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DOE OSTI2024

FUEL PERFORMANCE SIMULATION OF HIGH BURNUP FUELS IN PLANNED INTEGRAL DESIGN BASIS ACCIDENT EXPERIMENTS

High burnup (HBu) fuel rods from the Byron Nuclear Generating Station (BNGS) were recently received at Idaho National Laboratory (INL) to support a variety of planned Nuclear Energy fuel cycle R&D objectives ranging from fuel performance, fuel recycle, and spent fuel research topics. Among these R&D activities, these fuel rods will be the subjects of multiple in-pile experiment programs at the Transient Reactor Test (TREAT) facility as well as detailed characterization and testing in the hot cells at INL and Oak Ridge National Laboratory (ORNL). TREAT RIA experiments are planned for the Nuclear Energy Agency Framework for Irradiation Experiments (FIDES) Joint Experimental Program called High burnup Experiments in Reactivity Initiated Accident (HERA) program. TREAT and ORNL-furnace LOCA experiments are part of the Department of Energy (DOE) Advanced Fuels Campaign (AFC) program U.S. consensus LOCA test plan, and the in-pile experiments have also been proposed in a FIDES project called Loss of Coolant-High Burnup (LOC-HBu). The results of these test programs will provide crucial data about safety performance enabling extended licensable burnup limits for these fuels. The purpose of this paper is to document fuel performance computational simulations of the BNGS fuel using the Bison code. The detailed assessments include (1) the irradiation history of the fuel to provide prediction of as-run fuel conditions and (2) extending the irradiated fuel conditions into the as-designed experiment conditions for the HERA-HBu RIA experiments and for the LOC-HBu LOCA experiments. The results of these assessments will inform post-irradiation examinations (PIE) of the BNGS parent rods and detailed final design of the planned experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Fuel Performance Simulation of High Burnup Fuels in Planned Integral Design Basis Accident Experiments

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2016

Alternative Bio-Derived JP-8 Class Fuel and JP-8 Fuel: Flame Tube Combustor Test Results Compared using a GE TAPS Injector Configuration

This paper presents results from tests in a flame tube facility, where a bio-derived alternate fuel was compared with JP-8 for emissions and general combustion performance. A research version of General Electric Aviation (GE) TAPS injector was used for the tests. Results include combustion efficiency from gaseous emission measurements, 2D planar laser-based imaging as well as basic flow visualization of the flame. Four inlet test conditions were selected that simulate various engine power conditions relevant to NASA Fundamental Aeronautics Supersonics Project and Environmentally Responsible Aviation Program. One inlet condition was a pilot-only test point. The other three inlet conditions incorporated fuel staging via a split between the pilot and main circuits of either 10%/90% or 20%/80%. For each engine power condition, three fuel mixes were used: 100% JP-8; 100% alternative; and a blend of the two, containing 75% alternative. Results for the inlet cases that have fuel split between pilot and main, indicate that fuel from the pilot appears to be evaporated by the time it reaches the dome exit. Main circuit liquid evaporates within a downstream distance equal to annulus height, no matter the fuel. Some fuel fluorescence images for a 10%/90% fuel staging case show a distinct difference between JP-8 and bio-derived fuel. OH PLIF results indicate that OH forms in a region more centrally-located for the JP-8 case downstream of the pilot, in its central recirculation region (CRZ). For the bio-derived Hydrotreated Renewable Jet (HRJ) fuel, however, we do not see much OH in the CRZ. The OH image structure near the dome exit is similar for the two fuels, but farther downstream the OH in the CRZ is much more apparent for the JP-8 than for the alternate fuel. For all conditions, there was no discernable difference between fuel types in combustion efficiency or emissions.

gas turbine combustors↗

NASA NTRS1982

Characterization of an Experimental Referee Broadened Specification (ERBS) aviation turbine fuel and ERBS fuel blends

Characterization data and comparisons of these data are presented for three individual lots of a research test fuel designated as an Experimental Referee Broadened Specification (ERBS) aviation turbine fuel. This research fuel, which is a blend of kerosene and hydrotreated catalytic gas oil, is a representation of a kerojet fuel with broadened properties. To lower the hydrogen content of the ERBS fuel, a blending stock, composed of xylene bottoms and hydrotreated catalytic gas oil, was developed and employed to produce two different ERBS fuel blends. The ERBS fuel blends and the blending stock were also characterized and the results for the blends are compared to those of the original ERBS fuel. The characterization results indicate that with the exception of the freezing point for ERBS lot 2, which was slightly high, the three lots, produced over a 2 year period, met all general fuel requirements. However, although the properties of the fuels were found to be fairly consistent, there were differences in composition. Similarly, all major requirements for the ERBS fuel blends were met or closely approached, and the properties of the blended fuels were found to generally reflect those expected for the proportions of ERBS fuel and blending stock used in their production.

Seng, G. T.↗

DOE OSTI2025

Characterization of Fuel-to-Coolant Heat Transfer During Reactivity-Initiated Accidents Using Tightly Coupled Thermal Hydraulics and Fuel Thermomechanics

The reactivity-initiated accident (RIA) is a complex scenario with several tightly interacting physical phenomena. Accurately predicting fuel behavior during these transients is difficult due to limitations in the modeling of fuel-to-coolant heat transfer. Common approaches to simulate RIAs involve standalone calculations using either a fuel performance code or a thermal-hydraulic code. The complex interdependencies of thermal-hydraulic and fuel mechanical behavior suggest that a tight coupling between these codes may provide more accurate predictions of fuel-to-coolant heat transfer and cladding mechanical response. Here, RELAP5-3D and BISON are coupled in this paper to simulate RIAs, and a sensitivity analysis is performed to rank key thermal properties and two-phase heat transfer parameters relevant for fuel-to-coolant heat transfer and cladding failure mechanisms in UO 2 –Zircaloy-4 systems. Gas gap conductance, film boiling heat transfer uncertainty, pulse width, fuel-specific heat capacity, and cladding-specific heat capacity were identified as important parameters. Variations in figures of merit resulting from changes to pulse width and the material thermal properties indicate that time-dependent heat transfer rates are significant for safety-relevant mechanical parameters due to the time dependence of cladding ductility and pellet-cladding mechanical interaction loading. The results suggest that the thermal-hydraulic factors have a nonnegligible influence on the thermomechanical solution and vice versa. Tight coupling of both sets of physics is recommended to improve prediction of fuel behavior during RIAs. Highlights include the following: 1. The RELAP5-3D thermal-hydraulic code and the BISON fuel performance code are tightly coupled for simulation of RIA transients with energy depositions at the Zircaloy-4 cladding failure threshold. 2. Departure from nucleate boiling occurred for all simulated cases. Due to the ductility of fresh fuel, substantial ballooning occurred in most cases. 3. Gas gap conductance, fuel-specific heat capacity, cladding-specific heat capacity, transient pulse width, and film boiling heat transfer were the dominant thermal factors impacting the safety figures of merit at energy depositions.

Critical Heat Flux (CHF)↗

DOE OSTI2026

Fuel-Cladding Eutectic Study of Legacy Fast Flux Test Facility (FFTF) MFF HT9/U-10Zr Metallic Fuel

This report presents the first systematic investigation of fuel-cladding eutectic interaction (FCEI) in irradiated HT9/U-10Zr metallic fuel from the Fast Flux Test Facility (FFTF) Materials Fuels Form (MFF) program, using differential scanning calorimetry (DSC) coupled with scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). Two irradiated fuel cross-sections, MNT07H (9.5 at% burnup, x/L = 0.78) and MNT08H (7.0 at% burnup, x/L = 0.93), were subjected to three successive isothermal annealing rounds (R1–R3) at 820°C for 20 minutes each, yielding a cumulative transient duration of one hour. This study directly addresses a recognized gap in the existing FCEI database, which previously lacked irradiated HT9/U-10Zr data at burnup levels above 8 at%. Two principal findings emerge from the study. First, for both samples, FCEI remained spatially confined within the pre-existing fuel-cladding chemical interaction (FCCI) zone boundaries after R3, with no measurable eutectic penetration into unaffected cladding beyond the original FCCI layer. This self-limiting behavior is consistent with historical Fuel Behavior Test Apparatus (FBTA) results and is attributed to the near-eutectic phase composition of the FCCI zone, which rapidly absorb the available eutectic-forming constituents and then stall penetration once the FCCI zone is consumed. A comparison with unirradiated surrogate data further supports this mechanism: whereas a U–34 at.% Fe sample would be expected to show ~176 µm of iron penetration under comparable conditions, the irradiated samples exhibited only ~20 µm, a discrepancy attributed to irradiation-induced interfacial porosity and pre-existing FCCI composition gradients. Second, for MNT08H, FCEI was observed exclusively on the half of the cladding circumference where pre-existing steady-state FCCI was present, with no detectable FCEI on the opposite half. Three hypotheses are proposed to explain this asymmetry: the inhibiting role of a zirconium-rich rind at the fuel-cladding interface; the chemical sequestration of iron by redistributed zirconium within the fuel matrix; and the persistence of fuel-cladding gaps on the FCEI-free half that preclude direct contact. All three hypotheses require further experimental investigation. The results extend the empirical FCEI database into higher-burnup territory and demonstrate the viability of DSC-based testing as a substitute for the no-longer-available FBTA apparatus. Future work will include additional cross-section testing, compilation of the full FCEI dataset, model evaluation, and DSC testing of ternary fuel compositions to broaden the experimental basis for safety assessment of sodium-cooled fast reactor systems.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1993

Fuel-rich catalytic combustion of a high density fuel

Fuel-rich catalytic combustion (ER is greater than 4) of the high density fuel exo-tetrahydrocyclopentadiene (JP-10) was studied over the equivalence ratio range 5.0 to 7.6, which yielded combustion temperatures of 1220 to 1120 K. The process produced soot-free gaseous products similar to those obtained with iso-octane and jet-A in previous studies. The measured combustion temperature agreed well with that calculated assuming soot was not a combustion product. The process raised the effective hydrogen/carbon (H/C) ratio from 1.6 to over 2.0, thus significantly improving the combustion properties of the fuel. At an equivalence ratio near 5.0, about 80 percent of the initial fuel carbon was in light gaseous products and about 20 percent in larger condensable molecules. Fuel-rich catalytic combustion has now been studied for three fuels with H/C ratios of 2.25 (iso-octane), 1.92 (jet-A), and 1.6 (JP-10). A comparison of the product distribution of these fuels shows that, in general, the measured concentrations of the combustion products were monotonic functions of the H/C ratio with the exception of hydrogen and ethylene. In these cases, data for JP-10 fell between iso-octane and jet-A rather than beyond jet-A. It is suggested that the ring cross-linking structure of JP-10 may be responsible for this behavior. All the fuels studied showed that the largest amounts of small hydrocarbon molecules and the smallest amounts of large condensable molecules occurred at the lower equivalence ratios. This corresponds to the highest combustion temperatures used in these studies. Although higher temperatures may improve this mix, the temperature is limited. First, the life of the present catalyst would be greatly shortened when operated at temperatures of 1300 K or greater. Second, fuel-rich catalytic combustion does not produce soot because the combustion temperatures used in the experiments were well below the threshold temperature (1350 K) for the formation of soot. Increasing the temperature above this value would remove the soot-free nature of the process. Since all the fuels studied show a similar breakdown of the primary fuel into smaller molecular combustion products, this technique can be applied to all hydrocarbon fuels.

Brabbs, Theodore A.↗

DOE OSTI2025

Elucidating the effect of minor-actinide addition on fuel-cladding chemical interaction in an HT-9 clad U-Pu-Zr metallic fuel irradiated to 6.15 at.% burnup in EBR-II

Scanning and transmission electron microscopy (S/TEM) were used to characterize the local fuel-cladding chemical interaction (FCCI) in one cross-section taken from a HT-9 clad U-20.3Pu-10Zr-1.2Am-1.3Np (in wt.%) fuel irradiated to 6.15 at.% burnup with inner cladding temperatures ranging between 460–490 °C. Results showed that the total interaction thickness between fuel and cladding was <10 µm. Fe infiltrated the fuel to form U-Zr-Fe phases while fuel elements or lanthanides did not infiltrate into the cladding. Np was not involved in the formation of any phases in the examined locations; however, Am played a role by forming a ∼2 µm thick homogeneous Fe-Pu-Am planar front at the inner cladding wall. An oxidized Na layer existed in the fuel-cladding gap with Fe and lanthanide particles dispersed within, suggesting Na could facilitate the transport of fuel and cladding constituents. Secondary phases, including an FCC Zr-rich phase, lanthanide phases, and α’-Cr(Fe) were identified in the outer fuel and FCCI regions. Furthermore, this study suggests that, for the irradiation conditions specific to this cross-section, minor actinides have little impact on FCCI behavior beyond what would be observed in typical HT-9 clad U-Pu-Zr fuel pins systems.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Potential Adoption and Benefits of Co-Optimized Multimode Engines and Fuels for U.S. Light-Duty Vehicles

Exploring a diverse portfolio of technologies for decarbonization is crucial to understanding the potential impacts of different technological solutions and their associated environmental implications. Using high-octane, high-sensitivity biofuel blends in co-optimized multimode engines can increase engine efficiency and reduce vehicle emissions. Here, the multimode engine research focuses on the benefits of light-duty vehicle engines, which can operate in multiple modes depending on the vehicle's load. Low-temperature combustion can improve efficiency and reduce emissions (such as those from oxides of nitrogen and particulate matter) during low-load operation, while spark ignition performance is maintained in high-load operation. These advanced engines can be optimized to run on blends of biobased fuels. This analysis models scenarios for potential market adoption of co-optimized multimode vehicles fueled by three different bioblendstocks: ethanol, isopropanol, and isobutanol. An integrated modeling approach is used to forecast the energy and environmental impacts of the deployment of co-optimized multimode vehicles and fuels in the light-duty sector over the 2020-to-2050 time horizon. The multidisciplinary approach combines vehicle sales modeling, system dynamics modeling of the biorefining industry, and life cycle assessment to estimate the emissions and energy benefits. The models consider market forces such as consumer preferences for vehicle attributes, biofuel supply and demand dynamics subject to biorefinery capacity build-out and bioresource constraints, and forecasted changes to the U.S. bulk energy system over time. Market adoption of co-optimized vehicles is evaluated across a wide parameter space for incremental vehicle cost and engine efficiency improvement. This analysis reveals that the deployment of co-optimized multimode fuels and vehicles results in up to a 5% reduction in annual sector-wide life cycle greenhouse gas (GHG) emissions by 2050, relative to a business-as-usual scenario, but is also indicates environmental trade-offs, such as higher life cycle water-use. Emission benefits could potentially increase beyond 2050, as the new technologies penetrate the market and gain a foothold. Results also show that, under certain circumstances, vehicles with engines co-optimized for use with high-octane, high-sensitivity biofuel blends can be cost-competitive with conventional gasoline, while reducing GHG emissions. Our modeling results indicate that co-optimized multimode fuels and engines can be strategically leveraged in tandem with electrification to decarbonize the light-duty sector. Co-optimized vehicles could play a role in the early years of the time horizon, while electric vehicles (EVs) could become more competitive in the later years, highlighting the complementary benefits of these technologies for GHG reductions.

Oke, Doris↗

DOE OSTI2026

BISON analyses of TRISO fuel performance, its dependence on time-at-temperature, and possible implications for fuel design and qualification

The Advanced Gas Reactor Fuel Development and Qualification (AGR) program has established a substantial technical foundation to support private entry into the U.S. high-temperature gas-cooled reactor market. However, emerging tristructural isotropic (TRISO)-fueled reactor applications include small modular reactors and microreactors with longer fuel residence times, which may expose fuels to higher time-at-temperature (TAT) values than were explored by the AGR program. Increased TAT could affect diffusive and thermomechanical behaviors such as Pd penetration, fission gas release, creep, and fission product transport. In this work, we applied multiscale best-estimate BISON fuel performance modeling to assess these effects within a representative design space based on the AGR-5/6/7 experiment and analyzed trends in predicted particle and compact fuel performance metrics with possible implications for near-term fuel design and qualification. BISON unambiguously predicted that TRISO fuel performance is sensitive to TAT. Increasing TAT was not predicted to increase the magnitude of failure-inducing tangential stresses in particle coating layers. Predictions obtained using a mechanistic model for Pd penetration indicated that penetration depth does not depend strongly on TAT. While these observations suggest that AGR testing provides a conservative upper bound for the steady-state operation of TRISO particles at lower powers and higher residence times, BISON also predicted that the release of poorly retained Ag would increase with TAT. Because these analyses applied models to extrapolate beyond the available experimental data, the authors recommend performing targeted experiments to confirm these predictions. Nevertheless, these predictions may provide reactor developers with enough confidence to make near-term design decisions associated with the potential fuel performance trade-offs of increasing TAT.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2007

Alternate-Fueled Flight: Halophytes, Algae, Bio-, and Synthetic Fuels

Synthetic and biomass fueling are now considered to be near-term aviation alternate fueling. The major impediment is a secure sustainable supply of these fuels at reasonable cost. However, biomass fueling raises major concerns related to uses of common food crops and grasses (some also called "weeds") for processing into aviation fuels. These issues are addressed, and then halophytes and algae are shown to be better suited as sources of aerospace fuels and transportation fueling in general. Some of the history related to alternate fuels use is provided as a guideline for current and planned alternate fuels testing (ground and flight) with emphasis on biofuel blends. It is also noted that lessons learned from terrestrial fueling are applicable to space missions. These materials represent an update and additions to the Workshop on Alternate Fueling Sustainable Supply and Halophyte Summit at Twinsburg, OH, Oct. 17 to 18, 2007 (ref. 1).

Hendricks, R. C.↗

NASA NTRS2012

Alternate-Fueled Flight: Halophytes, Algae, Bio-, and Synthetic Fuels

Synthetic and biomass fueling are now considered to be near-term aviation alternate fueling. The major impediment is a secure sustainable supply of these fuels at reasonable cost. However, biomass fueling raises major concerns related to uses of common food crops and grasses (some also called "weeds") for processing into aviation fuels. These issues are addressed, and then halophytes and algae are shown to be better suited as sources of aerospace fuels and transportation fueling in general. Some of the history related to alternate fuels use is provided as a guideline for current and planned alternate fuels testing (ground and flight) with emphasis on biofuel blends. It is also noted that lessons learned from terrestrial fueling are applicable to space missions. These materials represent an update (to 2009) and additions to the Workshop on Alternate Fueling Sustainable Supply and Halophyte Summit at Twinsburg, Ohio, October 17 to 18, 2007.

Hendricks, R. C.↗

DOE OSTI2025

Reference Fuel Development for Non-Aluminum Spent Nuclear Fuel Management

The Savannah River Site (SRS) L Area Facility provides for the safe receipt, storage, handling, and shipping of spent nuclear fuel (SNF) and has received more than 47,000 SNF assemblies since 1964. In order to consolidate receipt and storage analysis, L Area criticality safety has historically used several aluminum-clad “reference fuels” to establish bounding storage, handling, and cask loading limits and then applied a reactivity comparison approach to demonstrate that candidate fuels may be processed under the reference fuel limits. Currently, only aluminum-clad SNF from off-site research reactors are transferred on-site. The Accelerated Basin De-Inventory (ABD) program will begin the removal of bundled Non-Aluminum Spent Nuclear Fuel (NASNF) from the L Area disassembly basin for dissolution and disposition, which has driven the need for a non-aluminum reference fuel. This paper discusses the process and results of creating a new fictional homogenous NASNF highly enriched uranium reference fuel, “MITZ,” to be used in nuclear criticality safety evaluations for upcoming SNF disposition operations. Data demonstrating the relationship between neutron multiplication behavior and fuel spacing is generated for the new reference fuel MITZ as well as existing reference fuels representing several types of SNF assemblies.

Reference Fuel↗

DOE OSTI2025

Reference Fuel Development for Non-Aluminum Spent Nuclear Fuel Management

Reference Fuel↗

DOE OSTI2025

Enabling BWR fuel rod analysis in the BISON fuel performance code

Nuclear fuel vendors around the world are pursuing approaches to sustain the existing nuclear reactor fleet consisting primarily of pressurized-water reactors (PWRs) and boiling-water reactors (BWRs). To support the industry's efforts, advanced modeling and simulation tools need to be capable of analyzing both legacy reactor concepts. BWR fuel rods are significantly different than those used in PWRs, which can affect fuel performance analysis. BWR fuel rods include: (1) an extensive use of gadolinia dopant as a burnable absorber, (2) an axial variation in fuel enrichment and gadolinia content, (3) the inclusion of a liner on the inner cladding surface to mitigate the impact of pellet-clad mechanical interaction (which impacts hydrogen and hydride distribution), (4) a lower initial fill gas pressure, (5) bottom-entry control rods, and (6) a lower coolant pressure that results in the two-phase flow boiling phenomenon. Although the primary focus of BISON has been in the area of PWR and advanced reactor fuel analyses, this paper presents the developments in BISON to support BWR fuel performance analysis. An overview of the models that account for the effects of gadolinia is highlighted. Internal mesh generation capabilities to include a liner is presented. Normal operating and transient (reactivity insertion accident) demonstration problems are presented to illustrate the impact of gadolinia, the hydrogen and hydride evolution due to the presence of the liner, and BISON's ability to simulate axially varying enrichments and dopant concentration. Bottom-entry control effects are captured by the axial power peaking factors present in the demonstration cases. Comparisons to integral experiments from the Halden IFA-681 experiments are discussed as initial validation. Reasonable comparisons are obtained for fuel centerline temperature and rod internal pressure as a function of time. In conclusion, simulations of additional experiments containing Gd 2 O 3 -bearing fuel are necessary to completely validate the code for BWR applications.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1977

Preliminary analysis of aircraft fuel systems for use with broadened specification jet fuels

An analytical study was conducted on the use of broadened specification hydrocarbon fuels in present day aircraft. A short range Boeing 727 mission and three long range Boeing 747 missions were used as basis of calculation for one-day-per-year extreme values of fuel loading, airport ambient and altitude ambient temperatures with various seasonal and climatic conditions. Four hypothetical fuels were selected; two high-vapor-pressure fuels with 35 kPa and 70 kPa RVP and two high-freezing-point fuels with -29 C and -18 C freezing points. In-flight fuel temperatures were predicted by Boeing's aircraft fuel tank thermal analyzer computer program. Boil-off rates were calculated for the high vapor pressure fuels and heating/insulation requirements for the high freezing point fuels were established. Possible minor and major heating system modifications were investigated with respect to heat output, performance and economic penalties for the high freezing point fuels.

Pasion, A. J.↗

NASA NTRS1928

The Effects of Fuel and Cylinder Gas Densities on the Characteristics of Fuel Sprays for Oil Engines

This investigation was conducted as a part of a general research on fuel-injection engines for aircraft. The purpose of the investigation was to determine the effects of fuel and cylinder gas densities with several characteristics of fuel sprays for oil engines. The start, growth, and cut-off of single fuel sprays produced by automatic injection valves were recorded on photographic film by means of special high-speed motion-picture apparatus. This equipment, which has been described in previous reports, is capable of taking twenty-five consecutive pictures of the moving spray at the rate of 4,000 per second. The penetrations of the fuel sprays increased and the cone angles and relative distributions decreased with increase in the specific gravity of the fuel. The density of the gas into which the fuel sprays were injected controlled their penetration. This was the only characteristic of the chamber gas that had a measurable effect upon the fuel sprays. Application of fuel-spray penetration data to the case of an engine, in which the pressure is rising during injection, indicated that fuel sprays may penetrate considerably farther than when injected into a gas at a density equal to that of the gas in an engine cylinder at top center.

Joachim, W F↗

NASA NTRS1953

Fuel characteristics pertinent to the design of aircraft fuel systems

Because of the importance of fuel properties in design of aircraft fuel systems the present report has been prepared to provide information on the characteristics of current jet fuels. In addition to information on fuel properties, discussions are presented on fuel specifications, the variations among fuels supplied under a given specification, fuel composition, and the pertinence of fuel composition and physical properties to fuel system design. In some instances the influence of variables such as pressure and temperature on physical properties is indicated. References are cited to provide fuel system designers with sources of information containing more detail than is practicable in the present report.

Barnett, Henry C↗