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DOE OSTI2014

Jointly Sponsored Research Program on Energy Related Research

Cooperative Agreements, DE-FC26-08NT43293, DOE-WRI Cooperative Research and Development Program for Fossil Energy-Related Resources began in June 2009. The goal of the Program was to develop, commercialize, and deploy technologies of value to the nation’s fossil and renewable energy industries. To ensure relevancy and early commercialization, the involvement of an industrial partner was encouraged. In that regard, the Program stipulated that a minimum of 20% cost share be achieved in a fiscal year. This allowed WRI to carry a diverse portfolio of technologies and projects at various development technology readiness levels. Depending upon the maturity of the research concept and technology, cost share for a given task ranged from none to as high as 67% (two-thirds). Over the course of the Program, a total of twenty six tasks were proposed for DOE approval. Over the period of performance of the Cooperative agreement, WRI has put in place projects utilizing a total of $\$$7,089,581 in USDOE funds. Against this funding, cosponsors have committed $\$$7,398,476 in private funds to produce a program valued at $\$$14,488,057. Tables 1 and 2 presented at the end of this section is a compilation of the funding for all the tasks conducted under the program. The goal of the Cooperative Research and Development Program for Fossil Energy-Related Resources was to through collaborative research with the industry, develop or assist in the development of innovative technology solutions that will: • Increase the production of United States energy resources – coal, natural gas, oil, and renewable energy resources; • Enhance the competitiveness of United States energy technologies in international markets and assist in technology transfer; • Reduce the nation's dependence on foreign energy supplies and strengthen both the United States and regional economies; and • Minimize environmental impacts of energy production and utilization. Success of the Program can be measured by several criteria. Using the deployment of the federal funding with industrial participation as a performance criterion, over the course of the program, the cosponsors contributed more dollars than the federal funds. As stated earlier, a little more than half of the funding for the Program was derived from industrial partners. The industrial partners also enthusiastically supported the research and development activities with cash contribution of $\$$4,710,372.67, nearly 65% of the required cost share. Work on all of the tasks proposed under the Cooperative Agreement has been completed. This report summarizes and highlights the results from the Program. Under the Cooperative Agreement Program, energy-related tasks emphasized petroleum processing, upgrading and characterization, coal and biomass beneficiation and upgrading, coal combustion systems development including oxy-combustion, emissions monitoring and abatement, coal gasification technologies including gas clean-up and conditioning, hydrogen and liquid fuels production, and the development of technologies for the utilization of renewable energy resources. Environmental-related activities emphasized cleaning contaminated soils using microbial fuel cells, development of processes and sorbents for emissions reduction and recovery of water from power plant flue gas, and biological carbon capture and reuse. Technology enhancement activities included resource characterization studies, development of improved methods, monitors and sensors. In general the goals of the tasks proposed were to enhance competitiveness of U.S. technology, increase production of domestic resources, and reduce environmental impacts associated with energy production and utilization. Technologies being brought to commercialization as a result of the funds provided by the Cooperative Agreement contribute to the overall goals of the USDOE and the nation. Each has broad applicability both within the United States and abroad, thereby helping to enhance the competitiveness of U.S. energy technologies in international markets and assisting in technology transfer. Under the Cooperative Agreement Program, WRI has furthered the development of two different coal upgrading technologies. River Basin Energy technology was scaled-up and demonstrated at a nominal 40 tpd size. Similarly, WRI’s patented mercury removal technology further developed into WRITE Coal technology which was then integrated into oxy-combustion and gasification systems for IGCC and fuels production. Integrated systems with WRITE Coal technology applied at the front end represent substantial environmental and efficiency gains. A variation of the RBE coal upgrading technology is being commercialized as a torrefaction technology for woody biomass. WRI worked with EPRI and NIST to develop and improve mercury calibration standards for emissions monitoring. Working with Chart Energy and Chemicals, WRI scaled-up compact reactor technology for the synthesis of fuels and chemicals from syngas. Compact reactor technology represents a five-fold increase in productivity over conventional reactors making smaller-scale distributed synthesis plants an economical viability. Similarly, WRI's patented mixed alcohol synthesis catalyst production is being scaled-up in collaboration with a commercial catalyst manufacturer.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

Technology Development for Aluminum-clad Spent Nuclear Fuel for Extended Dry Storage (Status Report)

A task group under the Spent Nuclear Fuel Working Group of the U.S. Department of Energy (DOE), Offices of Environmental Management (EM) and Nuclear Energy (NE) identified technical challenges (“information gaps"’) to the ability to provide for safe extended (>50 years) dry storage of Aluminum-Clad Spent Nuclear Fuel (ASNF) in a report issued in 2017, An Action Plan was developed, and a task- based program was launched under the sponsorship of DOE-EM, Office of Technology Development (EMTD) in October 2018 to close the gaps and complete the technical information set needed to implement extended dry storage with confidence. This interim status report summarizes the work to date of this EMTD program to complete the technical bases and demonstrate that extended dry storage is safe and viable.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

A regional inter-disciplinary partnership focusing on the development of a carinata-centered bioeconomy

Brassica carinata or Ethiopian mustard, a non-edible oilseed brassica, is a low carbon, purpose-grown, and none-to-low indirect land-use change bioenergy feedstock for the production of drop-in sustainable aviation fuel, biodiesel, renewable diesel, and a suite of value-added coproducts. Carinata oil converted to drop-in fuel using an American Society for Testing and Materials approved Catalytic Hydrothermolysis process has been successfully tested in commercial and military aviation. Carinata meal, the residue after oil extraction, is a high-protein feed supplement for livestock, poultry, and swine, and can also yield specialty products. The Southeast Partnership for Advanced Renewables from Carinata (SPARC) is a public–private partnership formed with a twofold mission: (1) Removing physical, environmental, social, and economic constraints that prevent regional intensification of carinata production as a low-carbon feedstock for renewable fuel and coproducts and (2) demonstrating enhanced value across the entire value chain by mitigating risk to farmers and other stakeholders. The partnership's goal is to energize the US bioeconomy through sustainable agriculture and thus contribute to energy security and economic diversification. SPARC relies on a combination of cutting-edge multidisciplinary research and active industry engagement to facilitate adoption of the crop. This involves informing stakeholders along the entire supply chain, from producers to end-users, policymakers, influencers, and the public, about the opportunities and best practices related to carinata. This article provides context and background concerning carinata commercialization as a winter cash crop in the Southeast US for renewable fuels and bioproducts. The advances made to date in the areas of feedstock development, fuel and coproduct development, meal valorization, supply chain logistics, and stakeholder engagement are outlined.

09 BIOMASS FUELS↗
DOE OSTI2016

Develop high activity, low cost non-PGM fuel cell electrocatalyst and stable supports

A unique approach has been developed to probe the non-PGM catalyst active site for the Oxygen Reduction Reaction (ORR) for PEMFC. Iron based functionalities have been engineered into Metallic Organic Framework (MOF) catalysts to evaluate their impact on activity for the ORR. A series of FePhen@MOF catalysts have been synthesized with varying [Fe] to investigate the effect on electrochemical and electrocatalytic properties. The magnitude of the Fe II/III redox couple and the electrochemical surface area are analyzed to determine if there is a correlation between [Fe] and the ORR onset potential and/or the relative number of active sites.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2019

A Python Package for Fuel Cycle and Waste Management Analysis - 19545

The future of nuclear power utilization in the United States may involve a transition from the once-through light water reactor fuel cycle to a so-called advanced fuel cycle. An advanced fuel cycle may offer improvements in natural resource utilization, reactor safety, and environmental impact. In addition, adoption of an advanced fuel cycle will result in changes in the amount, composition, and disposal of the nuclear wastes they produce. Characteristics intrinsic to the wastes themselves, such as mass and radioactivity at specific times, were used as waste management metrics in the Department of Energy 2014 Fuel Cycle Evaluation and Screening (FCES) study. Binning of these metrics informed fuel cycle according to relative potential benefit. However, waste properties alone cannot qualify management strategy. Therefore, comparing fuel cycles from the perspective of waste management can provide additional insights. To that end, an object-oriented Python package has been developed to perform fuel cycle waste management calculations. The package, named nwpy (short for Nuclear Waste analysis in Python), mimics the mass flow operations reported in the FCES study and interfaces with the ORIGEN-S code to assess metric data as reported in the FCES. In addition, this Python package determines the loading of waste streams into forms suitable for final disposal in a geological repository and uses such data for repository performance assessment. This work describes the Python package methodology, assumptions, and capabilities. As input data, the package requires information about the fuel cycle such as the mass of fuel discharged, the cooling time between reactor discharge and subsequent operations, and the separations process efficiencies and waste forms it produces. In addition, the isotopic composition of the reactor discharge stream, such as that available from the FCES database, is required. With that, it can perform prescribed mass flow and decay operations throughout the back end of the fuel cycle, the latter carried out by the ORIGEN-S code distributed with the SCALE6.2 software suite. The result is time-dependent data characterizing the waste on a per-package basis. Package loading for waste streams depends on the stream form (i.e. UNF vs. HLW, or glass HLW from aqueous reprocessing vs. ceramic HLW from electrochemical processing) and is based on literature review and engineering assumption. As an example of the application of the code, calculations for the areal footprint of direct-contact repositories for different fuel cycles is shown. Development is ongoing, and the package is expected to grow incorporating capabilities for waste management analyses such as waste transportation and radionuclide transport through the biosphere. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Co-Optimization of Fuels & Engines: Efficiency Merit Function for Spark-Ignition Engines; Revisions and Improvements Based on FY16-17 Research

Early in fiscal year 2016 (FY16), a fuel efficiency 'merit function' was developed to provide a simple tool to evaluate the potential thermal efficiency benefits of various fuels when multiple fuel properties or performance metrics are changing simultaneously. It has also proven to be useful for evaluating various fuel candidates and provides a useful framework for capturing and summarizing results from multiple projects within the Co-Optima Fuel Properties and Advanced Engine Development research portfolios. The objective of this report is to collect pertinent research results from FY16 and the first half of FY17, and to integrate them into an improved merit function.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Improved Fracture Models for Relocation Modeling

The BISON fuel performance code is being developed to provide a modern tool that has the flexibility to analyze a wide variety of fuel forms and to model conditions and phenomena that could not be represented in legacy tools. There are a number of motivations for this, including providing support for development of advanced fuel with improved accident tolerance for existing light water (LWR) reactors, improved understanding of mechanisms in fuel designs in current use in a wider variety of conditions, and facilitating the development of fuel for advanced reactor designs. To accomplish these goals, it is clear that BISON must rely on models of fuel behavior that are based on fundamental physical behavior, rather than on empirical correlations that represent that behavior in a simplified fashion. BISON still does employ many empirical models that were originally developed for other fuel performance codes, but efforts are underway to replace these with models that are more physically based. Radial relocation in LWR fuel is an example of a phenomenon that is currently represented by an empirical model, but which is ripe for replacement by physically based models. During normal operation, ceramic LWR fuel experiences significant fracturing that is driven by spatially nonuniform volumetric expansion. This occurs due to the significant thermal gradients within the fuel that occur in fresh and irradiated fuel, as well as nonuniform swelling due to fission products that occurs over longer-term irradiation. Fracture and fragmentation of fuel allows the outer radius of the fuel pellet to expand due to the loss of mechanical constraint and outward radial migration of fragments. This radial expansion has a significant effect on the fuel system response because it decreases the size of the gap between the fuel and cladding. This decreases the thermal resistance across that gap, which leads to decreased fuel centerline temperatures. This report documents recent work to improve the ability of BISON to model radial relocation using the extended finite element method (XFEM). These enhancements include the ability to include cohesive zone models, improved code architecture for propagating cracks based on fracture integrals, and improved handling of fuel and cladding interfaces with XFEM. These capabilities are demonstrated on a simulation of radial relocation including a surface interaction model that enforces residual opening.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Promising Fuel Cycle Options for R&D – Results, Insights, and Future Directions

The Fuel Cycle Options (FCO) campaign in the U.S. DOE Fuel Cycle Research & Development Program conducted a detailed evaluation and screening of nuclear fuel cycles. The process for this study was described at the 2014 ICAPP meeting. This paper reports on detailed insights and questions from the results of the study. The comprehensive study identified continuous recycle in fast reactors as the most promising option, using either U/Pu or U/TRU recycle, and potentially in combination with thermal reactors, as reported at the ICAPP 2014 meeting. This paper describes the examination of the results in detail that indicated that there was essentially no difference in benefit between U/Pu and U/TRU recycle, prompting questions about the desirability of pursuing the more complex U/TRU approach given that the estimated greater challenges for development and deployment. The results will be reported from the current effort that further explores what, if any, benefits of TRU recycle (minor actinides in addition to plutonium recycle) may be in order to inform decisions on future R&D directions. The study also identified continuous recycle using thorium-based fuel cycles as potentially promising, in either fast or thermal systems, but with lesser benefit. Detailed examination of these results indicated that the lesser benefit was confined to only a few of the evaluation metrics, identifying the conditions under which thorium-based fuel cycles would be promising to pursue. For the most promising fuel cycles, the FCO is also conducting analyses on the potential transition to such fuel cycles to identify the issues, challenges, and the timing for critical decisions that would need to be made to avoid unnecessary delay in deployment, including investigation of issues such as the effects of a temporary lack of plutonium fuel resources or supporting infrastructure. These studies are placed in the context of an overall analysis approach designed to provide comprehensive information to the decision-making process.

continuous recycle↗
DOE OSTI2014

Fuel Performance Experiments and Modeling: Fission Gas Bubble Nucleation and Growth in Alloy Nuclear Fuels

Advanced fast reactor systems being developed under the DOE's Advanced Fuel Cycle Initiative are designed to destroy TRU isotopes generated in existing and future nuclear energy systems. Over the past 40 years, multiple experiments and demonstrations have been completed using U-Zr, U-Pu-Zr, U-Mo and other metal alloys. As a result, multiple empirical and semi-empirical relationships have been established to develop empirical performance modeling codes. Many mechanistic questions about fission as mobility, bubble coalescience, and gas release have been answered through industrial experience, research, and empirical understanding. The advent of modern computational materials science, however, opens new doors of development such that physics-based multi-scale models may be developed to enable a new generation of predictive fuel performance codes that are not limited by empiricism.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Methodology for the development of empirical models relating 13C NMR spectral features to fuel properties

Effective formulation of new gasoline or diesel fuels for internal combustion engines would benefit from the development of reliable models for predicting key fuel properties based on a set of molecular descriptors obtained from a single measurement. This is particularly relevant in the case of renewable fuels, where the available fuel sample quantity may be limited. In this work, we present a statistically-based methodology for building empirical models to predict multiple properties from one-dimensional 13C nuclear magnetic resonance (NMR) spectra measured on around 200 microliters of a liquid fuel. NMR spectra contain information about the molecular composition of a sample and the carbon types and molecular substructures therein. Our approach uses this information to build sparse, interpretable models, where the predicted properties are linked to specific molecular features. The approach takes into consideration the constrained nature of the features making up the one-dimensional NMR spectrum, which, after standardization, represent a relative fuel composition. We point to the limitations in interpretability that arise when building this type of empirical predictive model and suggest how these limitations may be diminished. Among the many properties important for maximizing engine performance and minimizing emissions, we build models that predict derived cetane number and distillation temperatures as these are of particular interest because of their links to fuel economy, drivability, and engine-out emissions. Results suggest that the properties of interest may be impacted by only a few of the 27 13C NMR regions represented in the data, pointing to new directions for further testing in the development of improved fuels.

predictive models, biofuels., NMR Analysis↗
DOE OSTI2021

Dynamical System Scaling Application to Zircaloy Cladding Thermal Response During Reactivity-Initiated Accident Experiment

New fuel design and development currently requires 20 to 25 years to be qualified for use by the nuclear power industry. The thermal-hydraulics community has taken advantage of scaling theory to design reduced scale experiments that correctly preserve dominant key phenomena while quantifying distorted phenomena. These techniques can be leveraged in the design and analysis of fuel performance experiments to help reduce the timeline associated with fuel design and development. This study uses the Dynamical System Scaling (DSS) method to analyze cladding temperature data from the recent SETH-C experiment in the TREAT facility and accompanying BISON simulations to assess dynamic distortions occurring throughout the fast power excursion transient. The DSS analysis revealed that on the cool down from peak cladding temperature that the fuel radial power profile is the most sensitive modeling parameter with a heterogenous radial peaking factor corresponding to the lowest distortion compared to a uniform energy deposition. For the heat up to peak cladding temperature the heterogeneous radial power profile corresponded to the shortest process action. Finally, for the heat up to peak cladding temperature, the gap conductance model sensitivity was quantified using process action and shows that the default Light Water Reactor gap conductance model corresponded to the longest process action.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Development of criticality risk evaluation method for fuel debris in Fukushima Dai-ichi NPS - 14373

After the accident of Fukushima Dai-ichi Nuclear Power Station, there has been still damaged nuclear fuel in the reactor buildings, which is called 'fuel debris' and contains an amount of fissile materials show that it is currently subcritical, which must be kept until finishing retrieval work. In the latest plan, retrieving fuel debris is to start in 2025. The International Research Institute for Nuclear Decommissioning, IRID, has been developing the technology for decontamination in reactor building. A developed method will be reviewed and granted by the Nuclear Regulatory Authority in Japan, NRA, before the start of the retrieving. Criticality risk information will be needed for decision making on following two subcriticality issues, -Criticality control of fuel debris to keep is subcritical until the end of retrieval work. -Safe operation for retrieving fuel debris to keep it subcritical. Because fuel debris has been out of criticality control and the key condition for its current subcriticality is unknown, it is important to obtain criticality risk information as soon as possible. Applying conventional Probabilistic Safety Assessment, PSA, to fuel debris is difficult, because it is based on the probability of becoming out of criticality control due to troubles such as equipment failure, operation mistake and so on. A new method, which has been developed by Japan Atomic Energy Agency to technically support the NRA, is designed to estimate criticality risk based on a probability distribution of k{sub eff} due to uncertainty of composition and geometry of fuel debris, which method will provide risk information for the two subcriticality issues as well as for the tolerance level of criticality risk if it is unavoidable. Developed method contains four steps: two steps of analysis of criticality risk and two steps of quantification of the risk. A procedure of risk quantification has been defined, in which systematic analysis of criticality risk can be done by making 'status matrix'. A trial analysis by using the procedure shows that some events which can initiate criticality are able to be supposed to happen during maintenance period until the beginning of retrieving fuel debris, and that analysis also indicates countermeasures should be considered as soon as possible in order to reduce criticality risk for public and workers. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Developing an Energy-Conscious Traffic Signal Control System for Optimized Fuel Consumption in Connected Vehicle Environments

The project titled “Developing an Energy-Conscious Traffic Signal Control System for Optimized Fuel Consumption in Connected Vehicle Environments” addresses energy-related challenges associated with adaptive traffic control systems by integrating connected vehicles (CV) and connected infrastructure (CI). The system developed in this project, a CV-based adaptive traffic control system, aims to improve fuel consumption in mixed traffic environments by capitalizing on emerging CV and CI communication technologies, as well as leveraging recent advances in Artificial Intelligence (AI), optimization, and edge computing. The system was tested at the MLK Smart Corridor, an urban testbed managed by the University of Tennessee at Chattanooga (UTC) and the City of Chattanooga. The system was validated through extensive simulations, both Software-in-the-Loop (SILS) and Hardware-in-the-Loop (HILS), and was further implemented and tested in real-world conditions at several intersections along the corridor. The Fuel Consumption Performance Index (FC-PI) and the Ecological Performance Index (Eco-PI) were developed as the key components for evaluating the system’s impact on fuel consumption and emissions. These metrics provided a comprehensive means of understanding the impact of traffic signal control optimization in mixed traffic environments. The report presents an in-depth analysis of the Eco-PI, FC-PI, adaptive traffic control system integration, and the testing and field implementation of the system. The results demonstrate significant reductions in fuel consumption and emissions, showcasing the system’s capability to contribute to more sustainable urban traffic management. The report also documents the challenges encountered and recommendations for scaling and further improving the system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Alternative Fabrication of Volatile Metal Fuel Slugs for Sodium-cooled Fast Reactor

In order to develop alternative fabrication method of fuel slugs for preventing the evaporation of volatile elements such as AM,U-10wt.%Zr-Mn fuel slugs for SFR (: Sodium-cooled Fast Reactor) have been fabricated by modified casting method and characterized to evaluate the feasibility of the alternative fabrication. Metal fuels such as U-Zr/U-Pu-Zr alloys have been considered as a nuclear fuel for a sodium-cooled fast reactor (SFR) related to the closed fuel cycle for managing minor actinides and reducing a high radioactivity levels since the 1980's In order to develop innovative fabrication method of metal fuel slugs for preventing the evaporation of volatile elements such as Am, modified casting under inert atmosphere has been applied for metal fuel slugs for SFR. Alternative fabrication method of fuel slugs has been introduced to develop an improved fabrication process of metal fuel for preventing the evaporation of volatile elements. In this study, U- 10wt.%Zr-Mn fuel slugs for SFR have been fabricated by modified casting method and characterized to evaluate the feasibility of the alternative fabrication method. Alternative casting such as modified casting has been applied to develop fabrication method of fuel slugs for preventing the evaporation of volatile elements such as Am. U-10wt.%Zr-Mn containing a volatile surrogate Mn fuel slugs was soundly fabricated under inert atmosphere with dimensions of Φ5 - L 250 mm. Mass fraction of fuel loss was so low, up to 0.2%. Mn element was most recovered with prevention in evaporation of Mn. It was seen that the losses of volatile Am can be effectively controlled to below detectable levels using modest pressure. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Evaluating Cu/BEA Catalyst Performance with Techno-Economic Analysis to Develop a Market-Responsive Biorefinery Concept Around the Conversion of Methanol to High-Octane Hydrocarbons

A recent advancement in the conversion of methanol to hydrocarbon fuels is the development of a Cu-modified beta zeolite catalyst (Cu/BEA) that exhibits a higher productivity and yield than the parent H-form BEA catalyst in the production of branched C4-C8 hydrocarbons. This Cu/BEA catalyst enables process improvements in the High-Octane Gasoline (HOG) pathway, which operates under lower severity conditions than traditional methanol-to-fuels processes, offering a lower coke formation rate, higher selectivity to C5+gasoline-range hydrocarbons, and subsequently, improved process economics based on a recent process model and techno-economic analysis (TEA). Here, a market-responsive biorefinery concept around methanol and the HOG pathway is presented, where the major C4 products, isobutane and isobutene, serve as versatile intermediates that can either be recycled to increase the yield of the HOG product or directed to jet-fuel range hydrocarbons. Based on simulated recycle experiments with 13C-labeled isobutane, the Cu/BEA catalyst achieved increased yield to the HOG products during DME homologation by activating the co-fed isobutane and incorporating it into the chain growth pathway, as evidenced by the presence of isotopically-labeled 13C in C5+ products. Olefin coupling of an isobutene-rich mixture was also investigated, and the fuel properties of the resulting synthetic kerosene product were within the specifications for a typical jet-fuel. These experimental results were incorporated into an updated Aspen-based process model and TEA to quantify their impact on a market-responsive biorefinery concept. The improvements offered by C4 recycling with the Cu/BEA catalyst result in a decrease in the methanol-to-fuel synthesis cost from 101 cents per gallon of gasoline equivalent (GGE) with the baseline BEA catalyst to 72 cents/GGE, due in part to a significantly increased HOG yield from 40 to 55 GGE/dry-ton biomass. Expanding the process model to direct C4 products to a jet-range hydrocarbon product demonstrated a yield of 42 GGE/dry-ton HOG with 12 GGE/dry-ton distillate, resulting in a minor increase in the fuel synthesis cost to 77 cents/GGE versus the HOG-only case. With continued development, these advancements in fuel yield and reductions in cost position a market-responsive biorefinery around the HOG pathway to be competitive against mature fuel-synthesis technologies from a variety of carbon sources through methanol.

09 BIOMASS FUELS↗
DOE OSTI2026

Methods development towards automated, physics-informed, quantitative quality control of TRISO-SiC

Tristructural-isotropic (TRISO) fuel particles have been developed as a high-performance fuel for use in high-temperature gas-cooled reactor (HTGR) systems due to their high efficiency and stability under both normal and off-normal conditions. Broader deployment of this technology in advanced nuclear applications may benefit from quantitative quality assurance and quality control (QA/QC) methods that directly link TRISO properties to downstream performance. A key TRISO property is the SiC layer microstructure, which influences fission product retention during irradiation. However, existing QA/QC for the TRISO-SiC microstructure comprises only a qualitative visual inspection; therefore, there is a clear opportunity for the development of quantitative methods for TRISO QA/QC. Here, to this end, previous work has demonstrated an image processing approach to grain boundary (GB) identification and subsequent extraction of microstructural metrics; however, extensive twinning within the SiC layer complicates such analyses because twin GBs significantly influence microstructural metrics but are not expected to contribute to fission product transport. This study presents the initial development, training, and testing of an ML-based image segmentation algorithm designed to identify and remove twin GBs from standard backscattered electron micrographs, providing an industrially applicable, quantitative, and physically meaningful QA/QC approach for the TRISO-SiC microstructure. Although pixel-wise performance metrics for the twin predictions are low, the change in grain area and the number of GB pixels after twin removal predicted by the ML workflow are within 1% of the true values calculated using crystallographic data. This suggests that the model is well capable of predicting overall twin boundary structures and grain morphology, and continued advancement of this approach could enable automated, scalable, and physics-informed QA/QC for TRISO-SiC microstructures, supporting the reliable qualification of coated particle fuels for next-generation reactor systems.

Computer vision↗
DOE OSTI2017

Microstructure studies of interdiffusion behavior of U 3 Si 2 /Zircaloy-4 at 800 and 1000 °C

Fuel swelling during normal reactor operations could lead to unfavorable chemical interactions when in contact with its cladding. As new fuel types are developed, it is crucial to understand the interaction behavior between fuel and its cladding. Diffusion experiments between U 3 Si 2 and Zricaloy-4 (Zry-4) were conducted at 800 and 1000°C up to 100 hours. The microstructure of pristine U 3 Si 2 and U 3 Si 2 /Zry-4 interdiffusion products were examined using scanning electron microscopy (SEM) and transmission electron microscopy (TEM) equipped with an energy dispersive X-ray spectroscopy (EDS) system. The primary interdiffusion product observed at 800°C is ZrSi 2 , with secondary phases of U-Zr in the Zry-4, and Fe-Cr-W-Zr-Si phases at Zry-4/ZrSi 2 interface and Fe-Cr-U-Si phases at ZrSi 2 /U-Si interface. As a result, the primary interdiffusion products at 1000°C were Zr 2 Si, U-Zr-Fe-Ni, U, U-Zr, and a low melting point phase U 6 Fe.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Preliminary Evaluation of Alternate Designs for HFIR Low-Enriched Uranium Fuel

Engineering design studies of the feasibility of conversion of the High Flux Isotope Reactor (HFIR) from high-enriched uranium (HEU) to low-enriched uranium (LEU) fuel are ongoing at Oak Ridge National Laboratory (ORNL) as part of an effort sponsored by the U.S. Department of Energy s Global Threat Reduction Initiative (GTRI)/Reduced Enrichment for Research and Test Reactors (RERTR) program. The fuel type selected by the program for the conversion of the five high-power research reactors in the U.S. that still use HEU fuel is a new U-Mo monolithic fuel. Studies by ORNL have previously indicated that HFIR can be successfully converted using the new fuel provided (1) the reactor power can be increased from 85 MW to 100 MW and (2) the fuel can be fabricated to a specific reference design. Fabrication techniques for the new fuel are under development by the program but are still immature, especially for the complex aspects of the HFIR fuel design. In FY 2012, the program underwent a major shift in focus to emphasize developing and qualifying processes for the fabrication of reliable and affordable LEU fuel. In support of this new focus and in an effort to ensure that the HFIR fuel design is as suitable for reliable fabrication as possible, ORNL undertook the present study to propose and evaluate several alternative design features. These features include (1) eliminating the fuel zone axial contouring in the previous reference design by substituting a permanent neutron absorber in the lower unfueled region of all of the fuel plates, (2) relocating the burnable neutron absorber from the fuel plates of the inner fuel element to the side plates of the inner fuel element (the fuel plates of the outer fuel element do not contain a burnable absorber), (3) relocating the fuel zone inside the fuel plate to be centered on the centerline of the depth of the plate, and (4) reshaping the radial contour of the relocated fuel zone to be symmetric about this centerline. The present studies used current analytical tools to evaluate the various alternate designs for cycle length, scientific performance (e.g., neutron scattering), and steady-state and transient thermal performance using both safety limit and nominal parameter assumptions. The studies concluded that a new reference design combining a permanent absorber in the lower unfueled region of all of the fuel plates, a burnable absorber in the inner element side plates, and a relocated and reshaped (but still radially contoured) fuel zone will allow successful conversion of HFIR. Future collaboration with the program will reveal whether the new reference design can be fabricated reliably and affordably. Following this feedback, additional studies using state-of-the-art developmental analytical tools are proposed to optimize the design of the fuel zone radial contour and the amount and location of both types of neutron absorbers to further flatten thermal peaks while maximizing the performance of the reactor.

Renfro, David G.↗