Safeguards modeling of TRISO fuel fabrication facilities
Explore the source record for details and available documents.
Moosir, Patrick Michael↗
SEARCH · Engineering Papers
Results for “TRISO”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Modeling Approaches for Depletion of a TRISO-Fueled Microreactor
Explore the source record for details and available documents.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Select Proliferation Studies on TRISO-fueled, Heat-Pipe-cooled Microreactors
Nuclear microreactors carry the potential to open up new markets for the nuclear industry, as their expected cost competitiveness in non-traditional market segments (e.g., mines, military bases, extraterrestrial surfaces, and remote areas), and their inherent safety features make them deployable when other power sources are unavailable or difficult to exploit. For countries that have not traditionally participated in nuclear power, microreactors represent a clean energy solution [1]. However, their use, especially in non-weapons states, may entail challenges in terms of maintaining international nuclear safeguards [2]. Furthermore, the deployment locations where microreactors may prove most cost competitive would be difficult to access by state and International Atomic Energy Agency (IAEA) inspectors [3]. In addition to the isolated nature of potential deployment sites, the low-power characteristic of microreactors suggests that numerous microreactors would need to be deployed to meet energy demands. That, coupled with the unique physics of many current microreactor designs, opens up a new area of research with respect to nonproliferation and safeguards concerns [2]. Whereas traditional facilities are inspected as isolated cases when looking for signs of diversion or misuse; microreactors may need to be assessed in the context of the entire fleet to which they belong. International safeguards necessitate timely detection of any significant quantities (SQs) of material that are being diverted (e.g., 1 SQ of special nuclear material diverted over the course of a 1-year period) [4]. For low-enriched uranium, the IAEA defines 1 SQ as corresponding to 75 kg of 235U. The purpose of the present paper is to explore the detectability threshold for material diversion in microreactors by relying on critical control drum angles, excess reactivity, and the reactor lifetime as the selected operational parameters. For this assessment, a heat-pipe-cooled microreactor was regarded as the base design. While the conclusions reached in this paper are not readily extendable to the design of actual microreactors, the analysis herein enables conclusions to be drawn regarding the level of accuracy needed for reference calculations in order to detect diversion scenarios by utilizing the selected operational parameters (i.e., mainly control drum angles, critical insertion angle, and the reactor lifetime).
22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
AGR-5/6/7 Fuel Fabrication Report
The U.S. Department of Energy Office of Nuclear Energy (DOE NE) and the Idaho National Laboratory (INL) Advanced Reactor Technologies (ART) Advanced Gas Reactor (AGR) Fuel Development and Qualification program (referred to as AGR Fuel program hereafter) are pursuing qualification of tristructural isotropic (TRISO) coated particle fuel for use in high temperature gas cooled reactors (HTGRs). The AGR Fuel program was established to provide a fuel qualification data set in support of the licensing and operation of an HTGR. BWX Technologies Nuclear Operations Group (BWXT-NOG) was subcontracted to fabricate the fuel for the AGR program. Several investments and innovations were realized in preparation to fabricate fuel for the AGR-5/6/7 irradiation experiments that brought fuel fabrication fully out of the laboratory and into engineering-scale operations. These included: • Increased the kernel fabrication line capacity and uniformity • Upgraded ancillary support equipment and processes for the tristructural isotropic (TRISO) coating furnace • Demonstrated efficient production of the matrix precursor powder by dry jet milling of co mingled components • Demonstrated an engineering-scale method for quick and efficient overcoating TRISO particles with the matrix precursor • Demonstrated an automated, multi cavity compacting system with a volumetric feed system • Demonstrated a combined-cycle thermal treatment furnace These changes increased production rates of some of these processes by an order of magnitude or more while eliminating the use of flammable solvents, multiple grinding and sorting operations, and the weighing out of individual die charges. Three fuel kernel lots were fabricated for production of the fuel for AGR-5/6/7. The initial lot (J52R-16-39316) was certified to fuel specifications but was not used because the kernels had a high fraction of internal fissures that caused an unacceptable fraction of the kernels to fragment when charged to the coating furnace where the TRISO coating would be deposited. Fragmented kernels increased the dispersed uranium in the particles and produced a worrisome fraction of dimpled particles with an elevated probability of in-pile failure. After some efforts to identify the cause of the fissure formation, two additional lots were produced with much lower fissure fractions, J52R-16-69317 and 69318. The latter kernel lot was a backup to the first and was not needed. Multiple kernel batches were composited to form each of the lots so as to simulate a commercial-scale operation where kernel batches would also be composited. Multiple TRISO coating runs were performed and the product characterized so that several could be composited into a TRISO lot. TRISO lot J52R-16-98005 conformed to all fuel specifications except the mean outer pyrocarbon (OPyC) layer thickness was thinner than specified. Furthermore, it was determined that the TRISO lot had a dispersed uranium fraction (DUF) that might result in the compacts not meeting the DUF specification. A review of the role of the OPyC layer and consequences of the DUF by the Technical Coordination Team and INL concluded that the fuel was acceptable for use in the AGR-5/6/7 irradiation experiment. The TRISO particles were overcoated with the matrix precursor that had been produced in a jet-milling operation. The overcoating was performed in equipment originally designed to coat pharmaceuticals. The overcoating process performed well; producing highly spherical and uniform overcoats requiring little upgrading and no recycle or rework. TRISO particles were overcoated with the matrix precursor to achieve nominal volumetric packing fractions (PFs) of TRISO particles of 25% and 40% for the irradiation experiments. The 40% PF compacts occupy the first and fifth test capsule in the test train while the inner three capsules are loaded with 25% PF compacts. The resinated graphite matrix precursor powder was a derivative of the German A3-27 matrix formulation, which differs from previous AGR irradiation campaigns that used an A3-3 formulation. Jet milling of the matrix powder precursor produced a finer mean graphite particle size than the milling operations used for the A3-3 matrix powder precursor. Changes made in the matrix formula and equipment yielded compacts with significantly higher matrix density than was attained in previous AGR irradiation campaigns. The changes in the matrix formulation and the means of milling the powders also complicated resolution of the three fuel compact defect fractions, DUF, exposed kernel fraction (EKF), and the silicon carbide defect fraction (SDF). Characterization data from BWXT-NOG had some anomalous results, so samples of the fuel compacts and overcoated TRISO particles were also analyzed by Oak Ridge National Laboratory (ORNL) to ensure that the defect fractions were accurately characterized.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Assessment of Possible Cycle Lengths for Fully-Ceramic Micro-Encapsulated Fuel-Based Light Water Reactor Concepts
The tri-isotropic (TRISO) fuel developed for High Temperature reactors is known for its extraordinary fission product retention capabilities [1]. Recently, the possibility of extending the use of TRISO particle fuel to Light Water Reactor (LWR) technology, and perhaps other reactor concepts, has received significant attention [2]. The Deep Burn project [3] currently focuses on once-through burning of transuranic fissile and fissionable isotopes (TRU) in LWRs. The fuel form for this purpose is called Fully-Ceramic Micro-encapsulated (FCM) fuel, a concept that borrows the TRISO fuel particle design from high temperature reactor technology, but uses SiC as a matrix material rather than graphite. In addition, FCM fuel may also use a cladding made of a variety of possible material, again including SiC as an admissible choice. The FCM fuel used in the Deep Burn (DB) project showed promising results in terms of fission product retention at high burnup values and during high-temperature transients. In the case of DB applications, the fuel loading within a TRISO particle is constituted entirely of fissile or fissionable isotopes. Consequently, the fuel was shown to be capable of achieving reasonable burnup levels and cycle lengths, especially in the case of mixed cores (with coexisting DB and regular LWR UO2 fuels). In contrast, as shown below, the use of UO2-only FCM fuel in a LWR results in considerably shorter cycle length when compared to current-generation ordinary LWR designs. Indeed, the constraint of limited space availability for heavy metal loading within the TRISO particles of FCM fuel and the constraint of low (i.e., below 20 w/0) 235U enrichment combine to result in shorter cycle lengths compared to ordinary LWRs if typical LWR power densities are also assumed and if typical TRISO particle dimensions and UO2 kernels are specified. The primary focus of this summary is on using TRISO particles with up to 20 w/0 enriched uranium kernels loaded in Pressurized Water Reactor (PWR) assemblies. In addition to consideration of this 'naive' use of TRISO fuel in LWRs, several refined options are briefly examined and others are identified for further consideration including the use of advanced, high density fuel forms and larger kernel diameters and TRISO packing fractions. The combination of 800 {micro}m diameter kernels of 20% enriched UN and 50% TRISO packing fraction yielded reactivity sufficient to achieve comparable burnup to present-day PWR fuel.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Assessment of buffer-IPyC thermomechanical debonding behavior using new experimental strength data in BISON
TRIstructural ISOtropic (TRISO) fuel is a nuclear fuel commonly used in High Temperature Gas-cooled Reactors (HTGRs). A single sub-millimeter-diameter TRISO fuel particle consists of a spherical fuel kernel surrounded by four coating layers: a low-density pyrocarbon buffer layer, an inner pyrolytic carbon (IPyC) layer, a silicon carbide (SiC) layer, and an outer pyrolytic carbon (OPyC) layer. The kernel is commonly made of UO2 or a mixture of uranium carbide and uranium oxide (UCO). During reactor operation, the TRISO coating layers are subjected to irradiation-induced dimensional changes and the associated thermomechanical behavior of each layer. One of the observed behaviors is gap formation between the buffer and IPyC layer due to the porous buffer’s irradiation-induced shrinkage exceeding that of the IPyC layer. Not all irradiated particles will experience buffer-IPyC gap formation. The debonding may be partial, or it may be nearly total. However, from post-irradiation examination of UCO TRISO fuels irradiated as part of the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program, it was concluded that partial buffer-IPyC debonding was the most common type of buffer-IPyC interaction. To predict TRISO thermomechanical performance, multi-physics models have been built that are being continually updated and refined. The BISON code is a finite element-based nuclear fuel performance code that may be used for 1D, 2D, and 3D TRISO particle simulations. This code is used to calculate fuel temperature, kernel swelling, buffer densification, thermal and irradiation creep, fracture, and fission gas production and release. One of the recent additions to the BISON code is the ability to model the process of layer debonding. This paper will focus on the simulation results of the improved BISON debonding model that will utilize updated strengths measured from irradiated AGR TRISO fuel particles. The new experimental strength data from micromechanical tests of irradiated TRISO fuel samples were exercised in the BISON simulations and compared to baseline strength data to assess their applicability in the models. This also includes updated buffer-IPyC bond strengths to simulate layer delamination. Based on current experimental observations it is noted that the buffer-IPyC separation occurs not exactly at the junction of these two layers, but more on the side of the buffer layer. That observation is also implemented in the TRISO interface debonding model. This improved modeling approach using experimental strength data to characterize buffer-IPyC debonding and its potential subsequent cracking will be presented in the paper along with comparisons to available experimental observations.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Neutronics analysis of fuel-in-fiber concept
One of the consequences of Fukushima was the increase in interest in development of safer, more accident tolerant fuels and claddings. Accident tolerant fuels (ATF) are defined by the Nuclear Regulatory Committee (NRC) as fuels that, in comparison with the standard UO{sub 2}- Zircaloy system, can tolerate loss of active cooling in the core for a considerably longer time period while maintaining or improving the fuel performance during normal operations. One of the ideas being considered is tri-isotropic (TRISO) fuel particles. TRISO fuel pebbles consist of several layers - the outermost being graphite. TRISO pebbles are considered to be accident tolerant, because of their ability to retain fission products at high temperatures. One of the ideas implementing TRISO pebbles is Fully Ceramic Microencapsulated fuel where the pellet is comprised of TRISO pebbles in a matrix. TRISO particles though have a low maximum packing fraction when put in the spherical or cylindrical configuration with the current fabrication techniques (hot and cold press). This leads to considerable increase in enrichment to maintain cycle length for today's Light Water Reactors (LWR). The Fuel-in-Fiber concept, developed by FreeForm-Fiber (FFF), has the advantages of TRISO particles while utilizing a novel additive direct manufacturing technique for rapid fabrication. Fuel-in-Fiber are small fibers made of layers just like TRISO particles but because of their cylindrical nature, they can be packed with a tighter packing fraction than the TRISO particles. The fibers are woven within a SiC matrix and used to replace a typical pellet in a fuel pin. This means that they can easily be placed into LWR's without having to change the assembly or core structures. (authors)
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Internal Radiation Dose Evaluation For An Unruptured Post Release Tristructural Istropic Fuel Particle for Advanced and Micro-reactor Applications
There are unique benefits from advanced/micro reactor designs and fuel types that offer safety features in the case of an accident that may reduce environmental consequences compared to conventional reactors and fuels. Several micro reactor designs, for both civilian and military applications, are proposed using tristructural-isotropic (TRISO) fuel. TRISO particles are a robust advanced nuclear fuel type that leads to the unique question of how unruptured, activated TRISO particles will interact with humans. Human exposure to nuclear fuel, or radionuclides, includes all pathways of exposure. However, TRISO particles are 0.9 mm in size, and that particle size restricts internal dose assessment to the ingestion pathway; eliminating the inhalation and dermal absorption pathways. Furthermore, activity of the TRISO particle was established by High Temperature Engineering Test Reactor simulations assuming the TRISO particle was one day post-release from the reactor. International Commission of Radiological Protection publications 100 and 133 were used to develop the internal dosimetry model for an unruptured TRISO particle for the International Commission of Radiological Protection reference male and female dose assessment. The rectosigmoid colon had the highest internal organ dose for both reference male (2.1 Sv) and reference female (2.3 Sv). The internal dose from ingestion of the scenario-defined TRISO particle was 0.25 Sv for the reference male and 0.29 Sv for the refence female, which exceeds the annual occupational effective dose limit of 0.05 Sv in the code of federal regulations, 10.CFR.20 Subpart C.
61 RADIATION PROTECTION AND DOSIMETRY↗
Failure analysis of nuclear transient-tested UN tristructural isotropic fuel particles in a 3D printed SiC matrix
Fully ceramic microencapsulated fuel elements containing UN tristructural isotropic (TRISO) fuel particles within a 3D printed SiC matrix were subjected to transient testing with varying energy depositions. Detailed post-irradiation examinations were performed, including leaching in hot HNO3 and post-leaching X-ray computed tomography, to quantify the percentage of failed TRISO particles and crack propagation within the particles and surrounding fuel matrix. In parallel, detailed finite element analyses were performed for comparison with experimental findings and to better evaluate transient failure modes. The lowest transient energy deposition—which still exceeded bounding values for high-temperature gas-cooled reactor applications—resulted in no detectable TRISO particle failures or matrix cracking, which was consistent with the simulations. Simulations of the higher-energy transients for which significant TRISO particle failure was expected were generally able to reproduce the transient temperatures and matrix cracking. Thus, the TRISO particle failures were explained based on the effects of local SiC matrix thickness and porosity. Results generally confirmed the high strength of the additively manufactured SiC matrix but also affirmed the need for a modified UN TRISO architecture to prevent SiC matrix cracks from propagating through TRISO layers. This unique failure mode has not historically been considered for TRISO fuels contained in weaker graphite matrices.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Initial results from safety testing of US AGR-2 irradiation test fuel
Two cylindrical compacts containing tristructural isotropic (TRISO)-coated particles with kernels that contained a mixture of uranium carbide and uranium oxide (UCO) and two compacts with UO 2 -kernel TRISO particles have undergone 1600°C safety testing. These compacts were irradiated in the US Advanced Gas Reactor Fuel Development and Qualification Program's second irradiation test (AGR-2). The time-dependent releases of several radioisotopes ( 110m Ag, 134 Cs, 137 Cs, 154 Eu, 155 Eu, 90 Sr, and 85 Kr) were monitored while heating the fuel specimens to 1600°C in flowing helium for 300 h. The UCO compacts behaved similarly to previously reported 1600°C-safety-tested UCO compacts from the AGR-1 irradiation. No failed TRISO or failed SiC were detected (based on krypton and cesium release), and cesium release through intact SiC was very low. Release behavior of silver, europium, and strontium appeared to be dominated by inventory originally released through intact coating layers during irradiation but retained in the compact matrix until it was released during safety testing. Both UO 2 compacts exhibited cesium release from multiple particles whose SiC failed during the safety test. Europium and strontium release from these two UO 2 compacts appeared to be dominated by release from the particles with failed SiC. Silver release was characteristically like the release from the UCO compacts in that an initial release of the majority of silver trapped in the matrix occurred during ramping to 1600°C. However, additional silver release was observed later in the safety testing due to the UO 2 TRISO with failed SiC. Failure of the SiC layer in the UO 2 fuel appears to have been dominated by CO corrosion, as opposed to the palladium degradation observed in AGR-1 UCO fuel.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Reliability estimation of an advanced nuclear fuel using coupled active learning, multifidelity modeling, and subset simulation
Tristructural isotropic (TRISO)-coated particle fuel is a robust nuclear fuel and determining its reliability is critical for the success of advanced nuclear technologies. However, TRISO failure probabilities are small and the associated computational models are expensive. Here we used coupled active learning, multifidelity modeling, and subset simulation to estimate the failure probabilities of TRISO fuels using several 1D and 2D models. With multifidelity modeling, we replaced expensive high-fidelity (HF) model evaluations with information fusion from two low-fidelity (LF) models. For the 1D TRISO models, we considered three multifidelity modeling strategies: only Kriging, Kriging LF prediction plus Kriging correction, and deep neural network (DNN) LF prediction plus Kriging correction. While the results across these multifidelity modeling strategies compared satisfactorily, strategies employing information fusion from two LF models called the HF model least often. Next, for the 2D TRISO model, we considered two multifidelity modeling strategies: DNN LF prediction plus Kriging correction (data-driven) and 1D TRISO LF prediction plus Kriging correction (physics-based). The physics-based strategy, as expected, consistently required the fewest calls to the HF model. However, the data-driven strategy had a lower overall simulation time since the DNN predictions are instantaneous, and the 1D TRISO model requires a non-negligible simulation time.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
"Source Term Modeling for Advanced Gas Micro-Reactors"
Maintaining the safety of the public, environment, and operating personnel is the most important factor in designing, operating, maintaining, and decommissioning nuclear reactors. In recent years, there has been a growing interest in the development of micro-reactors employing TRi-structural ISOtropic (TRISO)-coated particle fuel. In gas reactors, TRISO fuel plays an important role in the safety case for high temperature reactors because of the fission product retention properties of the fuel. This ability enables the use of a functional containment strategy for the reactor where multiple barriers are used to prevent fission product release to the environment. Part of the safety analysis of these advanced reactors is the assessment of radionuclide releases under normal and accident conditions through the multiple credited safety barriers. Using conservative assumptions, a mechanistic analysis can be performed to quantify these releases that combines the probabilistic assessment of failure with analytic solutions to radionuclide transport equations. Source term modeling for TRISO fuel has been performed for previous reactor designs; however, these models are outdated, in many cases proprietary, and need updates to be applied to the current state of TRISO fuel technology and alternative gas reactor core configurations [1]. Currently, the only publicly available source term assessment for gas reactors is an expert-based Monte Carlo simulation based on the effectiveness of the fuel kernel, coating layers, and graphite block in a modular high temperature gas reactor [2]. Thus, there is a need to develop a simple, versatile, and mechanistic model of fission product release and transport in gas reactor cores that could be applied to a variety of reactors through user inputs and reactor-specific radionuclide inventories. The release is calculated by the diffusion of the key safety important fission products through the kernel, silicon carbide (SiC), graphite for both intact and defective TRISO particles based on fuel and graphite temperatures in the reactor under normal operation. These releases from the fuel enter the coolant where they can plate-out on cooler surfaces. A clean-up model is included for designs with a coolant purification system to remove fission gases. This initial distribution of fission products in the reactor serves as an initial condition for potential releases under postulated accident conditions. The model then can calculate the fission product release for any transient temperature profile and fission product releases can then be used to assess radiological dose to the workers and the public using conventional dose tools. Data on the diffusion of fission products is based on historic German TRISO experiments and the more current Department of Energy (DOE) Advanced Gas Reactor (AGR) TRISO fuel development program. The model is coded in python with inputs and outputs in excel spreadsheets, as well as python plotting utilities to aid in the interpretation of the results. References: [1] INL, NGNP Mechanistic Source Term White Paper, INL-10-17997, July 2010. [2] David A. Petti, Richard R. Hobbins, Peter Lowry, Hans Gougar, “Representative Source Terms and The Influence of Reactor Attributes on Functional Containment in Modular High Temperature Gas-cooled Reactors,” Nuclear Technology, Vol. 184, p. 181-197, Nov. 2013.
07 ISOTOPE AND RADIATION SOURCES↗
Fission gas retention of densely packed uranium carbonitride tristructural-isotropic fuel particles in a 3D printed SiC matrix
The Transformational Challenge Reactor (TCR) fuel form was designed to contain large, densely packed uranium carbonitride (UCN) tristructural-isotropic (TRISO) fuel particles within a 3D printed SiC matrix, increasing the uranium density compared to conventional TRISO fuel forms and offering full geometric freedom for core design. Here, this work summarizes initial low-burnup, high-power irradiation testing of TCR fuel materials, including loose UCN TRISO particles and integral fuel compacts with ~55% TRISO particles by volume, to evaluate fission gas retention. Fission gasses were fully retained in all loose particle tests and in integral compacts irradiated at low (<250 °C) surface temperatures. Initial testing at higher (~700–750 °C) fuel surface temperatures showed fission gas release (FGR) and complete fracture of three compacts, but no FGR was observed in later high temperature tests (~300–750 °C) of both fueled compacts and loose TRISO particles. Calculated thermal stresses in the failed compacts were far less than the measured strength of the SiC matrix and the stresses in some failed compacts were less than those in compacts that did not show FGR. Thermal stress-induced matrix cracks also would not cause complete fracture because the tensile stresses transition to compression in the higher temperature regions. Therefore, fuel failure was likely not caused by thermal stresses and may have been related to leakage currents from the electrical heaters and erratic fuel surface temperatures that were only observed in the test for which failure was observed. In any case, the matrix cracks propagated through the coatings of TRISO particles located in the high-density matrix regions on the peripheries of the compacts, resulting in measurable fission gas release. The discussion focuses on the importance of understanding matrix density distributions and the particle-matrix interface properties to prevent matrix cracks from causing TRISO particle failures.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Irradiation performance of AGR-1 high temperature reactor fuel
The AGR-1 experiment contained 72 low-enriched uranium oxide/uranium carbide TRISO coated particle fuel compacts in six capsules irradiated to burnups of 11.2 to 19.6% FIMA, with zero TRISO coating failures detected during the irradiation. The irradiation performance of the fuel including the extent of fission product release and the evolution of kernel and coating microstructures was evaluated based on detailed examination of the irradiation capsules, the fuel compacts, and individual particles. Fractional release of 110m Ag from the fuel compacts was often significant, with capsule-average values ranging from 0.01 to 0.38. Analysis of silver release from individual compacts indicated that it was primarily dependent on fuel temperature history. Europium and strontium were released in small amounts through intact coatings, but were found to be significantly retained in the outer pyrocarbon and compact matrix. The capsule-average fractional release from the compacts was 1 × 10 –4 to 5 × 10 –4 for 154 Eu and 8 × 10 –7 to 3 × 10 –5 for 90 Sr. The average 134 Cs fractional release from compacts was <3 × 10 –6 when all particles maintained intact SiC. An estimated four particles out of 2.98 × 10 5 in the experiment experienced partial cesium release due to SiC failure during the irradiation, driving 134 Cs fractional release in two capsules to approximately 10 –5 . Identification and characterization of these particles has provided unprecedented insight into the nature and causes of SiC coating failure in high-quality TRISO fuel. In general, changes in coating morphology were found to be dominated by the behavior of the buffer and inner pyrolytic carbon (IPyC), and infrequently observed SiC layer damage was usually related to cracks in the IPyC. Palladium attack of the SiC layer was relatively minor, except for the particles that released cesium during irradiation, where SiC corrosion was found adjacent to IPyC cracks. In conclusion, palladium, silver, and uranium were found in the SiC layer of irradiated particles, and characterization of these elements within the SiC microstructure is the subject of ongoing focused study.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Safety Testing of AGR-2 UCO Compacts 5-2-2, 2-2-2, and 5-4-1
Post-irradiation examination (PIE) is being performed on tristructural-isotropic (TRISO) coated-particle fuel compacts from the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program second irradiation experiment (AGR-2). This effort builds upon the understanding acquired throughout the AGR-1 PIE campaign, and is establishing a database for the different AGR-2 fuel designs. The AGR-2 irradiation experiment included TRISO fuel particles coated at BWX Technologies (BWXT) with a 150-mm-diameter engineering-scale coater. Two coating batches were tested in the AGR-2 irradiation experiment. Batch 93085 had 508-μm-diameter uranium dioxide (UO 2 ) kernels. Batch 93073 had 427-μm-diameter UCO kernels, which is a kernel design where some of the uranium oxide is converted to uranium carbide during fabrication to provide a getter for oxygen liberated during fission and limit CO production. Fabrication and property data for the AGR-2 coating batches have been compiled and compared to those for AGR-1. The AGR-2 TRISO coatings were most like the AGR-1 Variant 3 TRISO deposited in the 50-mm-diameter ORNL lab-scale coater. In both cases argon-dilution of the hydrogen and methyltrichlorosilane coating gas mixture employed to deposit the SiC was used to produce a finer-grain, more equiaxed SiC microstructure. In addition to the fact that AGR-1 fuel had smaller, 350-μm-diameter UCO kernels, notable differences in the TRISO particle properties included the pyrocarbon anisotropy, which was slightly higher in the particles coated in the engineering-scale coater, and the exposed kernel defect fraction, which was higher for AGR-2 fuel due to the detected presence of particles with impact damage introduced during TRISO particle handling.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Confirmatory Defect Analyses of AGR-5/6/7 Fuel
The Advanced Gas Reactor (AGR) Fuel Development and Qualification Program has executed a series of experiments to test and qualify tristructural isotropic (TRISO) particle fuels for use in high-temperature gas-cooled reactors. The most recent irradiation experiments, AGR-5/6/7, are testing fuel that was fabricated in near production-scale equipment. There are three important defect fractions that must be characterized, using a deconsolidation-leach-burn-leach (DLBL) method, to better predict and understand fuel performance during irradiation. These are the dispersed uranium fraction (DUF), exposed kernel fraction (EKF), and silicon carbide defect fraction (SDF). The DLBL characterization data from analyses of the four compact batches, fabricated and characterized by the BWX Technologies Nuclear Operations Group (BWXT-NOG), showed unexpectedly higher values for all three defect fractions relative to the parent TRISO particle defect fractions. The DUF and SDF should not have changed significantly during compact fabrication and the apparent increase in the EKF, a metric for particle damage, was higher than anticipated for the compacts with 40% volumetric packing fraction (PF). Analytical results showed no net increase in the EKF for the 25% PF compacts. Compacts from one compact batch of each packing fraction were sent to Oak Ridge National Laboratory (ORNL), along with uncompacted tristructural isotropic (TRISO) particles, overcoated to a thickness targeting a 40% PF, for confirmatory analyses of the defect fractions and determination of the source(s) of damage. The ORNL results did not confirm the BWXT-NOG results for either the DUF or the SDF; the ORNL results showed no significant change in these defect fractions relative to the parent TRISO particle lot. The ORNL results did, however, confirm that a large increase in the exposed kernel fraction was found in the 40% PF compacts and that the 25% PF compacts sustained little if any damage. Data suggest that a large majority of the mechanical damage to the TRISO particles occurred in the overcoater when targeting the 40% PF. The analytical laboratories at both BWXT-NOG and ORNL had inconsistent outcomes on analyses of individual batches. Although the ORNL data is more consistent with the parent TRISO lot and expectations, the data set is too limited in size to justifiably reject suspect data from either laboratory at this time. It is recommended that an additional analysis be done to provide sufficient data for estimating the true defect fractions for interpreting the radionuclide release data during the AGR-5/6/7 irradiation experiments.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Assessment of Buffer-IPyC Thermomechanical Debonding Behavior Using New Experiment Strength Data in BISON
TRIstructural ISOtropic (TRISO) single sub-millimeter-diameter nuclear fuel particle consists of a spherical fuel kernel surrounded by four coating layers. During reactor operation, the TRISO coating layers are subjected to irradiation-induced dimensional changes and the associated thermomechanical behavior of each layer. One of the observed behaviors is gap formation between the buffer and IPyC layer due to the porous buffer’s irradiation-induced shrinkage exceeding that of the IPyC layer. To predict TRISO thermomechanical performance, multi-physics models have been built that are continually updated and refined. The BISON code is a finite element-based nuclear fuel performance code that may be used for TRISO particle simulations. One of the recent additions to the BISON code is the ability to model the process of layer debonding. This paper will focus on the simulation results of the improved BISON debonding model that will utilize updated strengths measured from irradiated TRISO fuel particles. The new experimental strength data from micromechanical tests of irradiated TRISO fuel samples were exercised in the BISON simulations and compared to baseline strength data to assess their applicability in the models. This also includes updated buffer-IPyC bond strengths to simulate layer delamination. Based on current experimental observations it is noted that the buffer-IPyC separation occurs not exactly at the junction of these two layers, but more on the side of the buffer layer. This improved modeling approach using experimental strength data to characterize buffer-IPyC debonding and its potential subsequent cracking will be presented in the paper along with comparisons to available experimental observations.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
FABRICATION OF URANIUM OXYCARBIDE KERNELS AND COMPACTS FOR HTR FUEL
As part of the program to demonstrate tristructural isotropic (TRISO)-coated fuel for the Next Generation Nuclear Plant (NGNP), Advanced Gas Reactor (AGR) fuel is being irradiation tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). This testing has led to improved kernel fabrication techniques, the formation of TRISO fuel particles, and upgrades to the overcoating, compaction, and heat treatment processes. Combined, these improvements provide a fuel manufacturing process that meets the stringent requirements associated with testing in the AGR experimentation program. Researchers at Idaho National Laboratory (INL) are working in conjunction with a team from Babcock and Wilcox (B&W) and Oak Ridge National Laboratory (ORNL) to (a) improve the quality of uranium oxycarbide (UCO) fuel kernels, (b) deposit TRISO layers to produce a fuel that meets or exceeds the standard developed by German researches in the 1980s, and (c) develop a process to overcoat TRISO particles with the same matrix material, but applies it with water using equipment previously and successfully employed in the pharmaceutical industry. A primary goal of this work is to simplify the process, making it more robust and repeatable while relying less on operator technique than prior overcoating efforts. A secondary goal is to improve first-pass yields to greater than 95% through the use of established technology and equipment. In the first test, called “AGR-1,” graphite compacts containing approximately 300,000 coated particles were irradiated from December 2006 to November 2009. The AGR-1 fuel was designed to closely replicate many of the properties of German TRISO-coated particles, thought to be important for good fuel performance. No release of gaseous fission product, indicative of particle coating failure, was detected in the nearly 3-year irradiation to a peak burn up of 19.6% at a time-average temperature of 1038–1121°C. Before fabricating AGR-2 fuel, each fabrication process was improved and changed. Changes to the kernel fabrication process included replacing the carbon black powder feed with a surface-modified carbon slurry and shortening the sintering schedule. AGR-2 TRISO particles were produced in a 6-inch diameter coater using a charge size about 21-times that of the 2-inch diameter coater used to coat AGR-1 particles. The compacting process was changed to increase matrix density and throughput by increasing the temperature and pressure of pressing and using a different type of press. AGR-2 fuel began irradiation in the ATR in late spring 2010.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗