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DOE OSTI2024

Can an Efficient Nuclear Energy Industry Still be Resilient? On the Nature of Efficiency and Resiliency in Complex Systems

At the time of writing, the nuclear industry is on the precipice of a long-hoped for, but as-yet-unrealized, “nuclear renaissance.” Nuclear power plants in the United States and around the globe are aging, emphasizing the criticality of this moment. The importance of carbon free power sources combined with advancements in nuclear technology and innovation have brought a new potential landscape. As existing reactors and utilities cope with increased economic pressure by seeking out efficiencies the push towards novel nuclear platforms like microreactors and fission batteries will only increase this quest for efficiency gains, potentially at the detriment of safety. This paper argues that the concepts of efficiency and resiliency are fundamentally linked and that the change in one necessarily affects the other. As nuclear power is known for being incredibly resilient, this dichotomy needs attention from the current wave of research towards nuclear power efficiencies. This paper argues for resiliency at any cost. We argue that this resilience-first approach is the right path for nuclear power to take in this net-zero future. The paper is laid out as follows. Section 1 introduces the economic context and resilient nature of nuclear power. Section 2 discusses efficiency, resiliency, and the struggle between the two in nuclear power. Section 3 exemplifies our argument through case studies in the aviation and manufacturing industries and extends the argument to the nuclear industry. Section 4 concludes with a discussion of the implications of this idea.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Global Trends of ASME "N-Stamp" Certifications for Nuclear Component Vendors

Historically, nuclear component manufacturing vendors, from small businesses through large conglomerates, have felt compelled to obtain an American Society for Mechanical Engineers (ASME) Nuclear Certification, known colloquially as an "N-stamp", to assure supply chain quality standards that will be acceptable to regulators and safety concerns. Since the N-stamp quality standard is a U.S.-origin code, combined with the apparent decline in the U.S. nuclear industry alongside the growth of the Asian nuclear industry, there is the question of whether the rest of the world, including new entrants to the nuclear industry, also regard N-stamp as a needed certification. This study addresses this question through analysis of the entire N-stamp database of holders, and former holders, of N-stamp certificates of all types and for all regions worldwide from 1989-2020 (the dates available in the database). From this 30 years of data, we find that actually U.S.-based vendors still consistently obtain the largest number of N-stamps worldwide over all time periods, but also find that the countries participating in the N-stamp certification process has broadly expanded beyond just North America, Japan, S. Korea and Western Europe (the primary N-stamp recipients before the mid-2000's). We produced global heats maps and bar charts to illustrate our findings, as well as further investigation into why the data shows changes over time and region. We note that nuclear entities involved with Soviet-type reactors do not participate in the N-stamp process, but instead pursue the Russian version PNAE, which is substantially similar to the ASME code. We conclude that at least from the N-stamp database, the United States nuclear component manufacturing industry is alive and well, although there have been some consolidations, and that the ASME N-stamp appears to still be a valued certificate worldwide, including in China which now ranks second only to the United States in obtaining N-stamp certificates in recent years. We further note that the vendors of new reactor types, in particular High Temperature Gas-Cooled Reactors (HTGRs) and Small Modular Reactors (SMRs), are actively engaged with ASME (and other U.S.-based nuclear standards bodies such as the American Nuclear Society and Nuclear Energy Institute) to coordinate updates to the ASME N-Stamp criteria to ensure applicability of the code for these new designs. Implications of these findings include the following: The global use of the U.S.-origin N-stamp certification supports the view that, despite the decline of the U.S. nuclear industry, the United States remains an esteemed global leader in the area of nuclear safety. As the U.S. Government works to revitalize the U.S. nuclear industry, especially in the area of exports, it may be beneficial to leverage the global standing of the N-stamp certification. The findings indicate that the N-stamp database would be a useful tool for the U.S. Government to use to track the growth of the civil nuclear industry in foreign countries, under certain circumstances. The Excel-format N-stamp database produced as part of this study may be a useful tool for this purpose. N-stamp data may be a useful tool for foreign governments to use to identify nuclear manufacturers within their own country, especially to identify "targets" for outreach on nuclear export control compliance. The U.S. Government could carry this message to foreign partners during bilateral engagements or as part of Nuclear Suppliers Group (NSG) discussions on industry outreach.

42 ENGINEERING↗
DOE OSTI2024

NEAMS Burnup Extension Accomplishments and Remaining Modeling Gaps

The economic viability of light-water reactors (LWRs) in the United States is declining in heavily subsidized markets, and as a result, the nuclear industry is looking for opportunities to enhance the economic competitiveness of nuclear power. This is not a foreign concept to the nuclear industry: in the mid-2000s, the nuclear industry set out to achieve zero fuel failures by 2010. The goal in this effort was to drive down the cost of reactor shut down by replacing a pin or bundle in response to fuel rod failure. 2010 brought about the initiative to deliver the nuclear promise to reduce operating cost by 30% to improve nuclear energy’s economic competitiveness before 2020. The emergence of accident-tolerant fuel also offers the nuclear industry an opportunity to build on these past successes and deliver affordable, clean energy. Accident-tolerant fuel has been shown to provide superior performance compared to traditional Zircaloy/UO2 fuel concepts, offering the unique ability to remove operational limitations that inhibit the economic viability of nuclear power. This has led the industry to begin building a technical case to extend the peak rod average burnup beyond 62 GWd/tU to extend pressurized water reactor cycle lengths to 24 months and to develop more efficient boiling water reactor core designs. The Nuclear Energy Advanced Modeling and Simulation (NEAMS) program mission is to develop advanced modeling and simulation tools and capabilities to accelerate the deployment of advanced nuclear energy technologies. The primary safety concern inhibiting the nuclear industry from extending burnup is related to high-burnup fuel fragmentation, relocation, and dispersal. Therefore, the NEAMS program developed a targeted 5-year plan to support the industry’s efforts to extend burnup. This milestone report summarizes the 5-year plan that was enacted in FY20, followed by a discussion of the ongoing activates required to fulfill the 5-year plan, as well as the approach to address the current modeling gaps. Additionally, an LWR stakeholder meeting was held to communicate work performed in the NEAMS program over the past three years, to assess the LWR community’s perspective on the impact of the program, and to identify remaining significant gaps in the NEAMS suite of capabilities. This engagement will be documented by the Electric Power Research Institute and used by NEAMS to redirect current LWR scope as needed and to develop the next phase for LWR research and development.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Investing in STEM Benefits Community, Company, and Industry - 20243

Like many organizations and groups, the Department of Energy Environmental Management program and the nuclear industry are facing an aging employee population and record numbers of employee retirements. This 'silver tsunami' of retirees means the industry as a whole is recruiting graduates at a fast pace. So, how do we ensure the nuclear industry has a robust pipeline of graduates with the necessary background? Fluor Idaho's investment in science, technology, engineering, and mathematics (STEM) education programs helps promote the next generation of technical professionals, benefiting both the company and the industry. Through community outreach initiatives and student mentoring programs, Fluor Idaho promotes kids' interest in STEM. The programs are designed to spark STEM interest in grade school and then foster and grow that interest through high school and higher education. After igniting student excitement about STEM topics in school, Fluor Idaho focuses on providing work-specific opportunities including mentoring and intern programs. These programs give students a better look at real-world job opportunities while still stimulating their interest in STEM. These programs ultimately provide career opportunities for the students and a pipeline of workers. Fluor Idaho's strategy for its summer interns has been to place students in a wide variety of projects - from the commissioning of a first-of-a-kind nuclear processing facility, to operating nuclear waste management facilities, to developing computer programs and applications - and give them responsibilities that make them feel like valued contributors. This approach has created a positive and rewarding summer-intern program experience for the students. Fluor Idaho's investment in its future today is reducing the knowledge gap - or cliff - that many contractors in the nuclear industry are facing. It's a worthwhile investment that is readily visible within its many cleanup projects. The next generation of technical professionals is making an impact now - benefiting both the company and the nuclear industry. This paper will review Fluor Idaho's programs, including STEM community outreach and education and mentoring programs. It will also present statistics about the reach of those programs and their successes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Outlook on Industrial Requirements for Incorporating Nuclear Energy into Industrial Processes

There is an increasing interest globally and in the U.S. in decarbonizing heavy industrial processes which have large demands for heat and power. Currently these industries primarily use fossil fuels to meet these demands and they include: oil & gas, petroleum refining, chemicals and derivative products manufacturing, iron & steel production, polymers, ammonia and fertilizers, etc. The U.S. DOE Integrated Energy Systems (IES) program seeks to identify and analyze opportunities for integrating and substituting nuclear energy to fulfil these large heat and power demands in a cost competitive and sustainable manner while reducing carbon emissions of the processes by using clean nuclear power. Presently various representatives from a subset of these industrial companies have expressed interest in evaluating the options of integrating future advanced nuclear small modular reactors with their industries. This study is a scoping study to provide an outlook of industrial energy demands and the potential nuclear energy substitution potential. Future work will analyze in a more detailed manner the potential designs for coupling advanced nuclear reactors with various industries. The industrial processes of oil refining, methanol production, pulp and paper, ammonia and chlorine-alkali are described focusing on how heat and power is used within the facilities in the context of identifying nuclear substitution opportunities. The aim is to provide reliable, competitive, and sustainable energy that is clean while reducing carbon emissions and other environmental impacts such as water withdrawals, consumption, and contamination.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

The Cost of (In-) Accurate Waste Characterization in the U.S. Nuclear Power Industry - 20066

Proper disposal of waste has never been a human priority. Our history is full of examples of throwing away things with minimal effort or thought to consequence. That is until disease or toxicity become apparent and we realize we need to change. Unfortunately, we almost never have all the information we need at the time we make decisions. In addition to the technical and scientific issues, profits and politics are also factors. Newton's third law also applies to politics and so for every policy (action) put in place, there will be (opposite reaction) forces in play to push back against it. These forces are seldom balanced and so the reaction to the discovery of harm is to over-correct and destroy the benefit to be had. This of course causes those who want the benefit, or profit from it, to work to undermine or repeal those measures put in place to eliminate the harm. The issue is exacerbated when the problem to be solved is highly technical and at the edge of our science so that the harm and benefit cannot be easily or accurately quantified. At these times, reason often goes out the window and our decision makers are influenced by either greed or fear as these emotions are much easier to stoke. Those of us in the middle, with the charge to 'do the right thing for the least cost', are therefore frequently constrained and forced into actions that are neither technically the right thing to do and not cost effective. The cost of radioactive waste disposal is based on the concentrations of various radioisotopes in the waste. Some of these isotopes are relatively easy to quantify and some are not. Most laboratory methods for quantification are limited in the amount of activity that can be present during the measurement process. Current nuclear plants were not designed with the idea that taking truly representative waste samples would be important. The limits used to define waste class and therefore cost are precisely defined but the methods for determining those concentrations are far less precise. Improving the accuracy of radioactivity concentrations in waste and having consistent and reasonable oversight can reduce waste costs through active management of the process. So what can we do about it? Science may provide an answer. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Computer-Based Procedures Among Older Adults: Findings from the Rancor Microworld Simulator

As with many industries worldwide, nuclear energy is experiencing an aging workforce; older than other energy sources and the national average. For example, while almost one in three nuclear industry professionals are 55+ years, for oil and gas that number is one in five. The challenges brought about by an aging workforce are one of the industry’s top concerns. However, the industry lacks for empirical research that examines the effects of developmental aging in older workers, as well as the interactions between aging and new digital technologies. We present the results of an experiment that tested three different computer-based procedures in a sample of 30 older adults (55+ years). While the industry has traditionally relied on paper-based procedures, these are being modernized by digital technology. Participants were randomly assigned to one of three procedure-types that varied by the level of digitalization, based on the IEEE Standard-1786. Type 1 essentially represents a digital representation of a paper-based procedure, Type 2 adds embedded indicators, and Type 3 adds soft controls. Participants performed two different operational scenarios (startup and loss of feedwater) on a simplified nuclear power plant simulator. Results revealed a weak signal that Type 2 may produce lower workload and lower completion times in some instances. However, there were no significant effects of procedure-type across any other outcomes, including simulator log data, situation awareness, and preference ratings. We discuss our findings in terms of optimal levels of digitalization/automation for an aging nuclear workforce and suggest pathways for future directions.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2022

A structural description of the evolution of stakeholders and risk communication in the Department of Energy's defense nuclear facilities: Historical perspective, major stakeholders, and external events

Regulators and policymakers are routinely challenged with explaining complex concepts concerning risk. Part of the challenge is helping external and internal stakeholders to understand the context behind risk-related information and decisions. Here, this paper will describe the historical evolution of the safety and regulatory framework for an important category in the nuclear industry—defense nuclear facilities owned and operated by the US Department of Energy. In parallel with describing this evolution, three major events which occurred external to the complex of defense nuclear facilities will be summarized, and their impact on the maturation of the Department's safety and regulatory framework will be discussed. Finally, integrated with these two threads of discussion will be a chronicle of the changing set of involved organizations and the expanding set of external stakeholders involved in risk decisions—and therefore, the risk communications ecosystem surrounding defense nuclear facilities. It will be noted that this system was once describable as a classic “iron triangle,” but now has progressed to a complex network of federal and state organizations, numerous congressional committees, and expanding sets of external stakeholders. It is hoped that a comprehensive discussion of the context of risk assessment in the defense nuclear facilities complex—addressing historical insights, organizational evolution, and the maturing structure of regulation—will provide enhanced opportunities for building trust and understanding in this complex environment.

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

4th Big Data for Nuclear Power Plants Workshop 2023

The Ohio State University and Idaho National Laboratory organized the 4 th Big Data for Nuclear Power Plants Workshop in November, 2023 in Columbus, Ohio. Workshop topics were chosen to understand the challenges and gaps that need to be addressed to maximize the impact of data on the nuclear industry, as well as the associated applications and risks. Discussions were focused around six specific application areas: Operation and Maintenance; Machine Learning in Nuclear Materials and Advanced Manufacturing; Cybersecurity; High-Performance Computing and Massive Computation; Big Data and Digital Twins; and Nuclear Non-Proliferation. The opportunities, challenges, and risks identified in the six focus areas explored in this workshop are diverse, but some common themes emerge, such as the importance of data integrity, quality, coverage, privacy, and traceability. Big data and AI/ML tools can be leveraged to reduce costs, optimize human tasking, and reduce human error across various application areas. In order for the nuclear industry to benefit from big data and advanced analytic capabilities, it is essential to address challenges and risks, such as data privacy, model reliability, and computational resource availability. Learning from other industries that have successfully implemented big data and AI/ML technologies, like the aerospace industry, can help the nuclear industry successfully integrate these technologies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Phase 1 NuScale SMR FOAK Nuclear Demonstration Readiness Project (Final Scientific/Technical Report)

The overarching objective of the Phase 1 NuScale SMR First-of-a-Kind (FOAK) Nuclear Demonstration Readiness Project was to enhance competitiveness of the U.S. nuclear industry by enabling timely deployment of the NuScale small modular reactor (SMR). The scope of this Phase 1 project continued to advance the licensing and design maturity, particularly in those areas related to supporting customer readiness, supply chain integration, cost competitiveness, and cost confidence. This investment provided by the Government has accelerated development of these designs and technologies so that the existing domestic fleet of nuclear power plants remains viable and the most mature in the nuclear industry. The intent is to have the new, advanced U.S. designs be deployed as early 2026, and be globally competitive. As a part of the First-of-a-Kind Nuclear Demonstration Readiness Project, NuScale has been developing an advanced reactor design, leading the path for other development projects or complex technology advancements for existing plants that have significant technical and licensing risk. The NuScale Power team (NuScale) is advancing licensing, engineering, supply chain development, testing, and other required activities to enhance the innovation and competitiveness of the U.S. nuclear industry by enabling timely deployment of the NuScale SMR. Specifically, NuScale is performing the following activities in Phase 1. Fully supporting the NRC review of the NuScale DCA to ensure approval of a final safety evaluation report by the end of 2020. Improving plant cost confidence and cost competitiveness through design and supply chain advancement, incorporation of constructability best practices, and margin recovery to increase plant power output. Accelerating design maturity, technology development, and operational program readiness to support a customer commitment for plant deployment. The Department of Energy (DOE) Office of Scientific and Technical Information (OSTI), a unit of the Office of Science, fulfills agency-wide responsibilities to collect, preserve, and disseminate both unclassified and classified scientific and technical information (STI) emanating from DOE-funded research and development (R&D) activities at DOE national laboratories and facilities and at universities and other institutions nationwide. This scientific and technical report provides summaries of the analyses and research that was performed by NuScale under this project that achieves the objective of disseminating information to the nuclear industry to ensure the innovations realized are shared for the benefit of the industry at large.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

SATS Enhanced Capabilities and Demonstration of Improved Ramp Rates for In-Cell Testing

This report presents the development of the second-generation Severe Accident Test Station, referred to as SATS 2.0. SATS 2.0 represents a major advancement in addressing critical research needs for the United States nuclear industry, particularly in relation to fuel fragmentation, relocation, and dispersal (FFRD) concerns associated with the nuclear industry’s goal to extend fuel burnup beyond a peak rod average of 62 GWd/tU. The central objective of SATS 2.0 was the deployment a new furnace capable of achieving heating rates up to 100°C/s. This achievement addresses critical capability gaps, enabling assessment of prioritized research objectives established by the Electric Power Research Institute’s (EPRI) Collaborative Research on Advanced Fuel Technologies (CRAFT) working group. These research objectives are directly related to high-burnup loss-of-coolant accident (LOCA) conditions and the effects of prolonged exposure to elevated temperatures, both of which are crucial to enhancing nuclear safety and efficiency. The SATS 2.0 system builds upon prior experience with the original SATS system, which focused on evaluating accident-tolerant fuel (ATF) cladding concepts during accident conditions. However, the new system not only expands upon prior core capabilities by achieving higher heating rates with a better furnace but also plans to incorporate novel auxiliary systems to create a versatile platform for addressing current research needs. For example, a system was developed for the quantification and characterization of fission gas released during high-temperature transients. Additionally, in situ measurement capabilities were developed, such as digital image correlation which enabled the real-time capture of strain related to balloon and burst events and fiber-optic sensors that allowed for high-fidelity characterization of temperature gradients. Demonstration tests of the new 12-lamp furnace achieved heating rates up to 120°C/s. Notably, SATS 2.0 demonstrated its capacity to simulate LOCA burst tests at different pressures, yielding burst data that align with historical empirical models. Moreover, the system exhibited its capability to simulate complex conditions observed in anticipated operational occurrences, while effectively mitigating temperature overshoots. These accomplishments mark significant progress toward overcoming FFRD challenges and advancing the United States nuclear industry's safety basis and technical capabilities for extended burnup.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Modularity-at-scale for advanced reactors presentation

Modularity options have been limited for traditional nuclear energy deployment due to the conventional light water reactor (LWR) safety requirements, such as high pressure retaining heavy and robust containment structures. However, a relatively new regulatory approach called ‘Functional Containment’ has potential to allow less expensive and more flexible designs for non-LWRs. Functional containment provides flexibility in design and deployment based on risk-informed and performance-based criteria, so that reactors are not over-designed. Non-nuclear industry has successfully used modular design approaches in automotive, aerospace, chemical processing, building construction, and ship building. These industries have shown that modular construction reduces construction time by around 30% - 50% compared to the conventional stick-built approach. The nuclear industry can use similar approaches to reduce construction time and costs, balanced with safety requirements, using the functional containment approach. This paper discussing the background of modularity in nuclear energy, examples of less learned, modularity approaches in non-nuclear industries and the potential of cost and schedule savings through the emerging regulatory design flexibilities potentially enabling combination of modular deployment at different scales.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

MODULARITY-AT-SCALE FOR COST COMPETITIVE DEPLOYMENT OF NUCLEAR ENERGY

Modularity options have been limited for traditional nuclear energy deployment due to the conventional light water reactor (LWR) safety requirements, such as high pressure retaining heavy and robust containment structures. However, a relatively new regulatory approach called ‘Functional Containment’ has potential to allow less expensive and more flexible designs for non LWRs. Functional containment provides flexibility in design and deployment based on risk informed and performance-based criteria, so that reactors are not over-designed. Non-nuclear industry has successfully used modular design approaches in automotive, aerospace, chemical processing, building construction, and ship building. These industries have shown that modular construction reduces construction time by around 30% - 50% compared to the conventional stick built approach. The nuclear industry can use similar approaches to reduce construction time and costs, balanced with safety requirements, using the functional containment approach. This paper discussing the background of modularity in nuclear energy, examples of less learned, modularity approaches in non-nuclear industries and the potential of cost and schedule savings through the emerging regulatory design flexibilities potentially enabling combination of modular deployment at different scales.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Nuclear Decontamination Evolution and Revolution - 20349

Decontamination, one of the oldest practices in the nuclear industry, is about to change. While no single approach to decontamination is appropriate in all situations, decontamination of highly contaminated surfaces is historically viewed as difficult and/or marginally effective and fixatives and strippable coatings are often called on to manage time sensitive contamination control issues. The deferral of proper decontamination can lead to accumulated concentrations of radioactive material increasing the risk of cross-contamination of workers and equipment while also increasing radiation levels, which further discourages decontamination. The results of the subject testing demonstrate that superior decontamination factors are readily achievable and the ALARA benefit of decontamination is viable through advanced decontamination technologies in conjunction with innovative application techniques. The collateral benefits will save countless radiological man-hours and personnel radiological exposure. The appropriate use of radiological decontamination techniques can prevent or limit the adverse effects of highly radioactive contamination in the work area. High levels of radiological contamination are typically associated with some of the most physically demanding work in the nuclear industry. Additionally, working in highly contaminated environments increases the risk of exposure to elevated levels of airborne radioactivity and radiation from the source term of the contamination, particularly in hard to reach areas or complex equipment. Veolia's Alaron Nuclear Services (Alaron), a fully integrated nuclear facility, has provided the nuclear industry waste treatment, consolidation, repackaging, and broad decontamination services for almost 35 years. In looking at solutions for its customers, as well as for their own facility, Alaron has recently collaborated with Environmental Alternatives, Inc. (EAI), which has provided innovative solutions addressing difficult nuclear decontamination and industrial cleaning challenges since 1989. This broad range of experience along with the products to support the work created an ideal partner for Alaron's needs at their facility. The benefits of collaboration were immediately recognizable to the management of both companies although the decontamination challenge was significant. Due to the nature of the services offered, contamination at the Alaron facility is routine. The recent decontamination experience at Alaron utilized an innovative surfactant process that quickly produces remarkably higher decontamination factors for both removable surface contamination and fixed contamination. Considering the time to decontaminate areas historically designated for high radiological hazard work, the results from this decontamination effort not only reduced contamination levels but also significantly lowered exposure rates in the working environment. The relative ease with which the surfactant is applied, combined with extraordinary decontamination test results, indicates the potential to alter current radiological work processes in a way that improves worker comfort, and removes radiological engineering barriers, allowing Alaron to complete complex radiological tasks more efficiently and effectively. In a series of two simple applications of the decontamination agent to contaminated high bay vertical surfaces, as well as a variety of horizontal and vertical surfaces with variable porousness and surface sealants, there was an overall reduction in removable contamination of approximately 73% with a reduction in area dose of approximately 93%. The results indicate additional reduction in fixed contamination with application of the surfactant. These values are much higher than experienced with more traditional decontamination agents. In conjunction with demonstrating EAI's surfactant on room surfaces, additional studies were conducted on complex geometry equipment including waste processing equipment, tools, and heavily contaminated parts normally handled from Alaron's customers. Evaluations were made with straight application of EAI's surfactant as well as adding additional techniques to the treatment which afforded revolutionary improvements in the levels of contamination removed. Successful decontamination with up to 95% reduction in removable contamination with just one application were demonstrated in several of the trials. This paper outlines the planned approach to use this technology, the variety of surfaces and equipment treated, and the results of the decontamination efforts. Furthermore, this paper discusses options for pretreatment of certain heavily contaminated equipment prior to employees handling and/or working with the equipment. The potential for dose saving and the reduced risk of cross-contamination with the added benefit of lower PPE requirements, produces an enormous potential for cost and time savings. Attendees will benefit from Alaron's experiences and more fully understand the capabilities of EAI's decontamination process. With the variety of contamination agents, forms and surfaces on which the technology was demonstrated, the information will be valuable to a broad cross-section of industry users. The significance of this report demonstrates superior decontamination factors are achievable utilizing the next evolution of decontamination technology and that the ALARA benefits of decontamination are available through advanced and modern decontamination efforts. The collateral benefits will save countless radiological man-hours and valuable personnel radiological exposure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Advanced manufacturing and digital twin technology for nuclear energy*

Advanced manufacturing techniques and digital twin technology are rapidly transforming the nuclear industry, offering the potential to enhance productivity, safety, and cost-effectiveness. Customized parts are being produced using additive manufacturing, automation, and robotics, while digital twin technology enables the virtual modeling and optimization of complex systems. These advanced technologies can significantly improve operational efficiency, predict system behavior, and optimize maintenance schedules in the nuclear energy sector, leading to heightened safety and reduced downtime. However, the nuclear industry demands the highest levels of safety and security, as well as intricate manufacturing processes and operations. Thus, challenges such as data management and cybersecurity must be addressed to fully realize the potential of advanced manufacturing techniques and digital twin technology in the nuclear industry. This comprehensive review highlights the critical role of digital twin technology with advanced manufacturing toward nuclear energy to improve performance, minimize downtime, and heighten safety, ultimately contributing to the global energy mix by providing dependable and low-carbon electricity.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Additive Manufacturing in the Nuclear Reactor Industry

This article discusses the application of additive manufacturing in the nuclear reactor industry.Additive manufacturing for nuclear applications increased significantly in the late 2010s due to rapid progress in technology, particularly with methods using metals and ceramics.Because these manufacturing technologies are uniquely data-rich, they allow for an advanced understanding of materials, and they offer the potential to predict part performance based on build data. The inherent characteristics of additive manufacturing technologies allow for rapid prototyping and geometric freedom, making it possible to implement an accelerated agile design process for advanced nuclear reactor applications. Predictive high-fidelity multiphysics simulations are crucial to fully leverage this geometric flexibility. Qualification and regulator acceptance ultimately determine the breadth and scope of applications for these technologies. The US Department of Energy Office of Nuclear Energy Transformational Challenge Reactor program integrates many of these elements to accelerate the deployment of additive manufacturing technologies to industry.

Betzler, Benjamin↗
DOE OSTI2024

Initial Assessment of CTF for Time-at-Temperature Applications

The US nuclear industry is interested in improving the economics of their fleet of light-water reactors (LWRs) by uprating US plants. One option being considered is to regain lost margin from overly conservative fuel safety limits. The current limit requires avoidance of critical heat flux (CHF) and prevents further operation of fuel that experiences a dry-out in boiling water reactors (BWRs) or departure from nucleate boiling (DNB) in pressurized water reactors (PWRs); however, it has been shown that temporary, mild dry-out of the fuel does not necessarily increase the risk of fuel failure during its normal anticipated operating life. Such mild dry-out or DNB events may occur during a plant anticipated operational occurrence (AOO), such as a locked rotor in a PWR or a pump trip in a BWR. The time-at-temperature (TAT) approach to regulating fuel operation aims to demonstrate that the fuel rod’s integrity is not challenged during such a mild transient that leads to CHF in which the fuel operates at an elevated temperature for a brief period of time. However, implementing this approach will require extensive fuel material experimental data, as well as supporting modeling and simulation (M&S) predictions, to ensure that the predicted fuel response during AOOs, with all applicable uncertainty considered, will not threaten the safety of the fuel during the transient or the remainder of its anticipated lifecycle. To address this need, a comprehensive effort is being proposed that includes generating cladding material data under TAT conditions, assessment of available code capabilities for TAT conditions, development of new mechanistic models, and demonstration of the M&S capabilities for AOOs of interest. This will require a joint effort between the Nuclear Energy Advanced Modeling and Simulation (NEAMS) and Advanced Fuels Campaign (AFC) programs, as well as close collaboration with nuclear industry stakeholders. The outcome of this collaboration will result in development and assessment of capabilities that can be used by the nuclear industry to support qualification of a TAT-based fuel failure criteria safety limit. This report focuses on the thermal hydraulics (T/H) modeling capabilities and summarizes currently available data for validating the T/H subchannel code CTF for TAT conditions, as well as preliminary assessment results of the code. The initial assessment also resulted in implementation of an alternative post-CHF heat transfer package, which has been shown to significantly improve accuracy. This report is not a final assessment and does not consider all available validation data; it is intended that a future assessment will more fully validate the code for this application.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗