, affordable fission engine test article development program and accomplished viz cooperative efforts with Department of Energy labs, industry, universiites, and other NASA centers. This Technical Memorandum covers the analysis, testing, and data reduction of a 30-kW simulated reactor as well as an end-to-end demonstrator, including a power conversion system and an electric propulsion engine, the first of its kind in the United States.

VanDyke, M. K.↗

Manned space flight nuclear system safety. Volume 3: Reactor system preliminary nuclear safety analysis. Part 3: Nuclear Safety Analysis Document (NSAD)

Nuclear safety analysis as applied to a space base mission is presented. The nuclear safety analysis document summarizes the mission and the credible accidents/events which may lead to nuclear hazards to the general public. The radiological effects and associated consequences of the hazards are discussed in detail. The probability of occurrence is combined with the potential number of individuals exposed to or above guideline values to provide a measure of accident and total mission risk. The overall mission risk has been determined to be low with the potential exposure to or above 25 rem limited to less than 4 individuals per every 1000 missions performed. No radiological risk to the general public occurs during the prelaunch phase at KSC. The most significant risks occur from prolonged exposure to reactor debris following land impact generally associated with the disposal phase of the mission where fission product inventories can be high.

Source record↗

Review of End-of-Life Thermal Control Coating Performance

White thermal control coatings capable of long term performance are needed for Fission Surface Power (FSP) where heat from a nuclear reactor placed on the surface of the Moon must be rejected to the environment. The threats to thermal control coating durability on the lunar surface are electrons, protons, and ultraviolet radiation. The anticipated damage to the coating is a gradual darkening over time. The increase in solar absorptance would, in essence, add a cyclic heat load to the radiator. The greater the darkening, the greater the added heat load. The cyclic heat load could ultimately impart a cyclic influence on FSP system performance. No significant change in emittance is anticipated. Optical properties degradation data were found in the open literature for the Z-93 series of thermal control paints. Additional optical properties degradation data were found from the Lunar Orbiter V mission, the Optical Properties Monitor, and the Materials International Space Station Experiment. Anticipated end-of-life thermal control coating performance for a FSP installation is postulated. With the FSP installation located away from landing and launching areas, and out of line-of-sight, lunar dust from human activity may not be a threat. The benefits of investing in next generation thermal control paint chemistry are explored.

Jaworske, Donald A.↗

Special Considerations for the Removal and Disposal of Micro-Reactor Experiments

Idaho National Laboratory (INL) is preparing to host several microreactor experiments through 2030 and beyond. Two new test beds currently under development will operate as microreactor or nuclear system experiment user facilities. Test bed experiments will be performed in series, with each nuclear experiment installed, operated, and removed before installation of the subsequent experiment. The necessarily brief transition period between experiments introduces unique equipment removal and radioactive waste disposal challenges. This paper evaluates equipment removal and radioactive waste management topics associated with tight sequencing of nuclear experiments and presents some of the solutions and approaches currently planned to meet these special considerations for one such experiment, the Molten Chloride Reactor Experiment (MCRE), slated for operation at INL’s Laboratory for Operation and Testing in the United States (LOTUS). The MCRE project is a collaboration between Southern Company Services, TerraPower, and INL, among others, to provide integral nuclear data that will advance molten salt fast reactor technology. MCRE will be the first critical fast-spectrum circulating fuel system ever operated and the first experiment operated in the LOTUS test bed. The experiment will nominally operate at zero power with planned low power excursions as part of operational planning for MCRE has been to minimize at-power operations to limit fission product formation while still achieving experimental objectives. After the experiment is complete, MCRE will be allowed to radioactively decay for a short period (nominally 90 days) prior to system defueling, flushing, removal, and disposal of all MCRE equipment, readying the test bed for the next nuclear experiment. Equipment removal and radioactive waste disposal have been integral to MCRE project planning since the Cooperative Research and Development Agreement was formalized in 2021. Due to requirements for future use of the test bed, the MCRE system, of necessity, must be removed in a much shorter time frame than typical for historic reactor decommissioning projects at INL. This results in minimal time for radioactive decay, resulting in not only elevated radiation dose rates but also the presence of short-to-medium-lived isotopes not typically encountered in the reactor decommissioning and radioactive waste management space. Additional unique constraints placed on the project include lack of intrinsic remote-operations capabilities in the test bed, space constraints in the test bed once MCRE has been installed, and contamination minimization requirements to return the test bed to as-found conditions to enable future use. This paper discusses planned solutions to these challenges. Approaches for implementing remote or semi-remote technologies in a non-hot cell environment with limited space availability are discussed. The paper also summarizes the systems engineering approach for concept development and design of equipment removal systems, which are being implemented concurrent with the MCRE design phase, providing feedback to system designers to incorporate features enabling efficient and safe equipment removal approaches. The timing of this paper at a relatively early phase of the project is meant to highlight the importance of early planning for nuclear system decommissioning while reactor design is ongoing to allow design feedback on componentry driven from decommissioning system needs. As new, innovative nuclear reactor technologies enter the nuclear market sector, reactor experiments are crucial for providing new integral nuclear data that establish safe operational margins for technology advancement. Microreactor experiments at INL will require safe, effective, and timely decommissioning approaches, which in turn require nuclear systems designed to expedite decommissioning. In addition to the advancement of nuclear reactor technologies, these nuclear experiments provide an opportunity to demonstrate, deploy, and test new removal and disposal capabilities to support the next generation of nuclear reactor technology.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Investigation of neutron noise in a micro-scale, natural circulation molten salt fission battery system

The Molten Salt Reactor (MSR) concept is a rapidly evolving Generation IV design that has recently attracted favorable attention due to the potential for reducing waste generation, realizing passive safety features, and seizing on the opportunity for cost effective economics. A specific novel micro-MSR, natural circulation, battery design concept involves placing all primary components within a single reactor vessel containment without the need of primary forced pumping. This small modular, integral design presents potential cost savings while producing safety, reliable, and transportable carbon-free power for decades. This investigation evaluates the neutron noise induced by density and flow fluctuations in a natural circulation MSR battery concept being developed at the University of Idaho. This study finds numerical solutions to the one-dimensional, one-group, coupled diffusion equations for a bare, homogeneous core, and evaluates neutron flux and delayed neutron precursor concentration noise due to core flow and fuel salt density perturbation sources. Noise analysis shows both point kinetic and space-dependent behavior is present despite the small size, low-flow, closely-coupled nature of the natural circulation MSR concept. Analysis shows that the low flow of the convective system results in noise behavior typically representative of a larger forced-circulation MSR system. Finally, noise techniques may also be useful in MSR core diagnostics as a non-invasive, low-cost radiological option to traditional monitoring schemes.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗