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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Metallurgical Analysis and Forward Modeling of Weld Distortion in SMR Containment Vessels

This work aimed to apply Sandia’s expertise in metallurgy and modeling to enable the use of hybrid laser arc welding for building nuclear reactor containment structures, via a collaboration with Holtec International. Experimental observations were coupled with finite element analysis to resolve microstructure development, mechanical properties, distortion, and residual stress in welds relevant to the production of the Holtec SMR-160. High residual stresses were observed in welds that were not subjected to preheat. Meanwhile, the microstructure of the welds generally exhibited a narrow heat affected zone relative to conventional arc welds. FEA appeared to be effective in simulating the thermal/mechanical conditions that occur during hybrid laser arc welding of simplified and instrumented test welds. Subsequently, FEA was used to perform sensitivity analyses for various weld geometries that would be prohibitively costly to assess with physical experiments. Insights from the study were used to inform Holtec’s welding process, and successful production welds were performed in 2025.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Assessment of NuScale SMR Steam Heat Augmentation for Chemical Plant Decarbonization

Nearly 50% of the total energy consumed by the industrial sector in the United States is used to produce process steam with natural gas and coal-fired boilers1 . This project conducts a technoeconomic assessment of a NuScale Small Modular Reactor (SMR) coupled with a chemical plant as an Integrated Energy System (IES) where nuclear produces steam and electric power to meet the requirements of a large chemical plant. In a 2020 study, ORNL evaluated the feasibility of using advanced SMRs, including the NuScale design, to supply energy to the Eastman Chemical Plant. However, since that report was published, NuScale received NRC approval for its uprated 77 MWe design with 56% more power and has also introduced a high-temperature, high pressure, steam heat-augmentation system, a key focus of the new study. The new study also benefits from revised capital costs, a 10-day refueling outage time, reduced plant staffing, higher capacity factors, and a site boundary Emergency Planning Zone methodology. The study consists of a techno-economic assessment of two possible energy sources (nuclear and natural gas) in a number of steam and power generation configurations (NuScale Power Modules (NPMs), boilers and combinations of both) to satisfy the steam and power demand with the most reliable and cost competitive system. A total of 2,947.3 klb/hr of steam and 72.5 MWe of electricity are required for the demonstration case. A range of scenarios and solutions are explored, from a 12-NPM plant (3,000 MWth)—with excess capacity and redundancy, capable of supplying a significant amount of extra power to the grid—to a 4-NPM (1,000 MWth) plant—supplemented with existing boilers or grid power for redundancy. The study uses historical steam and power data from a chemical plant and examines the sensitivity to natural gas and grid power cost variations. Scenarios with up to two times gas and electricity costs were considered. Profitability in a 60-year time horizon was analyzed, consistent with NuScale’s design life specification. A steady-state site integration and reliability analysis was performed, and trade-offs were identified.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2016

Design of a Thermal Energy Storage System for SMR's

A potential deployment strategy for Small Modular Reactors (SMR's) is in hybrid energy systems where the presence of intermittent energy sources (wind and/or solar) subjects the reactor to a time varying electric load (1). Proposed options for accommodating this load have included operating the reactor in a load follow mode, or operating the reactor at or near steady state and bypassing steam around the turbine directly to the condenser (2). Both of these strategies result in lost energy potential. With the large financial investment associated with a nuclear power plant there is strong economic incentive to run the plant at maximum capacity. One method to accomplish this is the installation of Thermal Energy Storage (TES) that can be charged when grid demand is less than 100% plant capacity. The thermal energy can then be recovered, either as a supplement to the power plant during peak demand times, or can be used for other processes (1). Sensible heat thermal energy storage systems have been proposed for solar energy systems (3). This paper describes such a system for SMRs. These results show the feasibility of a TES system alongside a nuclear power plant that can limit load following operations for the reactor. Load following results in a decrease of capacity factor for the plant along with imposing significant stresses to plant equipment. With the implementation of a TES system these stresses can be transferred from the nuclear plant to the TES system. Not only does this equate to a longer overall life of the plant's hardware, but it also will dramatically increase the capacity factor of the system. This increase in capacity factor will lead to an improved economic return over the lifespan of the reactor. Future development in the near term will focus on coupling the TES system to the dynamic response of the reactor and energy conversion system and developing the models necessary to implement the discharge mode. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

A large scale system approach for stability analysis of multi-unit SMR plants - 248

In this paper we present a framework based on large scale system theory for analyzing the stability of coupled advanced high temperature molten salt small modular reactors. It has been suggested that small modular reactors be coupled through a common molten salt energy repository, called a salt vault. Using vector Lyapunov functions the connective stability of multiple reactors coupled through a salt vault can be guaranteed. In this theory, scalar Lyapunov functions are assigned to portions of the composite system state space. Functions are constructed for each small modular reactor (SMR), each Brayton cycle, and the salt vault. These functions are then aggregated, becoming components of a vector Lyapunov function. If this vector function possesses special properties, the composite system is stable. Bounds on the connective stability of a multi-reactor plant can be found in terms of a free parameter, in this case the mass of molten salt in the salt vault. Examining bounds on the connective stability allows one to use control theory as a tool for making performance and economic design decisions related to the size of the salt vault. This technique can produce a constraint that is used in a design optimization problem for finding the smallest-possible salt vault that ensures stability. It can also be used as an indicator of interconnection and its effect on system behavior. This, in turn, could be used to guide multi-unit control system design to ensure that highly coupled systems behave favorably. The theory for multi-unit control and operation is discussed. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Experimental Study for Two Phase Flow Instability in the PCHE Type Steam Generator in SMR

Conventional U-tube type heat exchangers have some limitations when applied to Small Modular Reactor (SMRs). In particular, the size of steam generators is important in the SMR, as it greatly affects the size, and thus the cost, of the reactor vessel.. Therefore, the circuit heat exchanger (PCHE) is suggested as an alternative. PCHE, a compact type heat exchanger manufactured by HEATRIC, has several advantages such as the reduced size, wide operation range until 900? and 900 bar and high power density due to the large heat transfer area over volume ratio. Recently, it is newly suggested as an application of a steam generator. MIT and KAIST have already conceptually suggested PCHE as a steam generator. Under boiling condition, flow instability is one of the critical issues-resulting in unstable mass flow rate, sudden temperature change and system control failure. According to the flow mechanism, there are various types of instabilities in the heat exchanger and each flow tendency is different. Typical examples are Ledinegg instability of the static instability and pressure-drop oscillation and density-wave oscillation of the dynamic instability. The characteristic of Ledinegg instability is that the flow under unstable condition changes into the stable flow. The characteristic of dynamic instability is that the flow fluctuates continuously. Pressure-drop oscillation has the period of tens of seconds and the system pressure also highly oscillates with the period of flow instability. In comparison, the density-wave oscillation has the period of few seconds and the system pressure is relatively stable. Previous studies on flow instability are focused on the single channel flow and helical tube type heat exchanger. There has been very limited experimental research on flow instability using PCHE. In KAIST, the test facility was constructed to study the thermal hydraulics in PCHE. The objectives of our test facility are: (1) to identify the occurrence of instability under two phase and super-heated steam flow in PCHE, and (2) to examine whether it can operate normally using throttling effect. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

SMR Re-Scaling and Modeling for Load Following Studies

This study investigates the creation of a new set of scaling parameters for the Oregon State University Multi-Application Small Light Water Reactor (MASLWR) scaled thermal hydraulic test facility which modeled the NuScale power SMR design. As part of a study being undertaken by Idaho National Lab involving nuclear reactor load following characteristics, full power operations need to be simulated, and therefore properly scaled. Presented here is the scaling analysis and plans for RELAP5-3D simulation. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Power Distribution Control Strategy of a Conceptual Soluble Boron Free SMR

In a commercial PWR, the two primary functions of control rods are to provide rapid shutdown and to control power distribution, whereas the initial excess reactivity associated with fuel loading is controlled by the soluble boron in the coolant and burnable absorbers. The required number of total control rods is determined by the shutdown margin of the reactor. The control rod grouping is also required to control power distribution. Therefore, removal of soluble boron requires extra reliance on the control rods to compensate excess reactivity. In a soluble boron free reactor which has highly negative MTC requires an increase in both worth and number of control rod assemblies to ensure adequate shutdown margin. In addition, since control rods are partially inserted into the reactor core, their presence adversely affects the power distribution and thus may make high peaking factors leading to an operating margin reduction. In this paper, the strategy of control rods operation to control excess reactivity and power distribution have been studied. Also, shutdown capability of the control rods was examined. A loading pattern for a Conceptual Soluble Boron Free Small Modular Reactor (CSBF-SMR) has been constructed. Two groups of regulating banks employ Ag-In-Cd to control excess reactivity and power distributions during the cycle operation and 1 group of shutdown bank made of B{sub 4}C were used.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Neutronic analysis of a PWR-type SMR core using duplex ThO{sub 2}-UO{sub 2} in TRISO fuel particles

Currently, studies on small modular reactors (SMRs) present an important development due to the potential they represent in terms of safety, operational flexibility, economy, and non-energy applications. Furthermore, there is increasing interest in studying the use of thorium as fuel, as an effective way to solve problems such as the shortage of uranium reserves, reduction of nuclear waste and nuclear proliferation. Also, the use of thorium combined with highly enriched uranium TRISO particles has been studied, showing proper performance. In this work, the concept of ThO{sub 2}-UO{sub 2} duplex fuel is used, for the core configuration of a PWR type SMR that uses TRISO fuel, designed to achieve extended fuel cycles. Three distribution cases of ThO{sub 2} and UO{sub 2} in TRISO particles inside the fuel rods are compared. First, particles composed by a homogeneous mixture of ThO{sub 2} and UO{sub 2} are distributed inside of fuel elements. Second, the fuel zone of the fuel elements is divided into two radially, an internal one where the TRISO particles composed of ThO{sub 2} are distributed and the external one where the TRISO particles composed of UO{sub 2} are distributed. The third case is like the previous one, except that the particles that contain UO{sub 2} are distributed in the inner zone and those that contain ThO{sub 2} in the outer zone of the fuel elements. The comparison of the cases is carried out in terms of cycle main isotopes' mass transmutation, power distribution and temperature reactivity coefficients. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Severe Accident Phenomena: A Comparison Among the NuScale SMR, Other Advanced LWR Designs, and Operating LWRs

During a severe accident in a nuclear reactor, there are a number of phenomenological events which can present a challenge to containment integrity. These include the generation and combustion of hydrogen, energetic fuel-coolant interactions, thermal attack of fission product barriers, core-concrete interactions, direct containment heating, and gradual overpressurization. The advanced design of the NuScale small modular reactor has resulted in the reduced likelihood and severity of severe accident challenges to containment. This paper discusses the features of the NuScale design that reduce the likelihood of occurrence of these severe accident phenomena, and discusses the ability of containment to survive in the unlikely event that they do occur. Here, the impact of severe accident phenomena for the NuScale design is compared and contrasted against other advanced light water reactors, such as AP1000 and ESBWR, as well as the existing fleet, using information from publicly available documents.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Digital Engineering and Cybersecurity Decision Analysis in Early Phases of SMR-Driven IES Projects

Considerable efforts are underway to ensure cybersecurity is integrated into the systems engineering lifecycle. Cyber-informed engineering and security-by-design frameworks are intended to identify and engineer out cybersecurity risks throughout the lifecycle. While these approaches are valuable for promoting the need to include cybersecurity considerations in early design phases to create more secure systems, they may not consider the entirety of digital risks. Digital risks in a digital instrumentation and control system include adversarial and unintentional risks from internal and external factors, such as human performance errors, design flaws, environmental conditions, and equipment degradation or failure. This report provides a detailed discussion on digital risk prior to describing the background and concept of operations for a small modular reactor-driven integrated energy system connected to industrial applications. The challenges of competing objectives and competing stakeholder requirements are discussed and the impacts on digital engineering, security considerations, and interdependencies are evaluated for mission-level, facility-level, and system-level decisions.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2014

SMR Handbook: Hybrid Energy Systems Involving SMRs

Large-scale nuclear reactors are traditionally operated for a singular purpose: steady-state production of dispatchable baseload electricity that is distributed broadly on the electric grid. While this implementation is key to a sustainable, reliable energy grid, SMRs offer new opportunities for increased use of clean nuclear energy for both electric and thermal applications in more locations – while still accommodating the desire to support renewable production sources. This chapter considers a scenario in which renewable generation would be tightly coupled with the nuclear generation source – behind the grid – to meet the grid demand as an integrated energy system while simultaneously producing other commodities with the available thermal energy.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

SMR Re-Scaling and Modeling for Load Following Studies

This study investigates the creation of a new set of scaling parameters for the Oregon State University Multi-Application Small Light Water Reactor (MASLWR) scaled thermal hydraulic test facility. As part of a study being undertaken by Idaho National Lab involving nuclear reactor load following characteristics, full power operations need to be simulated, and therefore properly scaled. Presented here is the scaling analysis and plans for RELAP5-3D simulation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Power distribution estimation method for SMR using ex-core detectors: experimental demonstration by plural control rod patterns at KUCA

The power distribution estimation method based on the ex-core detectors, or PHOEBE, was demonstrated at Kyoto University Critical Assembly, KUCA. Generally, core monitoring systems use in-core neutron detectors. Since inside the core is a harsh environment, the maintainability and reliability of the detectors are deteriorated. On the other hand, the environment outside the core is milder: core monitoring by the ex-core detectors improves the maintainability and reliability especially for small modular reactors and micro-reactors. However, neutron information from the inner region of the core is lost at the ex-core detectors. To recover the information, the authors proposed to utilize the power correlation between the fuel regions. PHOEBE concept was demonstrated at KUCA with distorted power distributions simulated by control rod patterns. The relative power distribution estimated by PHOEBE agreed with that calculated by Monte Carlo simulation code MVP. PHOEBE approximately reproduced the trend of the distorted power distributions calculated by MVP code. By contrast, the case of without power correlation between fuel regions produced significant different power distributions. Therefore, the advantage of considering the power correlation between fuel regions was also demonstrated. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Improvements in SMR Modular Construction through Supply Chain Optimization and Lessons Learned

Affordable energy is a critical societal need. Capital construction cost is a significant portion of nuclear energy cost. By controlling and reducing cost, companies can build more competitive nuclear power plants and hence provide access to more affordable energy. Modular construction provides an opportunity to reduce the cost of construction, and as projects scale up in number, the cost of each unit can be further reduced. The objective of this project was to advance design and construction methods for manufacturing Small Modular Reactors (SMRs), and in particular to improve modular construction techniques and develop best practices for designing and operating supply chains that take advantage of these techniques. The overarching objectives were to accelerate the construction schedule and reduce its variability, reduce the cost of construction, reduce interest costs accrued during construction (IDC), and thus enhance the economic attractiveness of SMRs. Our fundamental measure of merit was total capital investment cost (TCIC). To achieve these objectives, this project developed a decision support system, EVAL, to support identifying, addressing, and resolving or ameliorating challenges and deficiencies in the current modular construction approach. The results of this effort were consistent with the facts that the cost of a construction activity is often smallest when accomplished in the factory, greatest when accomplished at the construction site, and at an intermediate level when accomplished at an assembly area close to the construction site. Further, EVAL can aid in providing insight into ways to reduce waste, improve quality, efficiency, and throughput and reflects the fact that the more done early in the construction process, i.e., in the factory, the more upfront funding is required and hence the more IDC will be accrued. The analysis has lead to a better understanding of circumstances under which modular construction performed mainly in the factory will result in lower expected total cost, relative to more traditional, on-site construction procedures. Further, we anticipate that EVAL can be used to gain insight regarding what role standardization can play in order for modularization to be most effectively defined. Such results would ultimately benefit all (small and large) new nuclear construction.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Initial full core SMR simulations with NekRS

This document describes the completion of a recent milestone of the ExaSMR program concerning "Full core simulations". The ExaSMR project is developing tools for coupling Monte Carlo (MC) radiation transport solvers to a computational fluid dynamics (CFD) solver. Work is based on the Shift MC, OpenMC MC, and Nek5000/NekRS CFD codes. As part of this milestone, a novel set of pin-resolved CFD full-core simulations have been performed for the first time. These simulations represent a significant increase in capability in what is now possible with CFD on pre-Exascale systems. The simulations have been performed with the spectral element solvers NekRS on the supercomputer Summit. Multiple simulations campaigns have been conducted: (1) LES simulations in bare bundle, (2) RANS simulations in bare bundles, (3) RANS simulations with momentum sources and (4) Conjugate heat transfer calculations.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗