Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Fuel”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5

Reactor and fuel cycle performance of light water reactor fuel with 235 U enrichments above 5%

Recent advances in nuclear fuel materials research, particularly on the topic of accident-tolerant fuels, have brought up potential opportunities for expanding the operating envelope of existing light water reactors. As many of the performance improvements offered by these technologies may be most fully realized by increasing fuel enrichment beyond the standard 5% limit, this paper examines the potential reactor performance and fuel cycle performance of low-enriched uranium oxide fueled light water reactors by generically considering pressurized water reactors with 235 U enrichment from 5 to 7%. Advanced cladding, including accident-tolerant cladding, has the potential to increase fuel burnup limits related to hydrogen in the cladding that coincide with those limits associated with end-of-life reactivity. Therefore, higher enrichment will be necessary in order to realize the higher fuel burnups. This work includes evaluation of the fuel cycle length, discharge burnup, reactivity coefficients, and fuel cycle performance, including radioactive waste and environmental impact metrics per unit energy generated. The analysis was performed using the evaluation metrics from the US Department of Energy Office of Nuclear Energy Fuel Cycle Evaluation and Screening Study. The reactor performance and safety analysis show that enrichments between 5 and 7% would have similar fuel temperature and moderator temperature coefficients. However, the soluble boron coefficient would decrease in magnitude, requiring more corrosive boric acid in the coolant or other methods of reactivity control during the fuel cycle. At these higher enrichments the maximum burnup at the rim of the fuel pellet would increase by almost a factor of two, which is expected to impact the formation of high-burnup structure in the fuel and the corresponding thermo-mechanical fuel properties. The fuel cycle performance assessment shows that increasing enrichment reduces the quantity of high-level waste disposed per unit energy generated, but it increases the natural resource requirements normalized to a gigawatt-electricity-per-year basis. Another impact is the slightly higher discharge burnup, resulting in somewhat different activity levels of the spent nuclear fuel and high-level waste radioactivity at 100 and 100,000 years after fuel discharge. The environmental impacts—including land use, water use, carbon emission, and radiological exposure—are of the same magnitude per unit energy generated. Finally, however, the impacts are distributed differently. Less than 5% enrichment has marginally more impact on the back-end of the fuel cycle, and greater than 5% enrichment has marginally more impact on the front-end of the fuel cycle. Ultimately, no neutronic or reactor safety hindrances to employing light water reactor fuel with enrichments greater than 5% are identified; given the achievable reactor performance benefits with advanced fuels, further practical exploration of increased enrichment fuel is recommended.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Experimental Study of Molten Metallic Fuel Relocation in Sodium-Filled Fuel Structures

The Prototype Generation-IV Sodium-cooled Fast Reactor (PGSFR) is being developed by Korea Atomic Energy Research Institute (KAERI). While their design incorporates inherent safety features demonstrated in the landmark Shutdown Heat Removal Test (SHRT) conducted at EBR-II including a large pool configuration and uranium alloy fuel, it is still necessary to evaluate metal fuel relocation and theirs consequences in case of postulated core disruptive accidents. Extensive data regarding fuel relocation in sodium from both in-pile and out-of-pile tests were obtained for oxide fuels in the 1960's - 1970's, while few studies of metallic fuel behavior were performed because of concerns that metallic fuel could not achieve high burnup due to the irradiation induced swelling problem. Following new metal fuel design development that mitigated the swelling problem, experiments regarding interaction of molten metal fuels and liquid sodium have been conducted by several researchers. Most studies that were conducted using metal simulants in various liquids concluded that the molten metals were heavily fragmented after liquid contact and the dominant factors governing the fragmentation were superheating and latent heat of fusion of the molten metal fuel. Gabor et al. conducted experiments using kilogram quantities of various molten uranium alloys in an open sodium pool configuration. They found that the metal fuel fragments were basically in forms of filaments and sheets with a high bed voidage in the order of 0.9. Their calculation indicated that the debris beds formed by relocated metal fuels in an open sodium pool would be largely coolable by conduction heat transfer; and even if deep beds were to form, convective heat transfer and boiling heat transfer could preclude further melt penetration. Although Gabor's tests are useful in evaluating the coolability of relocated metal fuels during a postulated accident in a SFR, they focused on late phase behavior in which the core material relocates downward through the core support plate into the inlet plenum where the structures are more open and thus consistent with the open pool configuration. There is still a knowledge gap related to nature of metal fuel fragmentation and relocation within the fuel assembly structures. Argonne National Laboratory (ANL) is planning to conduct experiments regarding metal fuel relocation in the core structures which mock up the PGSFR's fuel assembly design. In the present study, preliminary tests for demonstration of melting and injecting the metal fuel were conducted using copper. Metal fuel relocation experiments with single fuel pin test section are planned to be conducted for understanding the flow and freezing behavior of the molten metal fuel in a narrow sodium channel and for evaluating the coolability of the relocated fuel. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Physics and technology considerations for the deuterium–tritium fuel cycle and conditions for tritium fuel self sufficiency

The tritium aspects of the DT fuel cycle embody some of the most challenging feasibility and attractiveness issues in the development of fusion systems. The review and analyses in this paper provide important information to understand and quantify these challenges and to define the phase space of plasma physics and fusion technology parameters and features that must guide a serious R&D in the world fusion program. We focus in particular on components, issues and R&D necessary to satisfy three 'principal requirements': (1) achieving tritium self-sufficiency within the fusion system, (2) providing a tritium inventory for the initial start-up of a fusion facility, and (3) managing the safety and biological hazards of tritium. A primary conclusion is that the physics and technology state-of-the-art will not enable DEMO and future power plants to satisfy these principal requirements. We quantify goals and define specific areas and ideas for physics and technology R&D to meet these requirements. A powerful fuel cycle dynamics model was developed to calculate time-dependent tritium inventories and flow rates in all parts and components of the fuel cycle for different ranges of parameters and physics and technology conditions. Dynamics modeling analyses show that the key parameters affecting tritium inventories, tritium start-up inventory, and tritium self-sufficiency are the tritium burn fraction in the plasma (f b ), fueling efficiency (η f ), processing time of plasma exhaust in the inner fuel cycle (t p ), reactor availability factor (AF), reserve time (tr) which determines the reserve tritium inventory needed in the storage system in order to keep the plant operational for time t r in case of any malfunction of any part of the tritium processing system, and the doubling time (t d ). Results show that η f f b > 2% and processing time of 1–4 h are required to achieve tritium self-sufficiency with reasonable confidence. For η f f b = 2% and processing time of 4 h, the tritium start-up inventory required for a 3 GW fusion reactor is ~11 kg, while it is <5 kg if η f f b = 5% and the processing time is 1 h. To achieve these stringent requirements, a serious R&D program in physics and technology is necessary. The EU-DEMO direct internal recycling concept that carries fuel directly from the plasma exhaust gas to the fueling systems without going through the isotope separation system reduces the overall processing time and tritium inventories and has positive effects on the required tritium breeding ratio (TBR R ). A significant finding is the strong dependence of tritium self-sufficiency on the reactor availability factor. Simulations show that tritium self-sufficiency is: impossible if AF < 10% for any η f f b , possible if AF > 30% and 1% ≤ η f f b ≤ 2%, and achievable with reasonable confidence if AF > 50% and η f f b > 2%. These results are of particular concern in light of the low availability factor predicted for the near-term plasma-based experimental facilities (e.g. FNSF, VNS, CTF), and can have repercussions on tritium economy in DEMO reactors as well, unless significant advancements in RAMI are made. There is a linear dependency between the tritium start-up inventory and the fusion power. The required tritium start-up inventory for a fusion facility of 100 MW fusion power is as small as 1 kg. Since fusion power plants will have large powers for better economics, it is important to maintain a 'reserve' tritium inventory in the tritium storage system to continue to fuel the plasma and avoid plant shutdown in case of malfunctions of some parts of the tritium processing lines. But our results show that a reserve time as short as 24 h leads to unacceptable reserve and start-up inventory requirements. Therefore, high reliability and fast maintainability of all components in the fuel cycle are necessary in order to avoid the need for storing reserve tritium inventory sufficient for continued fusion facility operation for more than a few hours. The physics aspects of plasma fueling, tritium burn fraction, and particle and power exhaust are highly interrelated and complex, and predictions for DEMO and power reactors are highly uncertain because of lack of experiments with burning plasma. Fueling by pellet injection on the high field side of tokamak has evolved to be the preferred method to fuel a burning plasma. Extrapolation from the DIII-D penetration scaling shows fueling efficiency expected in DEMO to be <25%, but such extrapolations are highly uncertain. The fueling efficiency of gas in a reactor relevant regime is expected to be extremely poor and not very useful for getting tritium into the core plasma efficiently. Gas fueling will nonetheless be useful for feedback control of the divertor operating parameters. Extensive modeling has been carried out to predict burn fraction, fueling requirements, and fueling efficiency for ITER, DEMO, and beyond. The fueling rate required to operate Q = 10 ITER plasmas in order to provide the required core fueling, helium exhaust and radiative divertor plasma conditions for acceptable divertor power loads was calculated. If this fueling is performed with a 50–50 DT mix, the tritium burn fraction in ITER would be ~0.36%, which is too low to satisfy the self-sufficiency conditions derived from the dynamics modeling for fusion reactors. Extrapolation to DEMO using this approach would also yield similarly low burn fraction. Extensive analysis presented shows that specific features of edge neutral dynamics in ITER and fusion reactors, which are different from present experiments, open possibilities for optimization of tritium fueling and thus to improve the burn fraction. Using only tritium in pellet fueling of the plasma core, and only deuterium for edge density, divertor power load and ELM control results in significant increase of the burn fraction to 1.8–3.6%. These estimates are performed with physics models whose results cannot be fully validated for ITER and DEMO plasma conditions since these cannot be achieved in present tokamak experiments. Thus, several uncertainties remain regarding particle transport and scenario requirements in ITER and DEMO. The safety standard requirements for protection of the public and release guidelines for tritium have been reviewed. General safety approaches including minimizing tritium inventories, reducing tritium permeation through materials, and decontaminating material for waste disposal have been suggested.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Fuel Cell Backup Power System for Grid-Service and Micro-Grid in Telecommunication Applications

This paper presents the feasibility and economics of using fuel cell backup power systems in telecommunication cell towers to provide grid services (e.g., ancillary services, demand response). The fuel cells are able to provide power for the cell tower during emergency conditions. This study evaluates the strategic integration of clean, efficient, and reliable fuel cell systems with the grid for improved economic benefits. The backup systems have potential as enhanced capability through information exchanges with the power grid to add value as grid services that depend on location and time. The economic analysis has been focused on the potential revenue for distributed telecommunications fuel cell backup units to provide value-added power supply. This paper shows case studies on current fuel cell backup power locations and regional grid service programs. The grid service benefits and system configurations for different operation modes provide opportunities for expanding backup fuel cell applications responsive to grid needs. The objective of this work primarily focuses on how fuel cells can become a significant part of the telecom backup power to reduce system costs, environmental impact, and dependence on fossil fuels, while ensuring continuity of indispensable service for mobile users. The study identifies the approaches on the fuel cell application through nano/microgrids for an extensive network of fuel cells as distributed energy resources. The possibilities of various application scenarios extend the fuel cell technologies and microgrid for reliable power supply.

30 DIRECT ENERGY CONVERSION↗

Fuel Safety Research Plan for Accident Tolerant Fuels

This document outlines a strategic plan for a safety research program for accident tolerant fuels. Accident tolerant fuels (ATFs) are nuclear fuel materials and designs for existing and future light water reactors. This effort is under the Department of Energy Office of Nuclear Energy’s Nuclear Technology Research and Development Advanced Fuels Campaign. The development of ATF is an industry lead initiative with fuel designs being championed by Westinghouse, Framatome, and General Electric. Industry goals for ATF deployment include implementing the first batch reloads of coated cladding and doped fuel designs into commercial reactors by 2023 and having the first batch reloads of more advanced designs into commercial reactors by 2026. Follow on goals include implementing the first full cores of coated cladding and doped fuel designs into commercial reactors by 2026 and implementing full cores of more advanced designs by 2030. The objectives of the national laboratory research programs within the Advanced Fuels Campaign related to ATF are: 1. Develop and maintain of unique nuclear testing infrastructure, which includes test reactors, hot cell PIE equipment, and unique out of pile separate effects testing facilities. 2. Respond directly to industry requests for support by partnering with the ATF vendors and executing experiments and/or analysis on their behalf. 3. Conduct independent scientific investigations into the performance of the different ATF concepts that are relevant to Industry designs. To achieve these objectives, the safety research program will execute transient irradiation experiments at the TREAT facility at Idaho National Laboratory with the aim of identifying the relevant transient fuel behaviors for each fuel design in order to establish appropriate fuel safety criteria and thresholds. Two test series are described in this plan, (1) an Integral Test Series, and (2) a Focused Effects Test Series. In fulfillment of the first objective for the safety research program, Integral Effects Tests will be developed and demonstrated using standard UO2 Zircaloy fuel designs in both the fresh and previously irradiated case. The Integral Test Series will consist of three campaigns to evaluate transient fuel performance in Reactivity Initiated Accidents, Loss of Coolant Accidents, and in generalized Power Cooling Mismatch scenarios. Development of these test programs also enables the safety research program to fulfill its second objective by making these three test programs available to each industry team. Initially, priority will be given in the integral test series to the coated cladding and doped fuel concepts as their deployment schedule is the most aggressive. To fulfill the third objective of the safety research program, a Focused Effects Test Series is also being developed which will examine specific transient fuel behaviors that are of general interest to all the ATF designs under development. These tests look at transient fuel behavior related to pellet cladding mechanical interaction, coated cladding swelling, rupture, and time at temperature behavior, non oxide fuel melting and mechanical interaction with Silicon Carbide cladding, UO2 and doped UO2 fuel fragmentation and transient fission gas release, and finally fuel coolant interaction. This document provides a general overview of the objectives of the safety research program as well as providing background into how programs like this have been used in the past to develop the criteria necessary for the safe operation of the present fuel designs. An overview of the materials and methods used for safety testing is presented. Finally the Integral and Focused Effects tests series are introduced and described. This document will be maintained as a “living” document with annual updates to reflect evolving requirements and needs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

BISON Fuel Performance Analysis of IFA-796 Rod 3 & 4 and Investigation of the Impact of Fuel Creep

In order to improve the accident tolerance of light water reactor (LWR) fuel, alternative cladding materials have been proposed to replace the currently used zirconium (Zr)-based alloys. Of these materials, there is a particular focus on iron-chromiumaluminum (FeCrAl) alloys because they exhibit slower oxidation kinetics in high-temperature steam than Zr-alloys. This should decrease the energy release due to oxidation and slow cladding consumption in the presence of high temperature steam. These alloys should also exhibit increased “coping time” in the event of an accident scenario by improving the mechanical performance at high temperatures, allowing greater flexibility to achieve core cooling. As a continuation of the development of these alloys, in-reactor irradiation testing of FeCrAl cladded fuel rods has started. In order to provide insight on the possible behavior of these fuel rods as they undergo irradiation in the Halden Boiling Water Reactor, engineering analysis has been performed using FeCrAl material models implemented into the BISON fuel performance code. This milestone report provides an update on the ongoing development of modeling capability to predict FeCrAl cladding fuel performance and to provide an early look at the possible behavior of planned in-reactor FeCrAl cladding experiments. In particular, this report consists of two separate analyses. The first analysis consists of fuel performance simulations of IFA-796 rod 4 and two segments of rod 3. These simulations utilize previously implemented material models for the C35M FeCrAl alloy and UO2 to provide a bounding behavior analysis corresponding to variation of the initial fuel cladding gap thickness within the fuel rod. The second analysis is an assessment of the fuel and cladding stress states after modification of the fuel creep model that is currently implemented in the BISON fuel performance code. Effects from modifying the fuel creep model were identified for the BISON simulations of the IFA-796 rod 4 experiment, but show that varying the creep model (within the range investigated here) only provide a minimal increase in the fuel radius and maximum cladding hoop stress. Continued investigation of fuel behavioral models will include benchmarking the modified fuel creep model against available experimental data, as well as an investigation of the role that fuel cracking will play in the compliance of the fuel. Correctly calculating stress evolution in the fuel is key to assessing fuel behavior up to gap closure and the subsequent deformation of the cladding due to PCMI. The inclusion of frictional contact should also be investigated to determine the axial elongation of the fuel rods for comparison with data from this experiment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Titanium and/or Aluminum Rod-Replacement Experiments in Fully-Reflected Water-Moderated Square-Pitched U(6.90)O 2 Fuel Rod Lattices with 0.67 Fuel to Water Volume Ratio (0.800 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 square-pitched UO2 fuel rods. The uranium is enriched to 6.90% by mass. Sets of 36 titanium and aluminum experiment rods with the same nominal outside diameter as the fuel rods were fabricated and used as replacements for fuel rods in the array. The twenty-four 7uPCX critical experiments reported here compare the effects of the titanium and aluminum replacement rods on nearly critical fuel rod arrays. The fuel used in these experiments was fabricated using unirradiated 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 nominal outside diameter of the fuel pellets is 0.207 in (0.52578 cm). The nominal outside diameter of the fuel rod cladding is 0.250 in (0.635 cm). The distance between the fuel rods in the square-pitched array is 0.315 in (0.8001 cm). This geometry gives a fuel-to-water volume ratio of 0.67 in the array. The twenty-four critical experiments in this series were performed in 2015 and 2016 at the Sandia Critical Experiments Facility. The first of the experiments had no replacement rods in the array and was intended to provide a baseline against which the experiments containing replacement rods could be compared. Eight critical experiments had titanium replacement rods in various numbers and arrangements near the center of the fuel array. Eight critical experiments had aluminum replacement rods in the same numbers and arrangements as in the eight experiments containing titanium experiment rods. In the final four experiments, fuel rods were removed from a central region of the array so that the pitch of the fuel rods in this part of the array was effectively doubled. This softened the neutron spectrum in the central part of the fuel array. Thirty-six replacement rods in different combinations of titanium and/or aluminum were placed in the interstices created in the center of the array. All twenty-four critical experiments are judged to be acceptable as benchmark experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Microstructural and Micro-Chemical Evolutions in the Irradiated UCO Fuel Kernels of AGR-1 and AGR-2 TRISO Fuel Particles

AGR-1 and AGR-2 TRISO fuel particles were fabricated with slightly different fuel kernel chemical compositions, modified fabrication processes, different fuel kernel diameters, and changed 235U enrichments. To correlate those differences with the fuel kernel responses to neutron irradiations in terms of irradiated fuel microstructure, fission products chemical and physical states, and fission gas bubble evolutions, extensive microstructural and analytical characterizations were conducted. The studies used a state of art transmission electron microscopy (TEM) equipped with Energy-dispersive X-ray spectroscopy (EDS) of four silicon solid-state detectors which have super sensitivity and fast speed. The TEM specimens were prepared from selected AGR-1 and AGR-2 irradiated fuel kernels exposed to safety testing after irradiation. The particles were chosen to represent a representative irradiation conditions with a fuel burnup within the range from 10.8 to 18.6% FIMA, and the time-average volume-average temperatures vary from 1070 to 1287°C. The 235U enrichment was 19.74 wt.% for the AGR1 fuel kernels and 14.03 wt.% for the AGR-2 fuel kernels. The TEM results show that there were significant microstructural reconstructions in the irradiated fuel kernels for both the AGR-1 and AGR-2 fuels. There are four major phases including fuel matrix of UO2 and UC, U2RuC2, and UMoC2 in the irradiated AGR2 fuel kernel. Zr and Nb form solid solution in the UC phase. UMoC2 phase often shows a detectable concentration of Tc. Pd was found to mainly locate in the buffer layer or to be associated with fission gas bubble within the UMoC2 phase. The EDS maps qualitatively show that the rare-earth fission products (Nb, et al.) preferentially reside in the UO2 phase. In contrast, in the irradiated AGR1 fuel kernel, no U2RuC2 or UMoC2 precipitates were positively identified. Instead, there is a high number of rod-shape precipitates enriched with Ru, Tc, Rh, and Pd observed in the fuel kernel center and edge zone. The difference of microstructural and micro-chemical evolutions in irradiated fuel kernels between the AGR-1 and AGR-2 TRISO fuel particle may result from a combined factor of irradiation temperature, fuel geometry and chemical composition. However, the irradiation temperature probably play a more deterministic role. Limited electron energy loss spectroscopy (EELS) characterizations on the AGR2 fuel kernel show that there is nearly no carbon in the UO2 phase while a small fraction of oxygen was detected in the UC/UMoC2 phase.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Benchmark Study on Innovative Fuels for Fast Reactors with fuel performance codes

The Working Party on the Scientific Issues of the Fuel Cycle (WPFC) has been established under the auspices of the Nuclear Energy Agency (NEA) Nuclear Science Committee (NSC), to co-ordinate scientific activities regarding various existing and advanced nuclear fuel cycles, including advanced reactor systems, associated chemistry and flowsheets, development and performance of fuels and materials, accelerators and spallation targets. Various expert groups were established to cover the above-mentioned topics. Within the WPFC, the Expert Group on Innovative Fuels (EGIF) was created with the objective of conducting joint and comparative studies to support the development of innovative fuels such as homogeneous and heterogeneous fuels, ADS fuels, and oxide, metal, nitride and carbide fuels, all of which can be implemented in advanced nuclear fuel cycles with fast reactors. The scope of the expert group covers innovative fuel fabrication techniques, irradiation performance of innovative fuels, characterisation and post-irradiation examination methods and predictive codes for innovative fuel fabrication and performance. This report presents the results of a benchmark study on innovative fuels for fast reactors using fuel performance codes. Irradiation results were shared among participants, and code calculations were performed to gain further insights on the fuel behaviour. Each participating institution used its own fuel performance code. Code to code and code to experiment comparisons are expected to provide data and improve understanding on the effects of minor actinides on fuel behaviour. In conclusion, the need for improvement of codes will be evaluated and the needs for new experimental data will be identified in order to finalise the code validation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Applying U.S. metal fuel experience to new fuel designs for fast reactors

With the increasing interest in small modular reactors or microreactors, developers are working to design and submit licensing approval requests of U–10Zr-fueled fast reactors. The developers and their proponents cite prior metal fuel experience (worldwide, but U.S. experience in particular for many developers) as the motivation and justification for their reactor concepts. The experience with metal fuel deployment in sodium-cooled fast reactors as well as the underlying irradiation testing database, provide a suitable basis for analytically justifying the use of metal fuel in new reactors. The evolution of metal fuel design and capability illustrates the importance of key fuel design parameters to consider in new applications of the prior experience: fuel smeared density, plenum-to-fuel volume ratio, the ratio of cladding radius to thickness, fuel composition, and cladding and duct materials. In-service operating and deployment conditions to be considered include fuel linear heat generation rate, fuel temperature, cladding temperature, peak burnup and peak fast fluence. Fuel designs and in-service conditions that are bounded by the database and experience are most easily addressed, but deviations from those previous parameters and conditions can be addressed by considering impacts on previously established behavior and applying other mitigating conservatisms, as appropriate. Here, the authors recommend any new deployment proceed with fuel surveillance and monitoring to mitigate risk, application of conservative measures to address uncertainties, and a fuel qualification program that addresses a range of in-service operating conditions with production fuel. The work reported should be of interest to students and regulators unfamiliar with metal fuel in fast reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Bio-fuel effects and seasonal fuel property variations related to abnormal combustion occurrences observed in the field

Since 2015, the automotive industry has regularly observed sharp increases in customer complaints of poor driveability and increased warranty claims during the months of September and October. These persistent seasonal complaint increases have been tracked to occur from increased abnormal combustion events that coincide with the seasonal transition from summer to winter fuel volatility, beginning on September 15th annually. The Reid Vapor Pressure (RVP) of gasoline during this seasonal transition has been found to be the primary property attributed to this annual issue. It’s hypothesized that an increase in volatile butanes and pentanes from advanced petroleum recovery techniques and hydrofracking production has hastened the transition from summer to winter fuel volatility in the marketplace, rather than the gradual increase of the RVP over time as historically intended. At worst, mid-winter fuel, with an RVP ranging from 12 to 16 psi, depending on location in the U.S., enters the market while ambient temperatures can still be above average for the winter season. This combination of high volatility fuel with unseasonably warm weather will increase fuel system flash boiling, injector spray cavitation, and spray collapse inside the engine’s combustion chamber, ultimately linking fuel property variations to abnormal engine combustion processes. This CRADA program will investigate these known knowledge gaps by coupling with two national laboratories, Oak Ridge National Laboratory, and the National Renewable Energy Laboratory to employ both unique tools and expertise throughout the industry to provide the insight, knowledge, and data critical to understand the observed interactions. Overall findings of this work are that fuel wall retention increased SPI proportionally, and fuels with an increased distillation (i.e. energy fraction) above the wall temperature increased fuel retention. Likewise fuels with increased enthalpy of vaporization (HoV) increased fuel retention proportional to the temperature reduction from the HoV (~13K reduction in this work). Thus, fuel with increased HoV and increased fuel distillation above the linear temperature also exhibited increased SPI rates. Fuel with high RVP did exhibit increased fuel spray collapse form spray imaging measurements, but in SPI testing the high volatility of these fuels at the tested conditions did not necessarily increase SPI rates despite exhibiting increased spray collapse in injector imaging and increased spray-wall impingement measured in fired engine testing. It was also found that spray imaging showed collapse was possible at throttled conditions, but this was not relevant to high boost pressures relevant to SPI conditions, however, under transient load and or speed encountered in real-world operation fuel spray collapse could affect fuel retention and real-world SPI that were not probed in the automated high load test sequence of this work.

09 BIOMASS FUELS↗

Advanced Nuclear Fuels and Materials Development and Philosophy of the DOE Advanced Fuels Campaign

The mission of the Advanced Fuels Campaign (AFC) is to perform Research, Development, and Demonstration (RD and D) activities for advanced fuel forms (including cladding) to enhance the performance and safety of the nation's current and future reactors; enhance proliferation resistance of nuclear fuel; effectively utilize nuclear energy resources; and address longer-term waste management challenges. This includes development of a state-of-the art Research and Development (R and D) infrastructure to support the use of a 'goal-oriented science-based approach.' AFC uses this approach to develop a fundamental understanding of fuel and cladding fabrication methods and performance under irradiation, enabling the pursuit of multiple fuel forms for future fuel cycle options. This approach includes fundamental experiments, theory, and advanced modeling and simulation. One of the most challenging aspects of AFC is the management, integration, and coordination of major R and D activities across multiple organizations. AFC interfaces and collaborates with other Fuel Cycle Technologies (FCT) campaigns, universities, industry, various DOE programs and laboratories, federal agencies (e.g., Nuclear Regulatory Commission [NRC]), and international organizations. Key challenges are the development of fuel technologies to enable major increases in fuel performance (safety, reliability, power and burnup) beyond current technologies, and development of characterization methods and predictive fuel performance models to enable more efficient development and licensing of advanced fuels. AFC is challenged with the research and development of fuels for two different reactor technology platforms, namely transmutation fuel for non-water cooled reactors and advanced fuel development for light water reactor (LWR) systems. This presentation will provide an overview of the Advanced Fuel Campaign activities including the near term activities in advanced nuclear fuel system research and development as well as highlighting general activities pursued to improve the study, modeling, and simulation of irradiated nuclear materials. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

INVESTIGATION INTO REACTIVITY SEPARATION BETWEEN DIRECT INJECTED AND PREMIXED FUELS IN RCCI COMBUSTION MODE

This experimental study focuses on the effects of the reactivity separation between the port injected fuel and the direct injection fuel, the amount of external-cooled exhaust gas recirculation (EGR), and the direct injection timing of the high reactivity fuel on Reactivity Controlled Compression Ignition (RCCI) combustion. The experiments were conducted on a lightduty, single-cylinder diesel engine with a production GM/Isuzu engine head and piston and a retrofitted port fuel injection system. The global charge-mass equivalence ratio, &straightphi;&prime;, was fixed at 0.32 throughout all of the experiments. To investigate the effects of the fuel reactivity separation, different Primary Reference Fuels (PRF) were port injected, with the PRF number varying from 50 to 90. To investigate the effects of EGR, an EGR range of 0 to 55% was used. To investigate the effects of the injection timing, an injection timing window of -65 to -45 degrees ATDC was chosen. The results indicate that there are several tradeoffs. First, decreasing the port injected fuel reactivity (increasing the PRF number) delays combustion phasing, decreases the combustion efficiency by up to 9%, increases the gross indicated thermal efficiency up to 22%, enhances the combustion sensitivity to the direct injection timing, and slightly increases the UHC, CO, and NOx emissions. Second, increasing the EGR percentage delays combustion phasing, lowers the peak heat release rate, and lowers the NOx emissions. The combustion efficiency first increases and then decreases with EGR percentage for high reactivity fuels (low PRF number), but only decreases for low reactivity fuels. Finally, delaying the injection timing advances combustion phasing and increases the combustion efficiency, but decreases the gross indicated thermal efficiency and increases the NOx emissions. Across all of the experiments, delays in CA50 increase the gross indicated thermal efficiency and decrease the combustion efficiency, which represents an inherent tradeoff for RCCI combustion on a lightduty engine.

Yan, Ziming↗

ASSESSING FUEL PROPERTY EFFECTS ON CAVITATION AND EROSION PROPENSITY USING A COMPUTATIONAL FUEL SCREENING TOOL

To advance compression ignition combustion strategies, researchers have evaluated fuel property effects and their impact on achieving higher efficiencies and lower emissions levels relative to current capabilities. Within the Department of Energy's Co-Optima initiative, there has been a recent focus on understanding the influence of fuel properties on fuel injection performance. To help identify candidate fuels that can meet desired injector performance metrics, a computational fuel screening tool is under development that can link fuel properties with the tendency of a given fuel to cavitate and lead to cavitation-induced erosion. In the initial development of this tool, five liquid fuel properties were selected to represent candidate fuels, namely density, viscosity, vapor pressure, surface tension, and heat of vaporization. A design of experiments methodology was employed to generate a set of pseudo fuel cases, which can represent the main effects and interactions among the fuel properties and be related to cavitation erosion predictions. Large eddy simulations were performed using a mixture modeling approach to predict the cavitation and erosion propensity of these pseudo-fuels in terms of the mean fuel vapor mole fraction and stored impact energy from repeated cloud collapse events. The low order regression models generated from this study revealed the importance of liquid fuel density on cavitation formation, whereas liquid viscosity was found to have a strong negative correlation with erosion severity. The surrogate models were then used in the fuel screening tool to rank the cavitation and erosion tendency of four candidate single-component fuels: methyl decanoate, isooctane, ethanol and n-dodecane. While the fuel screening tool was not able to quantitatively predict the cavitation and erosion response metrics, the tool was able to accurately rank the relative cavitation and erosion propensity of the four fuels. Overall, ethanol and iso-octane were observed to produce the highest levels of cavitation and erosion, respectively.

cavitation-induced erosion↗

Fuel-Lubricant Interactions on the Propensity for Stochastic Pre-Ignition

This work explores the impact of the interaction of lubricant and fuel properties on the propensity for stochastic pre-ignition (SPI). Findings are based on statistically significant changes in SPI tendency and magnitude, as determined by measurements of cylinder pressure. Specifically, lubricant detergents, lubricant volatility, fuel volatility, fuel chemical composition, fuel-wall impingement, and engine load were varied to study the physical and chemical effects of fuel-lubricant interactions on SPI tendency. The work illustrates that at low loads, with fuels susceptible to SPI events, lubricant detergent package effects on SPI were non-significant. However, with changes to fuel distillation, fuel-wall impingement, and most importantly engine load, lubricant detergent effects could be observed even at reduced loads This suggests that there is a thermal effect associated with the higher load operation. It was hypothesized that the thermal effect was associated with lube oil nitrogenation. To test this theory, nitromethane (CH3NO2) was blended at 6.5% by volume CH3NO2 resulted in significant sensitivity to lubricant additive package effect on SPI, even at reduced loads where no lubricant sensitivity was observed without the addition of CH3NO2. The combined results highlight the interplay of fuel-lubricant interaction on SPI events, but more importantly suggest that there is the potential of a chemical interaction unique to high-load engine operation that results in reactive chemical processes, such as nitration, where lubricant chemistry becomes an active pathway for SPI activity.

33 ADVANCED PROPULSION SYSTEMS↗

Scale effects on core design, fuel costs, and spent fuel volume of pressurized water reactors

The desire to improve the economic competitiveness and deployment pace of nuclear energy through modularization, manufacturing, and series production had led to the development of smaller size reactors. As the standard 17x17 fuel technology is mainly maintained in the pressurized water reactors (PWRs) category, this translates into a lower number of fuel assemblies in the core and sometimes a reduced fuel height. To assess the impact of such scale change in core design on fuel cycle cost and spent fuel volume, a scoping analysis tool is developed based on infinite lattice calculations, leakage, fuel management reduced models, and levelized unit cost of electricity (LCOE) estimate. As such, cost dynamics driven by fuel specific power, burnup, core leakage, feed, cycle length, fuel assembly height as well as uranium market data are captured with consistent set of assumptions and analysis methods. A selection of 5 reactor designs representative of leading PWR developers is assessed and compared. Pursuing higher specific powers and optimal burnups are highlighted as the main fuel cost reduction drivers, nevertheless, practical limitations and opportunities must be evaluated to establish the feasibility of such enhanced fuel operation. In consequence, a detailed core design is performed using SIMULATE3 code for 5 PWR variations including natural and forced coolant circulation modes, two reactor scales, power densities of 73, 112, and 123 kW/l and higher discharge burnups. Design and optimization are performed at the lattice level, for the reflector, and at the core loading level. Satisfactory steady-state operation including power distribution, coolant operating limits, and reactivity requirements are analyzed and reported in this paper. The fuel economics of the detailed core designs confirm the scoping analysis findings. Despite the unlocked power uprates in small PWRs, the achievable burnup for a given fuel specific power requires more enrichment and shorter fuel height results in higher fabrication costs per mass of fuel, which makes scaling down core size a more expensive endeavor on the fuel cycle front. Spent fuel volumes are reported for the PWRs designed in this paper. Furthermore, these volumes are driven by the core average discharge burnup regardless of the scale in consideration. Additional cost and core performance aspects related to heavy reflector gains, fuel-reflector substitution, and disposal cost policy in the U.S. are examined.

42 ENGINEERING↗

Development of LWR Fuels with Enhanced Accident Tolerance ATF Feasibility Analysis Report Deliverable for the Westinghouse Accident Tolerant Fuel Program

The Westinghouse Electric Company LLC (Westinghouse) accident tolerant fuel (ATF) program utilizes chromium (Cr) coated zirconium alloy cladding with uranium silicide (U 3 Si 2 ) high density/high thermal conductivity fuel for its lead test rod (LTR) program with irradiation beginning in 2019. The lead test assembly (LTA) program will use both SiC/SiC composites and Cr coated zirconium alloy claddings with the high density/high thermal conductivity U 3 Si 2 pellet which will begin in 2022. Over the past several years, Westinghouse has tested the Cr coated zirconium (Zr) and silicon carbide (SiC) claddings in autoclaves and in the Massachusetts Institute of Technology (MIT) reactor and the U 3 Si 2 pellets have been tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). High temperature tests at the state-of-the-art Westinghouse facilities in Churchill, PA have been carried out to determine the time and temperature limits for the SiC and Cr coated zirconium claddings. Fuel rod and assembly design in preparation for the LTR and LTA programs is underway as well as licensing efforts with the Nuclear Regulatory Commission (NRC). Finally, accident analyses coupled with economic evaluations for both operating savings as well as fuel savings have been initiated. Cr coated zirconium alloy claddings showed low corrosion rates in both autoclave and in-reactor tests and will be fabricated using commercial processes for the first LTRs for insertion in 2019. Current autoclave results for SiC composite claddings indicate that a corrosion rate of fewer than 2 micrometers per year which meets corrosion requirements may be achieved under normal operating conditions. Modular Accident Analysis Program 5 (MAAP5) calculations indicate that solid fission products can be contained within SiC cladding for up to two hours longer than current Zr based cladding in a station blackout scenario. This additional time is due to the much higher temperature capability of SiC (~2000°C). These two hours can be used to implement additional response options instituted through the FLEX program by reactor operators. While the Cr coated Zr alloy option offers more modest ATF gains (~200°C higher than bare Zr) in similar situations, the coatings do delay the runaway oxidation encountered by uncoated zirconium cladding. Both ATF cladding options also reduce hydrogen production which dramatically reduces primary system and containment pressure and the risk of fission product release beyond containment in the unlikely event of an accident. The lower pressure in the system allows more time to feed cooling water to the core, resulting in the avoidance of fuel melting. The coping time is extended indefinitely as long as the water flow continues. SiC exhibits the highest accident tolerance of any cladding and significant advances in understanding the design, manufacture and accident behavior of SiC cladding have been made. Department of Energy support is needed to continue the on-going experimental work addressing the interaction between U 3 Si 2 and SiC at temperatures >1200°C, the effect of SiC manufacturing methods and manufacturing variability on physical properties, and the ability to predict the mechanical properties of SiC composites based on the composite design. Additionally, experimental work on methods to rapidly fabricate SiC composite structures with high density and reduce the fabrication price of SiC fibers while maintaining a high level of performance is needed. Minimal (<1%) swelling of U 3 Si 2 and subsequent fission gas release has been demonstrated up to 20 MWd/kgU. Irradiation experiments with U 3 Si 2 fuel in ATR to determine these properties at 40 to 50 MWd/kgU are underway. These experiments will provide the data needed to license fuel rod design codes. Research is continuing on production methods for making U 3 Si 2 from UF 6 without going through the U metal step. Oxidation tests of fuel pellets and powder in steam and synthetic air indicate that U 3 Si 2 has a lower oxidation reaction initiation temperature than UO 2 . Options to reduce the U 3 Si 2 oxidation rate are being explored. A hybrid fuel design using pellets with the weight ratio of 30%/70% U 3 Si 2 /UN is currently undergoing testing in the ATR. This approach is being explored to further increase the positive economics of the U 3 Si 2 fuel. In addition to the work supported by the USDOE, research and testing activities are being carried on in a world-wide effort funded by many countries such as Sweden, United Kingdom, Belgium, Netherlands, Spain, Germany, Japan and France. This work is being facilitated through the Westinghouse led Collaboration for Advanced Research on Accident Tolerant Fuel (CARAT) program. Annual meetings are organized by Westinghouse as a venue for presentation of this work and to provide for the cross-fertilization of ideas among the many outstanding researchers in the ATF area. Since SiC, coated cladding and high density fuel options are not currently used in the nuclear industry, support from the government and industry members is needed to further the significant effort of setting new standards. The same is true for the Nuclear Regulatory Commission (NRC) which must review and approve the commercial use of these new fuels since all current regulations are oriented toward Zr/ UO 2 fuel. There are no showstoppers for accident tolerant fuel technologies when considering supply chain, fabrication, enrichment suppliers, production, and licensing. Due to the cost savings from higher density fuel and the accident tolerance of coated claddings, Exelon has identified potential commercial plants to host the LTRs and LTAs. Planning is underway to implement this schedule.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗