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This report contains a summary of irradiation testing in the ATR of NTRD ATF 1 experiments performed at the INL in FY 2019. Additionally, three capsules met the sponsor-specified burnup targets, and five capsules were shipped from the ATR to the HFEF at INL.
In 2024 the Fuel Motion Monitoring System (FMMS), or Hodoscope, at the Transient Reactor Test Facility, is being expanded from 96 viewing channels to 192 viewing channels, effectively doubling the FMMS field of view. Here, this increase in capability will allow the FMMS to support larger scale fuel tests, encompassing height-of-core test devices, test devices with multi-pin fuel assemblies, and test devices with recirculating coolant flow. Work supporting the expansion included refurbishing 96 additional proton recoil scintillator (PRS) detectors, doubling the data acquisition system (DAS) installed architecture, improving time synchronization in the DAS, and new research to measure the PRS detector energy-dependent, fast-neutron detection efficiency. In addition, laboratory activities have produced an improved benchtop testing capability for assessing the DAS, time synchronization, and external start triggering, along with an updated capability to scan PRS detectors to develop a preliminary flat-field normalization prior to deployment to TREAT.
Saturn I, IB, and V launch vehicle progress - second stage launching, static test failure, fabrication progress, and fuel tank hydrostatic pressure test
Velocity and drop size measurements are reported for a swirl-stabilized, combusting spray. For the gas phase, three components of mean and fluctuating velocity are reported. For the droplets, three components of mean and fluctuating velocity, diameter, and number flux are reported. The liquid fuel utilized for all the tests was heptane. The fuel was injected using an air-assist atomizer. The combustor configuration consisted of a center-mounted, air-assist atomizer surrounded by a coflowing air stream. Both the coflow and the atomizing air streams were passed through 45 degree swirlers. The swirl was imparted to both streams in the same direction. The combustion occurred unconfined in stagnant surroundings. The nonintrusive measurements were obtained using a two-component phase/Doppler particle analyzer. The laser-based instrument measured two components of velocity as well as droplet size at a particular point. Gas phase measurements were obtained by seeding the air streams with nominal 1 micron size aluminum-oxide particles and using the measured velocity from that size to represent the gas phase velocity. The atomizing air, coflow air, and ambient surroundings were all seeded with the aluminum-oxide particles to prevent biasing. Measurements are reported at an axial distance of 5 mm from the nozzle. Isothermal single-phase gas velocities are also reported for comparison with the combusting case.
In aviation gas turbine combustors, many factors, such as the degree and extent of fuel/air mixing and fuel vaporization achieved prior to combustion, influence the formation of undesirable pollutants. To assist in analyzing the extent of fuel/air mixing, flow visualization techniques have been used to interrogate the fuel distributions during subcomponent tests of lean-burning fuel injectors. Discrimination between liquid and vapor phases of the fuel was determined by comparing planar laser-induced fluorescence (PLIF) images, elastically-scattered light images, and phase/Doppler interferometer measurements. Estimates of Sauter mean diameters are made by ratioing PLIF and Mie scattered intensities for various sprays, and factors affecting the accuracy of these estimates are discussed. Mie calculations of absorption coefficients indicate that the fluorescence intensities of individual droplets are proportional to their surface areas, instead of their volumes, due to the high absorbance of the liquid fuel for the selected excitation wavelengths.
Conclusions: Validated the fuel estimation procedure using flight test data. A good fuel model can be created if weight and fuel data are available. Error in assumed takeoff weight results in similar amount of error in the fuel estimate. Fuel estimation error bounds can be determined.
The multicomponent nature of and variability of biomass makes chemical upgrading via a single process stream to a single end use infeasible for most feedstocks. A more promising approach is to identify upgrading strategies (encompassing bioprocessing, catalysis, and separations) which valorize varied biomass fractions to distinct products to which each is best suited. A robust procedure to carry out this goal should incorporate comparison of various upgrading procedures as well as suitability of products to a slate of identified end uses. We applied this strategy to one biomass-derived feedstock, volatile fatty acids (VFAs) derived from wet waste arrested anaerobic digestion, by developing a computer program, VFA Upgrading to Liquid Transportation fUels Refinery Estimation (VULTURE) which evaluates VFA catalytic upgrading to liquid transportation fuels. VULTURE considers multiple separations, catalysis (ketonization, hydrogenation), and fuel application options, generating hundreds of candidate scenarios for a given VFA stream, then selects several promising strategies that optimize bio-content of products with properties best suited for target fuel types. We find that VFAs are upgraded most efficiently when separate light alcohol (C3-6) and heavy hydrocarbon or alcohol (C7-13) fractions are targeted to create gasoline and heavy-duty (diesel or jet) fuels or fuel blends. Surrogate property testing of VULTURE-recommended fuels reveals that most predictive models employed are robust, while rigorous process simulation shows that the simple unit operation assumptions used in VULTURE are largely accurate, especially for heavy-duty fuel synthesis. Techno-economic and life-cycle analyses show that VFA-derived fuels are profitable and have dramatically (=57%) lower carbon intensities than fossil analogs.
The H-Canyon facility is currently dissolving spent nuclear fuel, including Material Test Reactor (MTR) and High Flux Isotope Reactor (HFIR) fuel. Dissolution of aluminum spent nuclear fuel produces hydrogen and other NOx gases. A theory long held by H-Canyon Engineering and Facility Technical Advisors that the silver nitrate-coated berl saddles, present in the iodine reactor, used for off-gas treatment were acting as a catalytic hydrogen recombiner was captured during an external review of the Accelerated Basin Deinventory program. Results from a separate SRNL project using a Raman Spectrometer to monitor the offgas from the dissolution process indicated a lack of the expected hydrogen in the off-gas stream. To test this hypothesis, a laboratory scale iodine reactor was assembled and filled with silver nitrate-coated berl saddles. Testing with this laboratory scale reactor confirmed the recombination of hydrogen when a simulated dissolver off-gas was passed through the reactor containing silver nitrate-coated berl saddles at 173-188 °C. Control experiments performed with uncoated berl saddles resulted in no change to the hydrogen concentration after passing through the reactor. The residence time of the gas in the reactor was varied to determine if residence time had an impact on the amount of hydrogen recombination occurring. Results from these experiments indicated that at the shortest residence times tested (~5 seconds) recombination of the hydrogen still exceeded 90%; however, the percent recombination did increase at longer residence times, reaching 97.9% or greater for residence times over 10 seconds. Finally, testing performed with a simplified off-gas composition containing only hydrogen and air gave similar results, indicating that the presence of NO and N 2 O gases in the stream do not play a role in the recombination reaction.
The Transient Reactor Test Facility (TREAT) loss-of-coolant (LOC) and high-burnup (HBu) experiment series, along with the Severe Accident Test Station (SATS) HBu experiment series, are integral LOC accident (LOCA) experiments planned under the DOE AFC program, which aim to support burnup extension needs by addressing identified R&D priorities in order to achieve an improved understanding of fuel fragmentation, relocation, and dispersal (FFRD) of HBu fuel during LOCA events. The data produced under this plan will be used to further validate and confirm existing models and inform future R&D and model development. The experimental program has been specifically designed to address knowledge gaps and opportunities identified through a detailed review of existing public knowledge on LOCA FFRD. The test program employs a unique combination of in- and out-of-pile experimental approaches and state-of-the-art facilities to provide a clear connection to the existing integral and semi-integral LOCA experiment database. The primary goal of the program is to investigate the impact of prototypic HBu fuel/cladding thermomechanical behaviors under postulated LWR LOCA conditions that have not yet been fully studied. These conditions correspond with prototypic decay-energy heatup (DEH) and stored-energy heatup (SEH) conditions. Importantly, TREAT’s unique capability will enable the first evaluation of the impact of SEH conditions on HBu fuels. The test program will emphasize the development of an improved mechanistic understanding of key experimental phenomena through independent experimental systems, development of a database to support fuel performance modeling tools and employing world-leading advanced materials characterization and in-situ diagnostics to evaluate FFRD. The results of the program will provide novel data to support modeling development and validation and will represent a significant advancement in evaluating prototypic conditions, as well as to inform the technical basis for LOCA-induced FFRD.
The High Load Charger (HLC) cask will be replacing the Advanced Test Reactor (ATR) spent fuel transfer cask that has been used at Idaho National Laboratory (INL) to wet-transfer spent ATR fuel elements from ATR to Idaho Nuclear Technology and Engineering Center (INTEC) in order to support future plans at both facilities. INTEC intends to discontinue use of the CPP-666 storage pools in compliance with the Idaho Settlement Agreement and the basins will no longer be available to store spent ATR fuel elements. In order to support the core-internals change out in 2021 for ATR, spent ATR fuel elements must be removed from the canal and shipped to INTEC. INL contractors will use the HLC cask for safe, dry transfer of spent Advanced Test Reactor (ATR) fuel elements between the ATR Complex managed by Battelle Energy Alliance, LLC and the Idaho Nuclear Technology and Engineering Center (INTEC) managed by Fluor Idaho, LLC. The HLC cask (also known as the High Load Charging Cask or High Load Charger) is a lead-shielded, stainless steel transfer container originally designed in 1954 by the Idaho Nuclear Corporation to meet the radiation and contamination controls requirements of the time for shipment of spent nuclear fuel. The cask has been modified over the years and is currently used for wet-to-dry transfers at INTEC. It is approved only for out-of-commerce transfers. The cask will arrive at the ATR where eight spent ATR fuel elements will be loaded into two, newly-designed buckets. Each bucket is a quarter section, right-cylinder shape that has four compartments. The cask will be lifted out of the ATR canal allowing most of the water to drain from the cask. Processing the 12,500 kg cask will be completed in ATR and then transported on a tractor trailer to INTEC where the loaded buckets will be removed from the cask. The loaded buckets will undergo a drying process before placing the four buckets into a canister for long-term storage in the Irradiated Fuel Storage Facility (IFSF) at INTEC. A new transportation plan that was submitted to, and approved by, the U.S. Department of Energy to provide the cask safety basis, which describes the hazard analysis and accident analysis for the cask during transport. Supporting accident analysis include criticality, thermal, dose, and drop analyses. Of particular interest for this cask was the drop analysis from which was derived the speed limit for the transport. The drop analysis addressed drops in air onto an unyielding surface and in water onto an energy-absorbing pad for the cask in the ATR facility. These analyses are typically applied as the bounding drop scenarios during transport; however, this resulted in a safety basis speed limit of 12.9 kph. In order to more accurately represent the in-transit accident scenario, LS-DYNA software was procured and the model was updated to more closely represent the potential drop heights and impact surfaces of asphalt and soil for the cask while in transit. This analysis resulted in a safety basis speed limit of 48 kph. This safety basis speed limit is more practical to implement and control. (authors)
The High Load Charger (HLC) cask will be replacing the Advanced Test Reactor (ATR) spent fuel transfer cask that has been used at Idaho National Laboratory (INL) to wet-transfer spent ATR fuel elements from ATR to Idaho Nuclear Technology and Engineering Center (INTEC) in order to support future plans at both facilities. INTEC intends to discontinue use of the CPP-666 storage pools in compliance with the Idaho Settlement Agreement and the basins will no longer be available to store spent ATR fuel elements. In order to support the core-internals change out in 2021 for ATR, spent ATR fuel elements must be removed from the canal and shipped to INTEC. INL contractors will use the HLC cask for safe, dry transfer of spent Advanced Test Reactor (ATR) fuel elements between the ATR Complex managed by Battelle Energy Alliance, LLC and the Idaho Nuclear Technology and Engineering Center (INTEC) managed by Fluor Idaho, LLC. The HLC cask (also known as the High Load Charging Cask or High Load Charger) is a lead-shielded, stainless steel transfer container originally designed in 1954 by the Idaho Nuclear Corporation to meet the radiation and contamination controls requirements of the time for shipment of spent nuclear fuel. The cask has been modified over the years and is currently used for wet-to-dry transfers at INTEC. It is approved only for out-of-commerce transfers. The cask will arrive at the ATR where eight spent ATR fuel elements will be loaded into two, newly-designed buckets. Each bucket is a quarter section, right-cylinder shape that has four compartments. The cask will be lifted out of the ATR canal allowing most of the water to drain from the cask. Processing the 12,500 kg cask will be completed in ATR and then transported on a tractor trailer to INTEC where the loaded buckets will be removed from the cask. The loaded buckets will undergo a drying process before placing the four buckets into a canister for long-term storage in the Irradiated Fuel Storage Facility (IFSF) at INTEC. A new transportation plan that was submitted to, and approved by, the U.S. Department of Energy to provide the cask safety basis, which describes the hazard analysis and accident analysis for the cask during transport. Supporting accident analysis include criticality, thermal, dose, and drop analyses. Of particular interest for this cask was the drop analysis from which was derived the speed limit for the transport. The drop analysis addressed drops in air onto an unyielding surface and in water onto an energy-absorbing pad for the cask in the ATR facility. These analyses are typically applied as the bounding drop scenarios during transport; however, this resulted in a safety basis speed limit of 12.9 kph. In order to more accurately represent the in-transit accident scenario, LS-DYNA software was procured and the model was updated to more closely represent the potential drop heights and impact surfaces of asphalt and soil for the cask while in transit. This analysis resulted in a safety basis speed limit of 48 kph. This safety basis speed limit is more practical to implement and control.
Many potential Accident Tolerant Fuel (ATF) technologies with the potential for making substantive improvements to the performance of Light Water Reactors (LWRs) in accident scenarios will require development and qualification timelines longer than 4 years. These technologies are named “Long Term” ATF. The attached report summarizes the irradiation testing capabilities available for use in the development and qualification of these technologies and presents a nominal test sequence.
The development of the technology required to operate an industrial gas turbine combustion system on minimally processed, heavy petroleum or residual fuels having high levels of fuel-bound nitrogen (FBN) while producing acceptable levels of exhaust emissions is discussed. Three combustor concepts were designed and fabricated. Three fuels were supplied for the combustor test demonstrations: a typical middle distillate fuel, a heavy residual fuel, and a synthetic coal-derived fuel. The primary concept was an air staged, variable-geometry combustor designed to produce low emissions from fuels having high levels of FBN. This combustor used a long residence time, fuel-rich primary combustion zone followed by a quick-quench air mixer to rapidly dilute the fuel rich products for the fuel-lean final burnout of the fuel. This combustor, called the rich quench lean (RQL) combustor, was extensively tested using each fuel over the entire power range of the model 570 K engine. Also, a series of parameteric tests was conducted to determine the combustor's sensitivity to rich-zone equivalence ratio, lean-zone equivalence ratio, rich-zone residence time, and overall system pressure drop. Minimum nitrogen oxide emissions were measured at 50 to 55 ppmv at maximum continuous power for all three fuels. Smoke was less than a 10 SAE smoke number.
The results obtained from fuel economy and emission tests conducted on a prototype Chrysler Volare diesel vehicle are documented. The vehicle was tested on a chassis dynamometer over selected drive cycles and steady-state conditions. The fuel used, was a DOE/BETC referee fuel. Particulate emission rates were calculated from dilution tunnel measurements and large volume particulate samples were collected for biological and chemical analysis. The vehicle obtained 32.7 mpg for the FTP urban cycle and 48.8 mpg for the highway cycle. The emissions rates were 0.42/1.58/1.17/0.28 g/mile of HC, CO, NOx and particulates respectively.
The back end of the fuel cycle focuses on the interim storage, transportation, and final disposition of the spent nuclear fuel from nuclear reactors. Commercial light water nuclear power stations across the United States operate with fuel assemblies being irradiated for up to 6 years (planned) in the reactor pressure vessel. After their planned irradiation, the fuel assemblies are moved to a spent fuel pool within the facility complex. After the spent nuclear fuel is removed from the fuel pool, it is typically inserted into a welded metal canister that can be transferred between overpacks for storage, transportation and possibly disposal. Most dry storage systems being used by industry today use dual purpose canisters (DPCs), designed for use in storage and transportation overpacks, but not specifically designed for disposal. Triple purpose-canisters, designed for disposal in addition to storage and transportation, have also been researched. Traditional manufacturing methods for spent fuel canisters involve fusion welding along the length or circumference of the canister which results in high tensile residual stresses in the joint weld zone (WZ) and heat affected zone (HAZ). In this paper, spent fuel canister designs were printed by wire arc additive manufacturing (AM) using the 316L SS welding wire to demonstrate: 1. Feasibility of spent nuclear fuel canister fabrication using this advanced manufacturing method, 2. Dynamic response of the additive manufacture canister design when subjected to the federally mandated Normal Conditions of Transport (NCT) and Hypothetical Accident Conditions (HAC) physical tests for Type B packages. This paper will focus on the canister printing design and structural tests. The AM 3D printed design, regulatory testing, and post-test evaluation of the canister tested to the 10 CFR 71.71 and 10 CFR 71.73 requirements will be presented. One AM canister design was subjected to the penetration, free drop, and puncture test. Before and after the dynamic structural tests, the AM canister design was scanned with a handheld scanner to capture a 3D CAD geometry to compare to the 3D printed canister design in the deformed shape. The scanned geometry was sectioned in areas with deformation and the cross-section profile was measured to determine accurate and repeated results of the deformed shape of the AM canister design.
The U.S. Department of Energy (DOE) is considering the development of one or more federal consolidated interim storage facilities (CISFs) to be used to store commercial spent nuclear fuel (SNF) at locations in the U.S. One of the first technical challenges of a CISF is performing an inspection of SNF canisters upon their receipt to confirm they can be placed into the CISF’s licensed storage configuration. The canister receipt inspection is critical to CISF site operations. The test is conceived as being a helium (He) leak check, intended to confirm that the confinement boundary of a SNF canister is intact. SNF canisters are filled with He when they are sealed, so detection of a He leak indicates that a through-wall flaw has occurred in the canister confinement boundary. Other measurements are planned to occur upon canister receipt in addition to the He leak check such as krypton-85 measurements, which would indicate confinement breaches of one or more fuel rods in addition to a breach of the SNF canister. However, the He leak check has been identified as one of such high importance and has such significant technical challenges that a full-scale demonstration is needed to confirm the He leak test’s viability and to assist in planning relative to its operational requirements. A modeling methodology for simulating the He detection test was developed to help inform the test plan and the design of the test vessels. To develop the modeling methodology a detailed computational fluid dynamics (CFD) benchmark model was constructed to compare against leak rate test data from a transportation package for radioactive material. This report is focused on modeling efforts to simulate the benchmark leak test.
The Transient Reactor Test (TREAT) facility resides at the Materials and Fuels Complex (MFC) at Idaho National Laboratory (INL). The TREAT reactor is currently undergoing design and engineering studies for its conversion from a high enriched uranium (HEU) to a low-enriched uranium (LEU) core. The conceptual design of the LEU fuel element identified two main design differences compared with the HEU fuel element; namely, it will contain four times more fissionable material in its graphite matrix and distinct nuclear-grade Zirconium alloy, as Zircaloy-3 was used in the HEU fuel assembly and is not commercially available currently. These design changes may impact the magnitude of chemical interaction between fuel and cladding materials during physical contact under expected TREAT operation conditions and, therefore, was evaluated through a combination of experimental testing and thermodynamic modeling in order to determine implications for the fuel assembly. In this study, two potential cladding material types, Zircaloy-4 or Zr-1Nb alloys, were evaluated, and it was found for both material types that the extent of interaction and specific chemical reactions are minimal and no detrimental effect on the overall cladding properties is observed. Here, the resulting interaction layer of 3-6 µm was measured after a 2-week exposure at 820°C. The thermodynamic analysis was extended to temperatures beyond the TREAT reactor operation and accident conditions in order to give some insight that may be of interest for other reactor systems as the High Temperature Gas Reactors (operation above 1,000°C) and for Nuclear Reactor Severe Accident phenomenology study where the UO 2 fuel could reach temperatures over 2,800°C and melt.
The performance and emissions for a downscaled single-cylinder 2-stroke crosshead engine were determined for a very low sulfur fuel oil (VLSFO) when blended with 10 wt.% fast pyrolysis (FP) or hydrothermal liquefaction (HTL) bio-intermediates. The FP and HTL oils were derived from biomass and were observed to contain lower molecular weight (MW) hydrocarbons than neat VLSFO (which was evaluated as a baseline comparison). The addition of either biofuel reduced the overall viscosity of the VLSFO. Aging tests at 50, 90, and 120°C showed that the dynamic viscosity of VLSFO increased with exposure time up to two weeks. Similar trends were observed for the FP and HTL blends, but a pronounced spike in viscosity occurred for these fuels during the early period of exposure. None of the viscosity increases exceeded the operational limits of fuel system pumps. Engine performance studies were conducted under low, medium and high load operational settings. The relative performance of the test fuels was highly dependent on operating condition. In general, the engine results for the three test fuels were similar, but modest improvements in brake thermal efficiency and brake specific fuel consumption were observed, which may be attributed to the heightened reactivity of low molecular weight fraction of the FP and HTL oils.