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SCALE 6.3 Modeling Strategies for Reactivity, Nuclide Inventory, and Decay Heat of Non-LWRs

To assess modeling and simulation capabilities for thermal hydraulics, accident progression, source term, and consequence analysis for non–light-water reactor (LWR) technologies, the US Nuclear Regulatory Commission (NRC) initiated a collaborative project between Oak Ridge National Laboratory (ORNL) and Sandia National Laboratories (SNL) in FY20, which is detailed in “Volume 3: Computer Code Development Plans for Severe Accident Progression, Source Term, and Consequence Analysis.” This project demonstrated the capabilities of the MELCOR and SCALE codes to calculate accident scenarios during operation of relevant non-LWRs. The following five non-LWR concepts were selected for capability demonstration based on recently renewed industry interest in the United States to develop and deploy such reactor technologies: pebble-bed high temperature gas-cooled reactors (HTGRs), pebble-bed fluoride salt-cooled reactors (FHRs), molten salt–fueled reactors (MSRs), heat pipe reactors (HPRs), and sodium-cooled fast reactors (SFRs).

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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.

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Post-irradiation examination of legacy high burnup fuel to support safety testing

Safety/transient testing to evaluate performance under off-normal conditions is an essential pillar for both the development of Accident Tolerant Fuels (ATF) and the optimization of fuel operation economics beyond current discharge burnups. Among other factors, the successful interpretation of the transient testing results relies upon the knowledge of the initial conditions of the test, including the characteristics of the fuel system under scrutiny. When testing pre-irradiated material, the assumptions that the fuel and the cladding still have the same properties as in the pre-irradiation stage is obviously wrong and could affect the results of the test. This is particularly true the more burnup accumulates in the fuel rod and irradiation progresses. The knowledge of the initial microstructure of both fuel and cladding allows a clearer interpretation of the subsequent transient testing results, provides validation of the physical phenomena underlying the model predictions and eliminates the uncertainties related to the limited knowledge of the sample status before the test. One example is the phenomenon of fine fragmentation that occurs in Light Water reactor (LWR) fuel. During a Loss of Coolant Accident (LOCA) or Reactivity Initiated Transient (RIA) the fuel can severely fragment. During LOCA, high burnup fuel tend to finely fragment, which has raised safety concerns due to the increased likelihood of dispersal of such small particles once the cladding has burst and due to the increased fission gas release. Therefore, efforts have been devoted to the assessment of a pulverization threshold that could determine the conditions under which fine fragmentation is predominant. However, the lack of information regarding the initial conditions of the fuel, and the connections between those conditions and the pre-transient irradiation history, have hindered the development of a fully mechanistic fragmentation and pulverization criterion. The empirical relationships rely on conservative estimations, due to the lack of information on critical material properties and characteristics. More generally, experimental evidence of the irradiation-induced modifications at microstructural scale are necessary to determine the behavior of the material at the macroscopic scale, with the latter being the one of technological interest. Significant progress has been made in the last two decades in the developments of analytical materials science techniques that can be applied to highly radioactive materials, such as high burnup fuels. The availability of new techniques and the improvement of existing ones has enabled investigations previously not possible that can deepen the understanding of the fuel characteristics and properties at high burnup. The better knowledge of material behavior and irradiation-induced phenomena could help the prediction of its performance. In this context, the scope of the present work is to apply a wide portfolio of advanced characterization techniques to determine properties that are relevant for safety and performance. The results are interpreted in the context of engineering scale post-irradiation examinations and available information on the irradiation conditions.

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Accelerated Irradiation and Qualification of Ceramic Nuclear Fuels

Accelerated irradiation efforts are an important topic in accelerated qualification of new nuclear fuel concepts for light water reactor (LWRs), microreactors, and other special purpose reactors. Accelerated fuel qualification combines both experimental and modeling work to expedite the total qualification time from approximately 20-25 years to 5-10 years timeframe. The scope covered under the current work package focuses on the experimental contributions for the neutron irradiations. Accelerated irradiation aims to reduce the total time needed for neutron irradiation to achieve targeted burnup, which is timely using conventional irradiation profiles. The purpose of this report is to detail the samples preparation for such irradiations, which contain standard, medium, and large grain undoped UO 2 , as well as large grain, Cr 2 O 3 -doped UO 2 . The data that will be generated from the irradiation of these samples will yield important information regarding fission gas retention as a function of grain size and the effect that Cr dopants have on diffusivity of fission gases.

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Molybdenum Sleeve Experiments in Fully-Reflected Water-Moderated Triangular-Pitched U(6.90)O 2 Fuel Rod Lattices (1.55 cm Pitch)

The US Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories. The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5 % 235 U. The 7uPCX assembly is a water-moderated and -reflected array of aluminum-clad U(6.90 %)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMP-THERM-096, LEUCOMP-THERM-097, LEU-COMP-THERM-101, and LEU-COMP-THERM-102. The purpose of these experiments was to measure the effects of molybdenum in nearly-critical systems. The molybdenum was introduced into the fuel arrays as tubular sleeves that surrounded some of the fuel rods in the fuel arrays measured. Four hundred molybdenum tubes nominally 12.7 mm outside diameter, 498 mm long, with 0.762 mm wall thickness were provided for the experiments by the Institut de Radioprotection et de Sûreté Nucléaire (IRSN). Small polyethylene adapters at each end of the tubes were used to center each tube on a fuel rod in the assembly. The critical experiments were done using a set of triangular-pitched grid plates fabricated for these experiments. The grid plate set accommodated a fuel array of a total of 1261 fuel rod positions on a pitch of 0.610 in (1.5494 cm) in a series of 20 hexagonal rings surrounding the central fuel rod. The fuel used in these experiments was fabricated using unirradiated 6.90 % enriched UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The five critical experiments in this series were performed in August through December 2022, in the Sandia Critical Experiments (SCX) at the Sandia Pulsed Reactor Facility. Case 1 had no molybdenum sleeves, Case 2 had 208 molybdenum sleeves clustered at the center of the array, Case 3 had 397 molybdenum sleeves clustered at the center of the array, Case 4 had 175 molybdenum sleeves in the central position and in five alternating hexagonal rings, and Case 5 had 331 molybdenum sleeves in the central position and in seven alternating hexagonal rings. All five critical experiments are judged to be acceptable as benchmark experiments.

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Complete the first phase of the comprehensive characterization of repair welding performed on irradiated Ni alloy 182

This report describes the research activities on post-weld evaluation and characterization of the quality and properties of welds made on the first phase of repair welding campaign on irradiated Ni alloy 182. The equipment and capabilities of the campaign were developed jointly by the U.S. Department of Energy, Office of Nuclear Energy, Light Water Reactor Sustainability Program, the Electric Power Research Institute, Long Term Operations Program (and the Welding and Repair Technology Center), and Oak Ridge National Laboratory. Irradiated nickel alloy 182 with doped boron ranging from 5 wppm to 15 wppm, were laser welded in the hot cell. The weld samples were cross-sectioned and characterized. The significant, on-going effort to weld irradiated alloys with high helium concentrations and comprehensively analyze the results will eventually yield validated repair techniques and guidelines for use by the nuclear industry in extending the operational lifetimes of nuclear power plants.

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Mesoscale simulations of High Burnup Fuel Fragmentation: Applying phase-field modeling to understand high burnup fuel fragmentation during loss of coolant accident conditions

During a loss-of-coolant accident (LOCA) in a nuclear power plant, a rapid increase in temperature is experienced in the fuel. In commercial light water reactors (LWRs), the high burnup structure (HBS) forms in regions of the UO 2 fuel where local burnup is high, characterized by smaller grain sizes and large, overpressurized bubbles. During a LOCA transient, fuel in the HBS region is susceptible to fine fragmentation, where the fuel breaks up into micron-size fragments (sometimes referred to as pulverization). To better understand the mechanisms behind this phenomenon, mesoscale computational modeling using the Idaho National Laboratory code Marmot has been employed to simulate the process of HBS formation and response to a LOCA transient. The process of complete and partial HBS formation was demonstrated in prototypical LWR conditions. The simulated HBS microstructures from these simulations were passed to a phase-field model of fracture. To provide a more direct comparison with experiments, a set of experiments conducted by Studsvik on fine fragmentation/pulverization during LOCA conditions was simulated using the BISON fuel performance code. The temperature profiles from the BISON simulations were passed to a phase-field model to determine the gas bubble pressure as a function of time. These pressure histories were used in a phase-field model of fracture to determine under what conditions and in which types of bubbles fine fragmentation was likely to occur.

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Residual Stress Measurements of Cr-coated Cladding

Accident-tolerant fuel concepts for light-water reactor applications have been developed and tested in diverse research programs around the world. Industry teams have developed coated cladding concepts using different coating application methods, such as physical vapor deposition and coldspraying. Recently, variations in thickness and application method were investigated, and their effects on the microstructure and mechanical properties were reported. The results suggest an increase in performance in an unirradiated state, however, it remains unclear what phenomenon drove this performance. One explanation to this performance is associated with the coating process imparting a residual stress. Residual stress analysis was performed on coatings produced with various process parameters to understand how a thin layer of Cr impacts the mechanical properties after coating application and after simulated operating conditions. The gathered information is intended to address safety concerns or support margin identification related to accident-tolerant fuels and to support subsequent modeling and simulation efforts.

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Tools And Methods to Analyze Plant Outage Schedule and Assist Schedulers in Improving Outage Resilience

Refueling outages of nuclear power plants (NPPs) are considered one of the most critical phases throughout the plant lifetime. In such instances, tens of thousands of activities (e.g., maintenance, surveillance) are performed in a short amount of time (typically 2-3 weeks unless major backfitting or modernization projects are carried out) by a large number of crews (e.g., electricians, mechanics) that are hired as contractors. As a consequence, a plant outage can be expensive not only in terms of costs (e.g., contractor labor, material), but also in terms of loss generation since the plant is taken off the grid during the full outage duration (an indicative metric is about 1.2M$/day of loss of revenue). Thus, there is a continuous need to decrease the economic impact of outages on plant finances. This can be done by: decreasing the frequency of plant outages (e.g., from 18 to 24 months), reducing the time to complete the outage, and reducing the risk of outage delays. The Optimization of Outage Activities project under the Risk Informed Systems Analysis Pathway (RISA) sponsored by Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program focuses on developing tools and methods to support NPPs with outage schedule optimization. The developed tools and methods are designed to analyze plant outage schedule with the goal of identify critical elements in the schedule that might pose a high risk of delays. These methods and tools can be considered resource-centric in the sense that they address outage challenges as a resource optimization problem. In this context, resources are either time and crews; outage delays occurs when either (or both) resources are insufficient to complete the set of tasks assigned at a specific time instant of the outage. This report provides details on how plant resources (time and crews) can be allocated in such a way that delays are minimized. In this respect, two classes of methods have been developed: the first one focuses on the time resource and how variability of the time to complete outage tasks may impact outage delays. The second one integrates available resources to assess when dailies activities should be performed such that the risk of outage delays are minimized.

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DISCOVARY PROJECT: Material Background Report

UC/UO 2 composites have been proposed as a next generation fuel for light water reactors (LWRs). Accident tolerant fuels (ATF) have been a focus in the Advanced Fuels Campaign (AFC) to improve the safety and performance of LWRs and includes research and development efforts on the cladding and fuel. The 10 wt.% UC/UO 2 composite fuel was selected as a result of an extensive literature review and was selected due to the improvement of the fuel cycle cost. The inclusion of a UC phase in the composite material improves on the properties of standard UO 2 by increasing the uranium density of the fuel and increasing the thermal conductivity. Significant development has been carried out to refine the processing and sintering parameters and has led to a dense composite without ternary phases present. Characterization of the chemistry and microstructure has been carried out to send ahead of neutron irradiations in the Belgium Research Reactor (BR2) at SCK-CEN.

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Recent High Burnup LOCA Testing at Oak Ridge National Laboratory

To improve fuel cycle economics, increasing the fuel burnup limit in light-water reactors requires a solid technical foundation. Observations from experiments at Halden and Studsvik highlighted severe fuel fragmentation during loss-of-coolant-accident (LOCA) conditions, indicating a need for further technical considerations. These experiments suggest that the fragmentation threshold for high-burnup fuel might be influenced by pre-transient power levels. Consequently, additional LOCA test data are essential to complement existing findings and to deepen our understanding. Oak Ridge National Laboratory’s Severe Accident Test Station has been instrumental in advancing knowledge about high-burnup fuel fragmentation, relocation, and dispersal. This milestone report details two high-burnup LOCA tests designed to evaluate the effects of terminal temperature and grid spacers (or cladding restraints) on fuel fragmentation and relocation susceptibility. In addition, BISON fuel performance modeling and out-of-cell benchmark testing were conducted to better interpret the in-cell test results. These tests were developed in collaboration with fuel vendors to ensure that the results provide valuable data for topical reports and support the Nuclear Regulatory Commission’s review.

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Accelerated Irradiation and Qualification of Ceramic Nuclear Fuels

Accelerated neutron irradiation testing is an component of accelerated qualification of new nuclear fuels for light water reactor (LWRs), microreactors, and other special purpose reactors. The qualification and licensing of nuclear fuel is a lengthy process that can take 20-25 years to bring a new fuel into service. Accelerated fuel qualification combines both experimental and modeling work to expedite the total qualification time to 5-10 years timeframe. The experimental aspect of this is accelerated irradiation aims to reduce the total time needed for neutron irradiation to achieve targeted burnup, which can take years using conventional irradiation profiles. The data that results from this irradiation testing can then be entered into BISON models to develop robust and reliable performance simulations to ensure safe operation under normal and off normal conditions. This milestone focused on the fabrication of test articles for accelerated irradiation testing at the Advance Test Reactor (ATR).

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An Integrated Framework for Risk Assessment of Safety-related Digital Instrumentation and Control Systems in Nuclear Power Plants: Methodology Advancement and Application

This report documents activities performed by Idaho National Laboratory (INL) during fiscal year (FY) 2024 for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program, Risk Informed Systems Analysis (RISA) Pathway, Digital Instrumentation and Control (DI&C) Risk Assessment project. The goal of the RISA Pathway is to optimize safety margins and minimize uncertainties to achieve economic efficiencies while maintaining high levels of safety. This is accomplished by providing scientific basis to better represent safety margins and factors that contribute to cost and safety, and by developing new technologies that reduce operating costs. The research efforts for FY 2024 encompass methodology refinement and exploration. The efforts include: (1) The implementation of a natural language processing tool to expedite key aspects of the reliability analysis methods developed by INL; (2) advances to support intersystem CCF analysis by providing guidance for and identification of coupling mechanisms that may contribute to CCF; (3) the investigation of how generative artificial intelligence tools can aid in hazard analysis and diversity and defense in depth (i.e., D3) assessments; (4) Industry collaboration, allowing the demonstration of and INL's risk assessment tools to support risk assessment of DI&C systems at early and late stages of development; (4) a roadmap for the development of a software for each of INL's risk assessment tools; (5) The development of a theory and methodology manual for a risk quantification methodology; (6) the development of a reliability analysis for machine learning (ML)-integrated control systems.

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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.

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C Modules Enrichment

Module C1 discusses the step in the nuclear fuel cycle where the UF6 solid in cylinders from the conversion plant is processed to enrich the percentage of U-235 from 0.711% to the 3–5% typical of the enrichment used for light-water reactor nuclear fuel fabrication. It involves receipt of UF6 feed stock in 12.5 ton cylinders, enrichment operations, formation of enriched UF6 solid, and shipment of 2.3 ton cylinders to fuel fabricators. In this module, “SWU” is taken as shorthand for kg-SWU, the formal units for enrichment work, assuming that heavy metal mass flows will be gauged in kg.

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Development and Refinement of Bison Models for Higher Burnup Application

Electric Power Research Institute (EPRI) is an international research organization funded by organizations in the energy and government sectors. The company conducts research to tackle the energy challenges of its member organizations. In support of the U.S. nuclear industry, EPRI and Idaho National Laboratory were awarded a U.S. Department of Energy Technology Commercialization Fund to develop a loss of coolant accident (LOCA) analysis tool. This tool was developed to support burnup extension activities by supplementing the existing capabilities of operators of existing large light-water reactor plants. The tool couples INL developed codes Bison and RELAP5-3D for advanced simulation of LOCA behavior. The project consists of seven major tasks, one of which is the development and refinement of Bison models for higher burnup applications. This task is broken down into six targeted areas of development and refinement including: formation of high burnup structure, fuel fracture and pulverization, transient fission gas release, axial gas communication within a fuel rod, cladding ballooning and burst, and axial fuel relocation. This report summarizes the models for both the fuel and cladding in Bison for high burnup application, identifies the areas of development and refinement necessary to enhance the Bison capabilities to be used in the coupled simulation tool with RELAP5-3D. Integration and regression testing to demonstrate proper implementation of the new features in Bison is highlighted.

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Post-irradiation Examination Status for the BSU-269 Project

High-density uranium inter-metallic uranium silicide (U 3 Si 2 ) was initially considered as a potential advanced nuclear fuel for light water reactor (LWR) systems due to several advantages it demonstrated in thermophysical properties, chemical, and irradiation stability. In addition to understanding the basic thermophysical and mechanical properties of U 3 Si 2 under LWR irradiation conditions, it is important to assess its performance with advanced claddings such as FeCrAl, SiC, or conventional Zr-based claddings. Several aspects of the fuel cycle and fuel performance are being evaluated for U 3 Si 2 coupled with different types of claddings. To thoroughly characterize the U 3 Si 2 -cladding system, their chemical compatibilities and the potential for fuel-cladding chemical interaction (FCCI) must be addressed. Interdiffusion studies have been performed between U 3 Si 2 /Zry-4 and U 3 Si 2 /FeCrAl using diffusion couples. For the U 3 Si 2 /Zry-4 system, ZrSi 2 was the primary interdiffusion product observed at 800°C in addition to other secondary phases from the Zr alloying elements such as Fe and Cr. Low melting point U 6 Fe was also observed at 1000°C. For the U 3 Si 2 /FeCrAl system, at temperatures above 500°C, chemical diffusion Fe-U and Fe-U-Si was observed, increasing with rising temperatures. Although information from these non-irradiated tests is a fundamental first assessment, follow-up with focused irradiation tests is necessary. Irradiation can significantly alter the structure and evolution of the FCCI layers compared to the non-irradiated conditions.

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Accident Tolerant Fuel Test (ATF-2c) Irradiation Test Report

A new fully prototypic testing platform for testing new accident tolerant fuel (ATF) designs for light water reactors has been established in the center flux trap of Idaho National Laboratory’s advanced test reactor (ATR). The irradiation experiment named ATF-2C has completed its first cycle of prototypic steady state irradiation. Irradiation conditions have been maintained via the loop 2a pressurized water coolant loop and have been monitored through in-situ instrumentation during each cycle. Power and fast neutron flux histories of each of the 24 test pins has been calculated.

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