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DOE OSTI2021

Characterization of Safeguards Implementation Schedules for Advanced Reactors

Advanced reactor designs differ from the traditional light-water reactor designs and operational requirements in nearly every facet, including the heat transfer fluids, operating temperatures and pressures, and fuel cycle requirements. To account for these differences, significant effort will be required to ensure appropriate safeguards implementation for US-based reactors intended for global deployment. This is the second in a series of three reports that examine facets of this issue. The first paper (ORNL/TM-2021/2142) examines potential construction schedules for advanced reactors to create a baseline understanding of the timeframes involved. This second report characterizes International Atomic Energy Agency (IAEA) safeguards implementation schedules for potential advanced reactors. Finally, the third report (ORNL/TM-2021/2208) examines existing gaps for safeguards implementation at advanced reactors.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Semi-Annual Report for Horizontal Compact High Temperature Gas Reactor (HC-HTGR) Development during Performance Period October 2022-March 2023

Horizontal Compact High Temperature Gas Reactor (HC-HTGR) is being designed by a multi-disciplinary team of nuclear, mechanical, and structural engineers under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed HC-HTGR in 3 years and support its commercialization as a safe, low-cost HTGR. Argonne National Laboratory (Argonne) is responsible for the design and analysis of the reactor cavity cooling system (RCCS) as a safety system for passive decay heat removal of the reactor concept. Additionally, Argonne is providing analysis of the primary heat transport system to ensure temperatures in the reactor systems, structures and components with significant safety margins during normal operation and design basis accident scenarios. This third semi-annual report summarized the progress made at Argonne on the two tasks during the first half of FY23. As a part of the RCCS design task, a design process for the water panel and the system configuration was performed to improve the thermal performance of the RCCS. The updated water panel design had achieved enhanced thermal performance with 0.96 MWth capability with major design updates made in structural interfaces with the RPV and initial configuration of the water tanks. The loop configuration of the RCCS has been proposed to have two independently working loops for system redundancy. A water panel material study was performed focusing on the use of carbon steel in water systems. Additional modeling strategies of primary system thermal fluids analyses were developed to meet modeling needs that are not well suited for the 1D-3D assembly level approach. The first of these is a reduced order assembly model, in which fuel centered unit cells are used to represent a fuel assembly. The 2D approach used in this model is much more computationally efficient, making this model useful for full core transient scenarios where fuel to coolant heat transfer is still the dominant flow path. The next model is the 3D core conduction model to be used to analyze decay heat removal in loss of primary system flow scenarios. Because these scenarios require a large domain to be modeled, a homogenized core model is being pursued to reduce the required computational costs. To accurately model decay heat scenarios it is necessary to couple a RCCS model to the 3D core conduction model. A simplified case is presented to demonstrate how the coupling methodology will be applied to the full core 3D conduction model.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Molten Salt Reactor Experiment Simulation using Shift/Griffin

The Department of Energy (DOE)’s NEAMS focuses its efforts on the development of advanced modeling and simulation (M&S) tools for light-water reactors (LWRs) and non–LWRs (i.e., molten salt reactors, high-temperature gas reactors, microreactors, and fast reactors). In the previous fiscal year, the Multiphysics Applications Driver Technical Area funded molten salt reactor (MSR) M&S at Oak Ridge National Laboratory (ORNL) to generate multigroup macroscopic cross sections with Shift for a MSRE 2D lattice model in Griffin. In addition, Shift’s capability to calculate gamma dose rates from activated components in the primary exchangers in a molten salt breeder reactor was also demonstrated. In fiscal year 2023, ORNL generated multigroup macroscopic cross sections using Shift for a 3D MSRE core model. MSRE depletion calculations using Griffin were also demonstrated in this fiscal year. For the depletion calculation, one-group microscopic cross sections for the 3D MSRE core were generated using Shift, and the decay transmutation library from ORIGEN was converted to an ISOXML file, which is required as input in Griffin. Several Monte Carlo codes, such as OpenMC and Serpent, were also used to benchmark and supplement multigroup cross sections generated by Shift. Multigroup libraries were generated with 8 and 20 group structures, and the study found the 8-group structure to be more accurate when comparing Griffin results to continuous energy (CE) Monte Carlo results. The average flux from CE Shift calculations is up to ~6% higher than the CE Serpent calculations because of different values applied for the energy released per fission (κ values). The average flux in the fuel salt calculated by Griffin using cross sections generated with Shift agrees well with the reference CE Shift solution; the same is valid for the corresponding Serpent results. The maximum relative error is ~6% and ~2% compared to the CE Shift and Serpent reference solutions, respectively. Meanwhile, the average flux calculated by Griffin in the graphite moderator shows a higher difference in the thermal range when compared to both reference Monte Carlo solutions; this result suggests a need for improvement in cross section generation for the graphite moderator in the thermal range in both Monte Carlo codes. Griffin depletion calculations using cross sections from Shift and Serpent were performed and compared against ORIGEN calculations, and the nuclide densities calculated by Griffin were found to be generally in agreement with those of ORIGEN. Because a different approach was taken to calculate the energy released per fission ( κ values) in Shift and Serpent, a difference in nuclide densities from differences in the average flux was observed between Griffin using Serpent and Shift cross sections. Griffin calculations with Shift cross sections produced higher average flux in the salt than with Serpent cross sections, leading to higher consumption of 235 U and higher production of 135 Xe. For time-dependent depletion calculations, cross sections were generated with Serpent, and Griffin’s results using these cross sections were compared to CE Serpent depletion results, demonstrating good agreement. The average difference in keff between Serpent and Griffin as a function of burnup is about 155 pcm. Similarly, good agreement with small differences up to ~0.5% was also noticed in the nuclide density of 235 U and 135 Xe. More details regarding the methodologies invoked to generate the cross section to make code-to-code comparisons are discussed further in this report. User feedback on Griffin and Shift capabilities that will enhance these calculations is provided in this report for future consideration. The work performed this fiscal year can be extended further for multiphysics coupling of Griffin-Pronghorn/SAM with Mole to study precursor flow and salt chemistry.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Effect of Lateral Conduction in a Rectangular Fuel Plate and Optimum Stripe Widths for the OPAL Reactor

The impetus for this work is the Proliferation Resistance Optimization (PRO-X) program, which was created by the National Nuclear Security Administration (NNSA) of the US Department of Energy (DOE) to provide a framework for developing reactor designs that minimize the production of special nuclear materials while maximizing performance for peaceful uses. The Argentine company INVAP and Argonne National Laboratory collaborated to share knowledge and expertise regarding the thermal analysis of research reactors. Working together, they designed a series of test problems based on the Open Pool Australian Light Water (OPAL) reactor, whose fuel is in the form of flat plates cooled by water flowing through narrow rectangular channels. ANL used their PLTEMP/ANL code. INVAP used their TERMIC code (and its new multi-plate version, TERMIC-MP). Then, INVAP and ANL compared the two sets of results. 1-D models were used during the collaboration since for research reactor analysis, largely 1-D thermal-hydraulics models are commonly used because they are simple to apply and technically defendable. The collaboration between the two organizations aims for improvements in thermal-hydraulic models. Improvements to methods and models can reduce modeling uncertainties and excessive conservatism, allowing greater reactor performance without reducing predicted safety margins. Therefore, these improvements potentially expand the design space, making additional designs feasible, which, in turn, may achieve better fuel utilization and proliferation resistance in the designs. This report provides justification for the lateral node size (stripe width) chosen for the 1-D computer models during the collaboration. The lateral heat conduction in OPAL fuel plates is evaluated using the two-dimensional conduction capability of PLTEMP/ANL to determine a representative hot-stripe width that can be conservatively used for one-dimensional steady-state thermal-hydraulic analysis. Basically, a representative hot-stripe width needs to be selected so that the actual heat flux averaged over this stripe width is greater than or equal to the maximum heat flux obtained by the two-dimensional analysis. Detailed results in this report show that a hot-stripe width of 8.125 mm can be conservatively used for the one-dimensional thermal-hydraulics analysis of all plates. Therefore, eight equal stripes (8.125 mm each) are recommended to be modeled in the MCNP and PLTEMP/ANL full core models of the OPAL reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Creation Synthetic Data to Train a Digital Twin to Predict Reactor Operations

Understanding techniques to strengthen the nuclear safeguards regime is crucial in preventing nuclear proliferation due to recent advancements in the nuclear energy industry such as Generation IV reactors and microreactors. Prior to the construction of a nuclear power plant, it is necessary to understand the proliferation potential of the plant's reactor. Digital twins serve as a unique solution to recognizing reactor behavior indicative of nuclear proliferation. A digital twin is defined as a virtual model that works in unison to represent a physical asset, with a transference of data between the virtual and physical assets [1]. This work serves as validation for training a digital twin on synthetic data fabricated via means of Serpent reactor physics and point kinetics equations simulations. In this case this work is based on parameters of Idaho State University's AGN-201 reactor. The synthetic data can then be utilized to train machine learning models in the future to further investigate the utility of these methods. The accuracy of the predicted data is measured against real operational data to verify the reliability of the synthetic data creation methods and decide whether these methods should be used in the future to inform inspectors of a reactor's proliferation potential.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2024

Technical and Economic Assessment and Gap Analysis of Advanced Nuclear Reactor Integration with a Reference Oil Refinery

Efforts to identify the most-economic methods to decarbonize several sectors of the U.S. economy are underway. Industrial processes such as crude-oil refining rely heavily on energy-dense and easily stored and transported fossil fuels for powering their operations. Refineries use large amounts of energy, primarily derived from fossil sources to separate crude-oil components, break down heavier hydrocarbons into lighter compounds, remove impurities, reform hydrocarbon molecules, and generate steam and electricity for pumps and compressors and other various auxiliary systems. Crude-oil refining operations such as distillation, cracking, desulfurization, reforming, utilities systems and some offsite facilities collectively account for most of the energy consumption. Other operations such as hydrocracking or hydrotreating also require hydrogen for developing hydrogenation reactions which involve substantial heating to keep the reactors at high-temperature and pressure levels. All heat and energy demands are typically provided by natural gas (NG), oil, or other fuels, which makes refinery industry one of the most-difficult sectors to decarbonize. Nuclear power is a viable and energy-dense source of clean electricity, heat, and hydrogen to provide the large, sustainable energy supply that the refining industry demands. The U.S. Department of Energy’s (DOE’s) Integrated Energy Systems (IES) program is working to perform research and development, design, economic siting, and risk analysis. This state-of-the-art work will enable the first on-site demonstrations and commercial deployments of advanced small modular nuclear reactors (SMNRs) integrated with industries such as chemical production, refining, iron and steel making, and more. IES seeks to demonstrate the ability of advanced nuclear reactors to meet the heat and power demands of these industries while reducing carbon emissions in a sustainable and cost-competitive way. The primary objective of this research effort is to analyze industrial-scale SMNR integration intended to decarbonize refining facilities. The foreseen outcome is the provision of reliable, cost-competitive, and sustainable clean energy, alongside a reduction of carbon emissions. Specifically, the focus of this work lies on meeting the reference facilities’ heat and electricity demands with nuclear power while also supplying clean hydrogen via integrated high-temperature steam electrolysis (HTSE). This report presents a comprehensive technical and economic assessment of the integration of advanced nuclear reactors into a reference refinery, leveraging financial incentives from the Inflation Reduction Act (IRA). The evaluation aims to explore the potential economic benefits and challenges associated with incorporating advanced nuclear reactors into refinery operations, particularly in terms of energy efficiency, economic implications and environmental impact. By examining both the technical feasibility and economic viability, this analysis seeks to identify existing gaps and propose solutions for successful nuclear integration implementation. The findings are intended to provide valuable insights for stakeholders considering the adoption of advanced nuclear reactors in the refining sector. A refinery reference-plant was developed, using an open-source refinery model, Petroleum Refinery Lifecycle Inventory Model (PRELIM) and expert assessment, as a base case for comparison with various nuclear integration options. The capacity of 100 kbd/day (KBD) of heavy crude-oil feed was selected to represent a general coking-type refinery with deep conversion capabilities (incorporating heavy-oil upgrading with FCC, coking, and associated hydrotreating process units), using a heavy crude-oil feed, which represents about 70% of U.S. refineries configurations. A summary of all cases considered in this study is shown in Table 1.

13 HYDRO ENERGY↗
DOE OSTI2023

United States–Brazil Joint Study: A Preliminary Assessment of Opportunities and Challenges for Small Modular Reactors in Brazil

This report supplies the technical information to enable a broader understanding of different technology choices for nuclear reactors in Brazil. The assessment characteristics of this process include reactor technology, economic costs for deployment, and regulatory analyses of small modular reactors, advanced reactors, and microreactors. The analysis documented in this report provides economic and technological information to assist Brazil, whose official indicative scenarios show an increase in operating nuclear power from 2 Gigawatt in 2022 to 8–10 Gigawatt by 2050, in policy making and long-term energy planning. To protect company proprietary information, the information in this report was limited to publicly available information and therefore can only inform preliminary reactor technology assessments. This report does not recommend or endorse any specific reactor developer or technology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

A Data-driven approach to Core Power distribution reconstruction in a Nuclear Reactor

This report presents the initial development of a data-driven approach for reconstructing the core power distribution in a nuclear reactor (power shape synthesis) using ex-core sensors. Traditional techniques rely on deploying a large number of detectors throughout the reactor core. However, this approach is not feasible for innovative reactor concepts like Advanced Reactors and Microreactors. First, the tight lattice pitch, designed to maximize power density, limits the space available for sensors. Secondly, the harsh operating conditions are not compatible with commercially available detectors. The method proposed in this work integrates high-fidelity modeling with data-driven techniques to accurately reconstruct power distribution across various reactor types, thereby reducing the reliance on in-core sensors. Purdue University Reactor One (PUR-1) was selected as the test case. The CAD model representing the latest configuration of the PUR-1 core was imported into the OpenMC simulation framework, and the model was built. Additionally, the previously developed MCNP6 model was updated. The two models were assessed against the data collected during an experimental campaign conducted in July 2024. Thirty gold foils were placed in three Irradiation Assemblies in PUR-1 core. Using the measured activity of the irradiated foils, the neutron flux at different core locations was estimated.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Advancements in NEAMS Tool Capabilities for Multiphysics Simulation of Fast Reactor Core Bowing and Identification of Validation Test Data

Under the U.S. Department of Energy Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) Program, an integrated multiphysics approach is being developed to model the core bowing phenomena important to liquid metal-cooled fast reactors. Core bowing is an important passive safety mechanism in liquid metal-cooled fast reactors and involves Multiphysics effects including radiation transport, fluid flow, heat transfer, and mechanical response to temperature and flux gradients. This report summarizes recent progress on developing a multiphysics, MOOSE-based workflow to predict core bowing and associated reactivity feedback. Last year, thermal fluids and mechanics were coupled on a multi-assembly benchmark problem based on ABR-1000 design. This year, the reactor physics code Griffin was assessed for readiness of core bowing calculations. Preliminary integration of Griffin’s ring-heterogeneous model with thermal fluids and thermal mechanics solvers was performed. Specifically, thermal-mechanics and reactor physics were coupled for single- and multi-assembly problems, and reactor physics and subchannel methods were coupled for a single assembly model. Finally, the workflow of all three physics was preliminarily demonstrated on a single assembly model. Caveats and future development needed have been identified. To supplement the multiphysics demonstration, verification and assessment efforts of thermos-mechanical capabilities for modeling thermo-mechanical core bowing behavior were continued by analyzing IAEA Verification Problem 5 which includes radiation swelling and creep. Additionally, a small core reactor physics benchmark defined by Japan Atomic Energy Agency (JAEA) was performed to assess neutronics models for estimating reactivity feedback. Finally, Fast Flux Test Facility (FFTF) validation test data for core bowing phenomena has been identified and summarized, with a recommended path forward for validation once this capability is mature.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Accident Progression and Source Term Demonstration Calculations for the Advanced Burner Test Reactor (ABTR)

As advanced reactor designers approach broad deployment of new reactor technologies and the associated applications, a critical milestone on this path includes licensing or authorization of these designs in the current regulatory environment. Commercial licensing and DOE authorization both consist of numerous aspects to not only certify the designed plant will operate as intended, but also related to confirmation of the safe operation of these facilities that comply with specific standards and requirements. To that end, domestic industry and regulators require toolsets and methods which can be used to confirm that advanced reactor designs not only align with expected performance during normal operation, but also a series of transient scenarios. These codes require a satisfactory validation basis, and in the absence of such a basis, code-to-code comparisons are often utilized as a surrogate to confirm model adequacy. To support this need for fast reactor technologies, a series of analyses using SAS4A/SASSYS- 1 and the Simplified Radionuclide Transport (SRT) code have been conducted for the Advanced Burner Test Reactor (ABTR). These analyses are expected to not only provide a baseline for transient and source term analyses of ABTR, but to also provide context for the key physics that determine evolution of specific transient scenarios in a sodium-cooled fast reactor (SFR). These codes are utilized for this work given their adoption in the SFR industry and by key SFR stakeholders.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Conjugate Heat Transfer Modeling of Salt-Filled Fuel Pins for Stable Salt Reactor Safety Analysis

The Stable Salt Reactor (SSR) combines the proven structural design of light water reactor fuel assemblies with the inherent safety and fuel-cycle advantages of molten salt technology. In its fast reactor configuration, the SSR utilizes recycled nuclear waste as fuel, sealed within narrow salt-filled fuel pins and cooled by a surrounding liquid salt coolant. Reliable transfer of heat from the molten fuel salt through the cladding to the external coolant is essential for both reactor safety and performance. This work investigates conjugate heat transfer (CHT) in the SSR’s salt-filled fuel pins using NekRS, a high-fidelity spectral element computational fluid dynamics (CFD) solver. The analyses capture internal natural convection within the molten fuel salt and external forced convection in the coolant, under steady-state and transient operating conditions. Parametric studies evaluate how variations in reactor power and coolant flow rate influence heat transfer distributions and system response. The high-fidelity CFD results are time-averaged and post-processed for direct comparison with moderate-fidelity Reynolds-averaged Navier–Stokes (RANS) models, and for the development of reduced-order models within the SAM system code. These validated models support fast-running safety analyses of normal and off-normal transients, improving predictive capability for key safety margins. By integrating advanced CFD with system-level safety tools, this study strengthens the modeling framework for SSR design, reduces uncertainty in molten salt CHT simulations, and accelerates the engineering and licensing of next-generation nuclear reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Energy Requirements for Integration of Nuclear Reactors with Iron and Steel Plants

This report identifies energy needs of heavy energy users within the domestic iron and steel industry and suggests solutions for integrating nuclear energy. The iron and steel industry, composed of several types of plants which perform different processes with varied energy demands and vectors, is a heavy consumer of electric power and fossil fuels including coke and natural gas. Almost all major process temperatures exceed the temperatures of direct heat available from advanced reactors, and so electricity and hydrogen were considered instead. Reference units were adopted and estimated energy demands computed for the blast furnace (BF), direct reduced iron (DRI) unit, electric arc furnace (EAF), and reheat furnaces. By utilizing production capacity data from industry reports, the ranges of power demands were estimated, including for hydrogen production by high temperature steam electrolysis (HTSE). For the EAF and DRI unit, more detailed integration studies with thermodynamic modeling were also conducted and determined a possible solution with a specific reactor design and number of modules. Furthermore, because many unit processes are co-located, entire plants were considered by adding the energy demands of the unit processes to form four hypothetical reference plants. The range of power needs for the reference plants is compatible with multi-unit banks of microreactors at the low end, and would create a need for multiple larger-capacity SMRs at the high end (1 GWe plus 0.14 GWt). Although the overall power need at the high end is well-matched with one present-day large reactor offering (1.1 GWe), redundancy considerations may require a minimum of two reactors, potentially eliminating the single large reactor from consideration. Auxiliary or house loads would increase the reference plant estimates. Finally, the report provides total estimated energy needs under integration of all U.S. units of each process (BF, DRI, EAF, and reheat furnaces), representing a national potential for nuclear energy in the industry. U.S. iron and steel plants may be candidates for integration with nuclear reactors via electricity and hydrogen, and many sites have energy requirements that correspond well to the capacities of several advanced nuclear power designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Application of Electrochemical Methods to Molten Salt Reactors: Draft TLR Documenting Assessment of Electrochemical Monitoring

Nuclear Regulatory Commission (NRC) is developing the regulatory framework and technical expertise to support regulatory review of advanced non-water reactors, including molten salt reactors (MSRs). In an MSR, it is essential that the salt chemistry be maintained in a desired range in terms of redox potential for reliable operation and mitigation of corrosion to structural materials in the reactor, particularly the reactor vessel and heater exchanger. Measuring the redox potential of the salt in the reactor would also allow for the material lifetimes to be predicted more accurately, and chemical issues to be diagnosed more quickly. In addition to the chemical composition analysis by ICP-MS, electrochemical methods including potentiometry and linear wave scanning (LSC) were also used in molten salt reactor experiment (MSRE) for redox potential monitoring purposes. Electrochemcial methods offers unique advantages such as quick turnaround in results and unique capability of in-line monitoring of redox potential, and are considered popular electroanalytical techniques that can be used to monitor redox potentials and salt chemistry including impurities. The last two decades have seen significant advances in science and engineering of electrochemical methods for potential application to molten salts. The primary goal of this report is to assist NRC in understanding the monitoring of the salt chemistry by electrochemical methods and provide NRC reviewers with necessary information and tools to support regulatory review of MSR designs. This reports consists of two majors parts—Part 1, chemical potential of molten salts and effects by fission process in MSR; Part 2, assessment of electrochemical methods for application to MSRs. The TRLs of the typical relevant electrochemical methods for molten salts were evaluated based on the DOE TRL guidelines and upon a review of the current status of the electrochemical methods for two typical salt systems, fluoride and chloride, for MSRs.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Intrinsic value of the international benchmark projects, ICSBEP and IRPhEP, for advanced reactor development

The International Criticality Safety Benchmark Evaluation Project, a sanctioned program under the auspices of the Nuclear Energy Agency of the Organisation for Economic Co-operation and Development, has been a highly successful and productive collaboration, now encompassing over 5,000 evaluated experimental benchmarks trusted and relied upon throughout the international nuclear communities. The success of this project led to the development of the International Reactor Physics Experiment Evaluation Project, which is dedicated to the evaluation of benchmark experiment data to sustain current and future reactor physics validation needs. These exemplary programs, and their widely utilized handbooks, serve as gold standards to which other databases strive to emulate. The purpose of the two projects is to preserve modern and legacy experimental data and evaluate it in a standardized handbook format to provide quality benchmarks to support modern and future criticality safety and reactor physics validation. These two projects have often served as the mechanism through which historic and modern neutronics experiments are evaluated and shared across international borders, to best provide unique, high-quality peer-reviewed, and often otherwise unavailable, benchmark data. The contents of these handbooks are utilized not only in validating criticality safety, reactor physics, and advanced reactor calculations, but are used to validate neutronics calculations and nuclear data for most other nuclear applications. This paper discusses both international programs and available content to enable advanced reactor design validation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Design of Novel Flash Ironmaking Reactors for Greatly Reduced Energy Consumption and CO2 Emissions

The development of a novel ironmaking technology based on fine iron ore concentrate in a flash reactor is summarized. The design of potential industrial reactors for flash ironmaking based on the computational fluid dynamics technique is described. Overall, this simulation work has shown that the size of the reactor used in the novel flash ironmaking technology (FIT) can be quite reasonable vis-à-vis the blast furnaces. A flash reactor of 12 m diameter and 35 m height with a single burner operating at atmospheric pressure would produce 1.0 million tons of iron per year. The height can be further reduced by either using multiple burners, preheating the feed gas, or both. The computational fluid dynamics (CFD)-based design of potential industrial reactors for flash ironmaking pointed to a number of features that should be incorporated. The flow field should be designed in such a way that a larger portion of the reactor is used for the reduction reaction but at the same time excessive collision of particles with the wall must be avoided. Further, a large diameter-to-height ratio that still allows a high reduction degree should be used from the viewpoint of decreased heat loss. This may require the incorporation of multiple burners and solid feeding ports.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Modeling the First Hydrogen Direct Reduction Pilot Reactor for Ironmaking in the USA Using Finite Element Analysis and Its Validation Using Pilot Plant Trial Data

Direct reduction of hematite pellets with hydrogen (H 2 ) was used to produce directly reduced iron (DRI) in a pilot scale reactor at a pellet feed rate of 21.4 kg/h. At a steady state, operational parameters of the pilot plant (gas recycling rate and inlet temperature) along with key reactor output parameters, the pellet metallization, and the internal temperature profile of the reactor were reported for two scenarios with high recycle and low recycle rate of H 2 . Scenario 1, with a high recycle rate of 400 L/min H 2 along with external heating of 870 °C, gave an average metallization of 91.8%, while Scenario 2, with low recycle rate of 100 L/min H 2 and external heating of 850 °C gave a metallization of 67.8% due to the higher moles of H 2 available for reduction and the external energy required for the endothermic reduction reaction in Scenario 1 as compared with Scenario 2. Finite element analysis was used to build a model of the shaft reactor, which was validated against the metallization and internal temperature profile data. The average metallization values predicted by the model were very close to the metallization values obtained from the pilot plant samples, with 90.9% average metallization for Scenario 1 and 65.6% average metallization for Scenario 2. The internal temperature profiles in the lower region of the reactor obtained from the model were very close to these pilot plant data, with a maximum difference of 52.7 °C and 67.6 °C for Scenarios 1 and 2, respectively. The pilot plant reactor model was used extensively in the commissioning of the pilot plant and to predict the startup outcomes for a given set of operating parameters.

08 HYDROGEN↗
DOE OSTI2020

Non-invasive in-situ imaging of interior of nuclear reactors

Techniques, systems, and devices are disclosed for non-invasive monitoring and imaging of nuclear fuel inside a nuclear reactor using muon detector arrays. In one aspect, these detector arrays are placed outside the reactor vessel or building for investigating the reactors without access to the cores, therefore the imaging process is non-invasive. In some implementation, these detector arrays measure both muon scattering and absorption to enable imaging and characterizing not only the very high-Z fuel materials, but also other materials in the reactor, thereby obtaining a more complete picture of reactor status. When applied to damaged reactors, the disclosed proposed techniques, systems, and devices, through the process of providing an image, can reveal the presence (or absence) of damage to fuel rod assemblies or puddles of molten fuel at the bottom of the containment vessel, thus providing crucial information to guide decisions about remedial actions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Coupling of Pronghorn and RELAP-7 for a Pebble Bed Reactor

High temperature gas cooled reactors (HTGR) are a candidate for timely Gen-IV reactor technology deployment because of high technology readiness and walk-away safety. Among HTGRs, pebble bed reactors (PBRs) have attractive features such as low excess reactivity and online refueling. Pebble bed reactors pose unique challenges to analysts and reactor designers such as continuous burnup distribution depending on pebble motion and recirculation, radiative heat transfer across a variety of gas-filled gaps, and long design basis transients such as pressurized and depressurized loss of forced circulation. Modeling and simulation is essential for both the PBR’s safety case and design process. In order to verify and validate the new generation codes the Nuclear Energy Agency (NEA) Data bank provide a set of benchmarks data together with solutions calculated by the participants using the state of the art codes of that time. An important milestone to test the new PBR simulation codes is the OECD NEA PBMR-400 benchmark which includes thermal hydraulic and neutron kinetic standalone exercises as well as coupled exercises and transients scenarios. In this work, the reactor multiphysics code MAMMOTH and the thermal hydraulics code Pronghorn, both developed by the Idaho National Laboratory (INL) within the multiphysics object-oriented simulation environment (MOOSE), have been used to solve Phase 1 exercises 1 and 2 of the PBMR-400 benchmark. The steady state results are in agreement with the other participants’ solutions demonstrating the adequacy of MAMMOTH and Pronghorn for simulating PBRs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗