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Silicon Carbide Composite Cladding Qualification

This report examines the process to qualify a new fuel-cladding type focusing on the data requirements and types of irradiation testing necessary to meet the regulatory burden and related guidance applicable to fuel qualification of accident-tolerant fuel. The report considers the use of accelerated fuel qualification techniques and lead-test specimen programs that may shorten the timeline for qualifying fuel for use in a nuclear reactor at the desired burnup. The assessment framework particularly emphasizes the identification of key fuel manufacturing parameters, the specification of a fuel performance envelope to inform testing requirements, the use of evaluation models in the fuel qualification process, and the assessment of the experimental data used to develop and validate the empirical models and empirical safety criteria.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Free-flight Performance of a Rocket-boosted, Air-launched 16-inch-diameter Ram-jet Engine at Mach Numbers up to 2.20

The investigation of air-launched ram-jet engines has been extended to include a study of models with a nominal design free-stream Mach number of 2.40. These models require auxiliary thrust in order to attain a flight speed at which the ram jet becomes self-accelerating. A rocket-boosting technique for providing this auxiliary thrust is described and time histories of two rocket-boosted ram-jet flights are presented. In one flight, the model attained a maximum Mach number of 2.20 before a fuel system failure resulted in the destruction of the engine. Performance data for this model are presented in terms of thrust and drag coefficients, diffuser pressure recovery, mass-flow ratio, combustion efficiency, specific fuel consumption, and over-all engine efficiency.

AIR INLETS - NOSE, ANNULAR↗

Establishment of a Vertically Integrated Domestic Manufacturing Process for Production of Substrates Needed for Manufacture of Gas Diffusion Layers

In this project, AvCarb, LLC evaluated the baseline performance metrics of commercial carbon veils and their corresponding Gas Diffusion Layers (GDLs) with the goal of establishing an optimized, vertically integrated production system for wet-laid nonwoven substrates used in gas diffusion media for electrochemical energy storage and conversion devices. Mechanical testing and microstructural characterization were conducted and used to develop a multiscale computational model capable of simulating and predicting the performance of GDLs in fuel cells. Although the project successfully generated foundational transport and modeling data, it was terminated prior to identifying the critical GDL design parameters necessary for full optimization. The program aimed to improve carbon veil fabrication through enhanced fiber dispersion, fiber-fiber adhesion control, and improved web formation, enabling the production of high-quality, uniform substrates. Simulations were intended to guide mixing and solution delivery system design and process conditions, followed by production-scale trials to evaluate fiber dispersion, web uniformity, and mechanical robustness. At full deployment, the proposed production line would have been capable of producing approximately 650,000 m² of carbon veil annually. This capability remains strategically important, as the United States currently lacks a domestic source of wet-laid nonwoven carbon substrates that satisfy the stringent quality requirements for fuel-cell GDLs and electrolyzers representing an ongoing supply-chain vulnerability. Beyond supply-chain benefits, the project established a robust benchmarking dataset for existing commercial carbon veils while advancing next-generation material concepts targeting improved performance and manufacturing consistency.

Olson, Cynthia Lemay↗

Summary and Assessment of Metal Fuel Capabilities in Bison

The work described in this report was performed under funding from the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. This report is issued in satisfaction of the level 2 milestone M2MS-18IN0201012 on Release Bison with Initial Metallic Fuel Performance Capability. Metallic fuel development began in Bison a few years after light water reactor development began (~ 2009). The initial development was funded by the Advanced Fuels Campaign. With recent interest from industry, the Nuclear Regulatory Commission, and the Versatile Test Reactor program, the Nuclear Energy Modeling Simulation Program has increased funding for metallic fuel development and validation in FY18. The material models with the most mature development are binary uranium-zirconium and ternary uranium-plutonium-zirconium alloys for fuel and HT9 for cladding. The first material models were incorporated from open literature sources, which include mechanical and thermal material properties that are functions of temperature, porosity, and zirconium concentration, swelling, fission gas release, zirconium diffusion, creep, and sodium coolant channel boundary conditions. These material models have been utilized to simulate ERB-II fuel pins and the results compared to measurements. The EBR-II experiment measurements mostly consist of cladding strain and zirconium redistribution. As such, comparisons to EBR-II measurements are currently limited to these two figures of merit. Simulations and comparisons to experiment measurements have also been done for transient testing of EBR- II fuel pins in TREAT, which included temperature measurements. Preliminary comparisons between Bison calculations and experiment measurements are favorable. These comparisons have also highlighted the importance of the fuel swelling and fission gas release models on cladding strain. Also, Bison metallic fuel simulations are currently being run in support of ATR experiments and VTR exploratory design calculations. Further development and evaluation of individual material models and fuel system models are planned for FY19.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Preliminary Characterizations of Altair Lunar Lander Slosh Dynamics and Some Implications for TVC Design

During thrust maneuvers, the sloshing of fuel in partially filled tanks could interact with the controlled system in such a way as to cause the overall system to be unstable. This failure mode could be a result of poor coordination between systems engineers of Structures, Propulsion, GN&C, Mission Operations, and other subsystems. Attentions to the following is a minimum: Placements of fuel tanks, Tank shapes and baffle designs, Separation of TVC BW from slosh mode frequencies, Adequacy of excursion range of engine gimbal actuators in all engine burns, BW of sensors (e.g., gyroscopes) and actuators (e.g., engine gimbal), Structural frequencies of spacecraft and engine mounts, Prediction of S/C's c.m. location, canting of gimbal null axis, others. Check overall TVC performance via validated simulation test bed. Modeling fuel slosh during spacecraft thrusting maneuvers • Placement of fuel tanks to guarantee stable interactions between fuel slosh mode and the S/C rigid-body mode • Estimation of slosh frequencies (as a function of mission phases): – Estimation of slosh mode damping • Some implications for Thrust Vector Control design: – Selection of TVC controller bandwidth – Adequacy of the excursion range of engine gimbal actuator • TVC system design: Complex Interactions between GN&C, Propulsion, Structure, and Other Subsystems

Thrust vector control↗

MELCOR Modeling of Accident Scenarios at a Facility for Aqueous Reprocessing of Spent Nuclear Fuel

The work presented in this report applies the MELCOR code to evaluate potential accidents in non-reactor nuclear facilities, focusing on Design Basis Accidents. Ten accident scenarios were modeled using NRC's best-estimate severe accident analysis code, MELCOR 2.2. The accident scenarios simulated a range of explosions and/or fires related to a nuclear fuel reprocessing facility. The objective was to evaluate the radionuclide source term to the environment following initiating explosion and/or fire events. The simulations were performed using a MELCOR model of the Barnwell Nuclear Fuel Plant, which was decommissioned before beginning reprocessing operations. Five of the accident scenarios were based on the Class 5 Design Basis Accidents from the Final Safety Analysis Report. Three of the remaining accident scenarios include sensitivity studies on smaller solvent fires. The final two accidents included an induced fire from an initial explosion. The radionuclide inventory was developed from ORIGEN calculations of spent PWR fuel with an initial enrichment of 4.5% U-235 by weight. The fuel aged for five years after a final 500-day irradiation cycle. The burn-up was conservatively increased to 60 GWd/MTU to bound current US operations. The results are characterized in terms of activity release to the environment and the building decontamination factor, which is related the leak path factor used in Department of Energy safety analyses. The MELCOR 2.2 results consider adverse consequences to the filters, ventilation system, and structures as a result of the explosions and fires. The calculations also include best-estimate models for aerosol transport, agglomeration, and deposition. The new calculations illustrate best-estimate approaches for predicting the source term from a reprocessing facility accident.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Cluster dynamics simulation of xenon diffusion during irradiation in UO 2

Diffusion of fission gas in UO 2 nuclear fuel impacts several important performance metrics, such as fission gas release, swelling, and thermal conductivity. Current empirical models of fission gas release have significant uncertainty, some of which derives from the bulk diffusion rate and its dependence on, for example, fuel chemistry and irradiation. In this work, we have applied the previously-developed Free Energy Cluster Dynamics (FECD) methodology in the code Centipede to calculate xenon cluster concentrations in UO 2 under intrinsic (high temperature) and irradiation-enhanced (intermediate temperature) conditions in order to develop a model of the xenon diffusion coefficient based on the atomic scale mechanisms responsible for transport. While the diffusion mechanism for xenon in UO 2 is adequately described by the Xe + U 2 O vacancy cluster for intrinsic conditions, a similar process is not capable of capturing measured in-pile fission gas diffusivity at intermediate temperatures. Therefore, a different diffusion mechanism must dominate under this regime. Using calculated atomistic data, we have shown that irradiation-enhanced diffusion at intermediate temperatures occurs via the larger Xe + U 4 O y vacancy clusters, which have lower migration barriers and increase in concentration by several orders of magnitude compared to intrinsic conditions. This mechanism is enabled by the increased uranium vacancy concentration under irradiation due to Frenkel pair production. In addition, the fast migration of uranium interstitials with two attached oxygen interstitials lowers the total uranium interstitial concentration through reactions with sinks. This allows the extended defects, such as Xe + U 4 O y vacancy clusters, to maintain high concentrations by limiting annihilation with attached vacancies. Furthermore, predictions using the Xe + U 4 O y diffusion mechanism are in good agreement with experiment, albeit with some differences in the Arrhenius slope, which we believe may be related to either experimental or model parameter uncertainty. Lastly, an analytical expression suitable for application in fuel performance simulations was derived to capture the predictions of the Centipede simulations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Modeling and Measurement of Axial Gas Transport in Nuclear Fuels

This document is an American Nuclear Society (ANS) transaction for the ANS annual conference. This transaction provides an overview of the Modeling and Measurement of Axial Gas Transport Laboratory Directed Research and Development project including preliminary modeling results. The goal is to provide model for axial gas transport in the Bison Fuel Performance code to support industry's desire to achieve higher burnups in existing light water reactors. A brief overview of the experimental approach and associated modeling activities is presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

MELCOR Input Model for Spent Fuel Transportation and Storage Canister

This report documents the progress and current results of the MELCOR spent fuel cask input model. The MELCOR model is being developed to investigate aerosol transport and deposition given the aerosol physical phenomena models within MELCOR. To perform the analyses, a general portrayal of the MAGNASTOR® cask system has been employed; however, this system was selected based on available information to provide a reasonable representation of a spent fuel cask. The analytical results are not intended to characterize the performance of the MAGNASTOR® cask. Instead, the provided results are intended to enhance our general understanding of the aerosol behavior within casks and the validity of current models. The current model efforts are being performed to investigate hypothetical UO 2 release from failed fuel pins within a spent fuel cask. The existing MELCOR model of the MAGNASTOR® cask system has been adapted to permit future comparative analyses with the GOTHIC representation of the MAGNASTOR® cask. To support this comparison, the PNNL model characteristics that are unrelated to the aerosol modeling were applied to the MELCOR model. These characteristics included improved comparability of the axial fidelity, total spent fuel power, fuel pin axial power profile, and heat losses from cannister. The thermal-hydraulic solutions are improved within the capability of the MELCOR code and will permit better overall agreement with the GOTHIC results. Detailed results are presented on the thermal-hydraulic analysis of the MELCOR cask as well as characterization of UO 2 aerosol dispersion and deposition within the cask.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Impact of anisotropy on TRISO fuel performance

Manufacturing of tristructural isotropic (TRISO) particles involves the deposition of pyrolytic carbon (PyC) and silicon carbide (SiC) layers using the fluidized bed chemical vapor deposition (CVD) process. The CVD process is known to generate polycrystalline layers with crystallographic textures, which imparts anisotropic thermophysical properties to the layers. Past studies have shown the risk for particle failure increases with an increase in anisotropy. The limit beyond which the anisotropy of PyC layers becomes unacceptable due to failure risk has been identified as a high-priority knowledge gap. This work presents a first systematic study on the effects of anisotropic thermal and mechanical properties on TRISO fuel performance. This computational study, performed using the fuel performance code BISON, investigates how the anisotropy in elasticity and thermal properties affect the stresses, temperature, and failure of a TRISO particle. The influence of other factors, such as operating temperature and particle geometry on the anisotropy effects, also has been analyzed. The studies utilize the recently published anisotropic elasticity and thermal behavior models for TRISO PyC and SiC layers implemented using tensors with full anisotropic capability. The spherical TRISO particles with anisotropic properties were found to have greater maximum tensile stress and significantly higher failure probability than the spherical particles with isotropic properties. In conclusion, the fuel performance predicted using these recently developed models was found to be comparable with the performance obtained using the historical models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Performance Assessment Modeling and Sensitivity Analyses of Generic Disposal System Concepts

The Used Fuel Disposition Campaign (UFDC) of the U.S. Department of Energy (DOE) Office of Nuclear Energy (NE) is conducting research and development (R&D) on generic deep geologic disposal systems (i.e., repositories) for high-activity nuclear wastes (i.e., used nuclear fuel (UNF) and high-level radioactive waste (HLW)) that exist today or that could be generated in future fuel cycles. This report describes specific activities in FY2014 toward the development of an enhanced generic disposal system modeling and analysis capability that utilizes high performance computing (HPC) environments to simulate important multi-physics phenomena and couplings associated with the potential behavior of a geologic repository for UNF and HLW.

Sevougian, S. David↗

High-Burnup BWR LOCA Burst Analysis Using High-Fidelity Multiphysics Simulations

The US nuclear industry is looking to improve on the operating economics of the current fleet of light-water reactors (LWRs). One way of achieving this is by operating fuel to higher burnup. In pressurized water reactors (PWRs), relaxing the current burnup limit will allow for cycle length extensions and power uprates; in boiling water reactors (BWRs) it may allow for improved fuel utilization and reduced feed assemblies, as well as more efficient power uprates and increased capacity factors that will support the Administration’s Executive Order to facilitate 5 GW of power uprates at existing nuclear facilities. However, one of the key limitations to operating fuel to higher burnup is the risk of fuel fragmentation, relocation, and dispersal (FFRD). Recognizing the high interest in extending burnup limits, the US Nuclear Regulatory Commission (NRC) has issued Draft Regulatory Guide DG-1434, which defines an approach that would be acceptable to the NRC for addressing FFRD risk. The approach defined will require better understanding of the phenomena leading to FFRD as well as best-estimate simulation methods to understand FFRD risk in high-burnup cores. The Nuclear Energy Advanced Modeling and Simulation program is supporting the FFRD industry challenge problem through development of state-of-the-art, high-fidelity modeling and simulation LWR analysis capabilities; namely, the BISON fuel performance code and the VERA core simulator software. These tools, along with the US NRC TRACE system analysis code, have been utilized for analysis of FFRD risk in both PWR and BWR cores in recent years. The work documented in this report addresses the lack of high-fidelity research for BWRs and builds on a previous activity where the framework has been applied to Cycles 16 through 18 of Limerick Unit 1, a BWR/4, with introduction of 8 high-burnup lead use assemblies (HBLUAs) that were representative of the 8 HBLUAs loaded into Limerick Unit 2 in 2021. VERA was used in this previous activity to model rod-by-rod depletion in these cycles, and its solution was used to initialize a TRACE simulation of a large-break loss-of-coolant accident (LBLOCA) at the end of Cycle 18. In the work documented in this report, the TRACE model was improved by refining the core mesh and utilizing a new feature that allows for capturing the full 3D VERA power distribution in the model. This allows for a more detailed solution for setting BISON boundary conditions. Furthermore, the solutions from VERA and TRACE were used to set up and perform BISON simulations of about 1,000 rods sampled from the core, including all burnup levels. Utilizing two cladding burst models, it was shown that no fuel rods were predicted to burst during the postulated LBLOCA transient. Additionally, a sensitivity study was performed by artificially increasing linear heat rate during the postulated LBLOCA to identify parameters that correlate with rod burst susceptibility. Burnup, fission gas release, and hoop strain were all found to be positively correlated with rod burst susceptibility. Small-break loss-of-coolant accident (SBLOCA) analyses were also performed; these analyses predicted cladding temperature increases that were bounded by the LBLOCA cladding temperatures for all small break sizes studied for this plant. However, future refinements to the plant response assumptions during the SBLOCA could impact the predicted cladding response. Finally, a benchmark study was performed between CTF and TRACE for LOCA conditions to better qualify CTF for BWR LOCA modeling.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Optimizing Performance and Accuracy with LIFQWIK

For the 2020 Summer Internship period, optimization and analysis was performed of a new iteration of the LIFQWIK PLIF model, used to evaluate the accuracy of CFD simulations of fuel injector performance. This presentation details the accuracy and performance optimization steps taken and presents the results of that optimization.

CFD↗

Aviation Fuel Tracer Simulation: Model Intercomparison and Implications

An upper limit for aircraft-produced perturbations to aerosols and gaseous exhaust products in the upper troposphere and lower stratosphere (UT/LS) is derived using the 1992 aviation fuel tracer simulation performed by eleven global atmospheric models. Key Endings are that subsonic aircraft emissions: (1) have not be responsible for the observed water vapor trends at 40 deg N; (2) could be a significant source of soot mass near 12 km, but not at 20 km; (3) might cause a noticeable increase in the background sulfate aerosol surface area and number densities (but not mass density) near the northern mid-latitude tropopause; and (4) could provide a global, annual mean top of the atmosphere radiative forcing up to +0.006 W/sq m and -0.013 W/sq m due to emitted soot and sulfur, respectively.

Danilin, M. Y.↗

Aviation Fuel Tracer Simulation: Model Intercomparison and Implications

An upper limit for aircraft-produced perturbations to aerosols and gaseous exhaust products in the upper troposphere and lower stratosphere (UT/LS) is derived using the 1992 aviation fuel tracer simulation performed by eleven global atmospheric models. Key findings are that subsonic aircraft emissions: (1) have not been responsible for the observed water vapor trends at 40degN; (2) could be a significant source of soot mass near 12 km, but not at 20 km; (3) might cause a noticeable increase in the background sulfate aerosol surface area and number densities (but not mass density) near the northern mid-latitude tropopause; and (4) could provide a global, annual mean top of the atmosphere radiative forcing up to +0.006 W/sq m and -0.013 W/sq m due to emitted soot and sulfur, respectively.

Danilin, M. Y.↗

Effect of fuel injector type on performance and emissions of reverse-flow combustor

The combustion process in a reverse-flow combustor suitable for a small gas turbine engine was investigated to evaluate the effect of fuel injector type on performance and emissions. Fuel injector configurations using pressure-atomizing, spill-flow, air blast, and air-assist techniques were compared and evaluated on the basis of performance obtained in a full-scale experimental combustor operated at inlet conditions corresponding to takeoff, cruise, low power, and idle and typical of a 16:1-pressure-ratio turbine engine. Major differences in combustor performance and emissions characteristics were experienced with each injector type even though the aerodynamic configuration was common to most combustor models. Performance characteristics obtained with the various fuel injector types could not have been predicted from bench-test injector spray characteristics. The effect of the number of operating fuel injectors on performance and emissions is also presented.

Norgren, C. T.↗

A study on the impact of using a subchannel resolution for modeling of large break loss of coolant accidents

The nuclear industry is investigating the feasibility of transitioning from 18- to 24-month fuel cycles because of the positive impact it would have on the operational costs for the current fleet of light-water reactors. A challenge to making this change is the increased risk of fuel fragmentation, relocation, and dispersal (FFRD) due to the known potential for ceramic fuel to pulverize into fine particles at the higher discharge burnups. Previous work has been performed by the Nuclear Energy Advanced Modeling and Simulation program to assess FFRD risk in high-burnup cores using the BISON fuel performance code and a coarse mesh thermal hydraulics (T/H) solution for a loss-of-coolant accident (LOCA) using the TRACE system T/H code. Because of the importance of the T/H solution for FFRD assessment, this study seeks to investigate the impact of using higher-fidelity subchannel techniques for modeling of the LOCA transient. CTF was used to model a subregion of a high-burnup core that was depleted by the Virtual Environment for Reactor Applications (VERA) multiphysics core simulator. Both coarse-mesh and pin-resolved models were created in CTF, and a consistent coarse-mesh TRACE model was also developed to allow for benchmarking the code results. Further, a large-break loss-of-coolant accident (LBLOCA) reflood transient was simulated using these three models, and results were compared. Results showed some consistent differences between the CTF and TRACE coarse models, including a higher peak cladding temperature (PCT) prediction in CTF and later quenching in CTF; however, the transient clad temperature behavior was similar, and these differences are likely due to post-critical heat flux heat transfer modeling differences and minimum film boiling temperature model differences. The pin-resolved results indicate that the PCT in the lumped model is often under-predicted by as much as 70 °C and that PCT occurs at a different location than the high-power pin in the assembly. The lumped model predicts a difference of 10 °C or less between the average and hot pins in the assembly, whereas the pin-resolved model predicts a range of over 100 °C. These results indicate that higher-fidelity T/H results may have an impact on predicted core behavior during LOCA, which may be important to consider when assessing FFRD risk.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Model of U3Si2 Fuel System using BISON Fuel Code

This research considers the proposed advanced fuel system: U3Si2 combined with an advanced cladding. U3Si2 has a number of advantageous thermophysical properties, which motivate its use as an accident tolerant fuel. This preliminary model evaluates the behavior of U3Si2 using available thermophysical data to predict the cladding-fuel pellet temperature and stress using the fuel performance code: BISON. The preliminary results obtained from the U3Si2 fuel model describe the mechanism of Pellet-Clad Mechanical Interaction for this system while more extensive testing including creep testing of U3Si2 is planned for improved understanding of thermophysical properties for predicting fuel performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗