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DOE OSTI2026

BISON analyses of TRISO fuel performance, its dependence on time-at-temperature, and possible implications for fuel design and qualification

The Advanced Gas Reactor Fuel Development and Qualification (AGR) program has established a substantial technical foundation to support private entry into the U.S. high-temperature gas-cooled reactor market. However, emerging tristructural isotropic (TRISO)-fueled reactor applications include small modular reactors and microreactors with longer fuel residence times, which may expose fuels to higher time-at-temperature (TAT) values than were explored by the AGR program. Increased TAT could affect diffusive and thermomechanical behaviors such as Pd penetration, fission gas release, creep, and fission product transport. In this work, we applied multiscale best-estimate BISON fuel performance modeling to assess these effects within a representative design space based on the AGR-5/6/7 experiment and analyzed trends in predicted particle and compact fuel performance metrics with possible implications for near-term fuel design and qualification. BISON unambiguously predicted that TRISO fuel performance is sensitive to TAT. Increasing TAT was not predicted to increase the magnitude of failure-inducing tangential stresses in particle coating layers. Predictions obtained using a mechanistic model for Pd penetration indicated that penetration depth does not depend strongly on TAT. While these observations suggest that AGR testing provides a conservative upper bound for the steady-state operation of TRISO particles at lower powers and higher residence times, BISON also predicted that the release of poorly retained Ag would increase with TAT. Because these analyses applied models to extrapolate beyond the available experimental data, the authors recommend performing targeted experiments to confirm these predictions. Nevertheless, these predictions may provide reactor developers with enough confidence to make near-term design decisions associated with the potential fuel performance trade-offs of increasing TAT.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2007

Alternate-Fueled Flight: Halophytes, Algae, Bio-, and Synthetic Fuels

Synthetic and biomass fueling are now considered to be near-term aviation alternate fueling. The major impediment is a secure sustainable supply of these fuels at reasonable cost. However, biomass fueling raises major concerns related to uses of common food crops and grasses (some also called "weeds") for processing into aviation fuels. These issues are addressed, and then halophytes and algae are shown to be better suited as sources of aerospace fuels and transportation fueling in general. Some of the history related to alternate fuels use is provided as a guideline for current and planned alternate fuels testing (ground and flight) with emphasis on biofuel blends. It is also noted that lessons learned from terrestrial fueling are applicable to space missions. These materials represent an update and additions to the Workshop on Alternate Fueling Sustainable Supply and Halophyte Summit at Twinsburg, OH, Oct. 17 to 18, 2007 (ref. 1).

Hendricks, R. C.↗

NASA NTRS2012

Alternate-Fueled Flight: Halophytes, Algae, Bio-, and Synthetic Fuels

Synthetic and biomass fueling are now considered to be near-term aviation alternate fueling. The major impediment is a secure sustainable supply of these fuels at reasonable cost. However, biomass fueling raises major concerns related to uses of common food crops and grasses (some also called "weeds") for processing into aviation fuels. These issues are addressed, and then halophytes and algae are shown to be better suited as sources of aerospace fuels and transportation fueling in general. Some of the history related to alternate fuels use is provided as a guideline for current and planned alternate fuels testing (ground and flight) with emphasis on biofuel blends. It is also noted that lessons learned from terrestrial fueling are applicable to space missions. These materials represent an update (to 2009) and additions to the Workshop on Alternate Fueling Sustainable Supply and Halophyte Summit at Twinsburg, Ohio, October 17 to 18, 2007.

Hendricks, R. C.↗

DOE OSTI2021

Methods of forming fuel rods comprising porous fuel materials

A method of forming a fuel rod for a nuclear reactor comprises disposing a powder comprising particles of a fuel material on a substrate, exposing the powder to energy from an energy source to form a first layer of a nuclear fuel, the first layer comprising inter-granular bonds between the particles of the fuel material, disposing additional powder comprising particles of the fuel material over the first layer of the nuclear fuel, and exposing the additional powder to energy from the energy source to form a second layer of the nuclear fuel and to form the nuclear fuel to have a void fraction greater than about 0.20, the second layer comprising inter-granular bonds between the additional powder and the first layer of the nuclear fuel. Related nuclear fuels comprising a porous structure, fuel rods, nuclear reactors, and methods are disclosed.

O'Brien, Robert C.↗

DOE OSTI2021

Numerical Analysis of Fuel Effects on Advanced Compression Ignition Using a Cooperative Fuel Research Engine Computational Fluid Dynamics Model

Growing environmental concerns and demand for a better fuel economy are driving forces that motivate the research for more advanced engines. Multi-mode combustion strategies have gained attention for their potential to provide high thermal efficiency and low emissions for light-duty applications. These strategies target optimizing the engine performance by correlating different combustion modes to load operating conditions. The extension from boosted spark ignition (SI) mode at high loads to advanced compression ignition (ACI) mode at low loads can be achieved by increasing the compression ratio and utilizing intake air heating. Further, in order to enable an accurate control of intake charge condition for ACI mode and rapid mode-switches, it is essential to gain fundamental insights into the autoignition process. Within the scope of ACI, homogeneous charge compression ignition (HCCI) mode is of significant interest. It is known for its potential benefits, operation at low fuel consumption, low NOx, and particulate matter (PM) emissions. In the present work, a virtual Cooperative Fuel Research (CFR) engine model is used to analyze fuel effects on ACI combustion. In particular, the effect of fuel octane sensitivity (S) (at constant Research Octane Number (RON)) on autoignition propensity is assessed under beyond-RON (BRON) and beyond-MON (BMON) ACI conditions. The three-dimensional CFR engine computational fluid dynamics (CFD) model employs a finite-rate chemistry approach with a multi-zone binning strategy to capture autoignition. Two binary blends with Research Octane Number (RON) of 90 are chosen for this study: primary reference fuel (PRF) with S = 0 and toluene–heptane (TH) blend with S = 10.8, representing paraffinic and aromatic gasoline surrogates. Reduced mechanisms for these blends are generated from a detailed gasoline surrogate kinetic mechanism. Simulation results with the reduced mechanisms are validated against experimental data from an in-house CFR engine, with respect to in-cylinder pressure, heat release rate, and combustion phasing. Thereafter, the sensitivity of combustion behavior to ACI operating condition (BRON versus BMON), air-fuel ratio (λ = 2 and 3), and engine speed (600 and 900 rpm) is analyzed for both fuels. It is shown that the sensitivity of a fuel’s autoignition characteristics to λ and engine speed significantly differs at BRON and BMON conditions. Moreover, this sensitivity is found to vary among fuels, despite the same RON. It is also observed that the presence of low-temperature heat release (LTHR) under BRON condition leads to more sequential autoignition and longer combustion duration than BMON condition. Finally, the study indicates that the octane index (OI) fails to capture the trend in the variation of autoignition propensity with S under the BMON condition.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Criticality Safety and Fuel Performance Considerations for Enrichment Above 5 Weight Percent in the Uranium Dioxide Fuel Cycle

The U.S. Nuclear Regulatory Commission (NRC) is preparing for anticipated licensing applications requesting fuel enrichments of UO 2 ceramic fuels enriched in excess of 5 weight percent (w/o) 235 U for commercial light-water reactors (LWRs). PNNL has been tasked with providing technical assistance to the NRC related to the review and approval of requests for enrichment increases above the current 5 w/o 235 U enrichment limit. This report will provide the agency with technical assistance to enhance the staff’s knowledge base and to identify developmental needs required to support the licensing of greater than 5 w/o UO 2 ceramic fuels. This report provides a background on increasing enrichment of UO 2 LWR fuel beyond 5 w/o 235 U. The primary concern of increasing enrichment is the impacts to criticality safety. This report will focus on criticality safety as it relates to enrichment, conversion of uranium hexafluoride to UO 2 , fuel assembly fabrication, transportation of fresh/spent fuel assemblies, reactor operations, and storage of fresh/spent fuel assemblies. The report provides a general summary of each of the steps in the UO 2 fuel cycle starting from transportation of enriched UF 6 through dry cask storage of spent fuel assemblies. This report also discusses other impacts of increased enrichment during reactor operation and the surrounding fuel cycle activities. Current needs regarding both data and analytical codes to support the increase above 5 w/o 235 U are identified and discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Reference Fuel Development for Non-Aluminum Spent Nuclear Fuel Management

The Savannah River Site (SRS) L Area Facility provides for the safe receipt, storage, handling, and shipping of spent nuclear fuel (SNF) and has received more than 47,000 SNF assemblies since 1964. In order to consolidate receipt and storage analysis, L Area criticality safety has historically used several aluminum-clad “reference fuels” to establish bounding storage, handling, and cask loading limits and then applied a reactivity comparison approach to demonstrate that candidate fuels may be processed under the reference fuel limits. Currently, only aluminum-clad SNF from off-site research reactors are transferred on-site. The Accelerated Basin De-Inventory (ABD) program will begin the removal of bundled Non-Aluminum Spent Nuclear Fuel (NASNF) from the L Area disassembly basin for dissolution and disposition, which has driven the need for a non-aluminum reference fuel. This paper discusses the process and results of creating a new fictional homogenous NASNF highly enriched uranium reference fuel, “MITZ,” to be used in nuclear criticality safety evaluations for upcoming SNF disposition operations. Data demonstrating the relationship between neutron multiplication behavior and fuel spacing is generated for the new reference fuel MITZ as well as existing reference fuels representing several types of SNF assemblies.

Reference Fuel↗

DOE OSTI2025

Reference Fuel Development for Non-Aluminum Spent Nuclear Fuel Management

Reference Fuel↗

DOE OSTI2024

Spark plasma sintering of fuel meats for U 3 O 8 based dispersion fuels

Research and test reactors often use dispersion-type fuel due to its increased thermal conductivity and burn-up capabilities compared to conventional fuel. Al-U 3 O 8 (aluminumtriuranium octaoxide) dispersion fuels have several advantages over their competitors, such as higher service temperature and better stability of oxygen stoichiometry. However, the two-step fabrication of dispersion fuel causes undesirable porosity in cold-pressed fuel meats that is preserved in co-extruded fuel plates. To combat this, spark plasma sintering (SPS) was used for the fabrication of Al-15, 20, and 30 vol% U 3 O 8 and 8 and 12 vol% Mo-U 3 O 8 fuel meats for the Al-U 3 O 8 time. The in situ SPS data was used to construct and validate Master Sintering Curves (MSCs) with accuracies in Al fuels at 0.02 g/cm 3 , and Mo fuels at 0.07 and 0.17 g/cm 3 . The as-sintered fuel meats were characterised using x-ray diffraction (XRD) and scanning electron microscopy (SEM) to understand chemical and physical changes following the SPS process. The pellets exhibited very high relative densities, the U 3 O 8 was observed to undergo reduction to UO 2 .

Aluminium↗

DOE OSTI2021

Low-Cost Intermediate-Temperature Fuel-Flexible Protonic-Ceramic Fuel Cell and Stack

Large, centralized power plants are currently the most efficient way to convert fuels such as natural gas to electricity. Fuel cells, however, could become highly efficient generators across a range of sizes from tens of watts to megawatts. In particular, fuel cells with an electrical efficiency of 50% could displace small generators of 25 kilowatts (kW) or less in applications such as remote power, telecommunications, and residential cogeneration. Current 25 kW natural gas generators employing internal combustion engines are typically only 25-30% efficient and expensive to maintain. Furthermore, fuel cells could provide valuable services to the grid, such as the ability to ramp power up or down in response to load conditions. While there are different types of fuel cells, each with their strengths and weaknesses, fuel cells generally are very expensive. For example, lower temperature fuel cells can be started up quickly, but require highly pure hydrogen fuel and expensive catalysts. High-temperature fuel cells can operate on a range of fuels, but they have costly system components and can degrade rapidly.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2025

Enabling BWR fuel rod analysis in the BISON fuel performance code

Nuclear fuel vendors around the world are pursuing approaches to sustain the existing nuclear reactor fleet consisting primarily of pressurized-water reactors (PWRs) and boiling-water reactors (BWRs). To support the industry's efforts, advanced modeling and simulation tools need to be capable of analyzing both legacy reactor concepts. BWR fuel rods are significantly different than those used in PWRs, which can affect fuel performance analysis. BWR fuel rods include: (1) an extensive use of gadolinia dopant as a burnable absorber, (2) an axial variation in fuel enrichment and gadolinia content, (3) the inclusion of a liner on the inner cladding surface to mitigate the impact of pellet-clad mechanical interaction (which impacts hydrogen and hydride distribution), (4) a lower initial fill gas pressure, (5) bottom-entry control rods, and (6) a lower coolant pressure that results in the two-phase flow boiling phenomenon. Although the primary focus of BISON has been in the area of PWR and advanced reactor fuel analyses, this paper presents the developments in BISON to support BWR fuel performance analysis. An overview of the models that account for the effects of gadolinia is highlighted. Internal mesh generation capabilities to include a liner is presented. Normal operating and transient (reactivity insertion accident) demonstration problems are presented to illustrate the impact of gadolinia, the hydrogen and hydride evolution due to the presence of the liner, and BISON's ability to simulate axially varying enrichments and dopant concentration. Bottom-entry control effects are captured by the axial power peaking factors present in the demonstration cases. Comparisons to integral experiments from the Halden IFA-681 experiments are discussed as initial validation. Reasonable comparisons are obtained for fuel centerline temperature and rod internal pressure as a function of time. In conclusion, simulations of additional experiments containing Gd 2 O 3 -bearing fuel are necessary to completely validate the code for BWR applications.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1977

Preliminary analysis of aircraft fuel systems for use with broadened specification jet fuels

An analytical study was conducted on the use of broadened specification hydrocarbon fuels in present day aircraft. A short range Boeing 727 mission and three long range Boeing 747 missions were used as basis of calculation for one-day-per-year extreme values of fuel loading, airport ambient and altitude ambient temperatures with various seasonal and climatic conditions. Four hypothetical fuels were selected; two high-vapor-pressure fuels with 35 kPa and 70 kPa RVP and two high-freezing-point fuels with -29 C and -18 C freezing points. In-flight fuel temperatures were predicted by Boeing's aircraft fuel tank thermal analyzer computer program. Boil-off rates were calculated for the high vapor pressure fuels and heating/insulation requirements for the high freezing point fuels were established. Possible minor and major heating system modifications were investigated with respect to heat output, performance and economic penalties for the high freezing point fuels.

Pasion, A. J.↗

NASA NTRS1928

The Effects of Fuel and Cylinder Gas Densities on the Characteristics of Fuel Sprays for Oil Engines

This investigation was conducted as a part of a general research on fuel-injection engines for aircraft. The purpose of the investigation was to determine the effects of fuel and cylinder gas densities with several characteristics of fuel sprays for oil engines. The start, growth, and cut-off of single fuel sprays produced by automatic injection valves were recorded on photographic film by means of special high-speed motion-picture apparatus. This equipment, which has been described in previous reports, is capable of taking twenty-five consecutive pictures of the moving spray at the rate of 4,000 per second. The penetrations of the fuel sprays increased and the cone angles and relative distributions decreased with increase in the specific gravity of the fuel. The density of the gas into which the fuel sprays were injected controlled their penetration. This was the only characteristic of the chamber gas that had a measurable effect upon the fuel sprays. Application of fuel-spray penetration data to the case of an engine, in which the pressure is rising during injection, indicated that fuel sprays may penetrate considerably farther than when injected into a gas at a density equal to that of the gas in an engine cylinder at top center.

Joachim, W F↗

NASA NTRS1953

Fuel characteristics pertinent to the design of aircraft fuel systems

Because of the importance of fuel properties in design of aircraft fuel systems the present report has been prepared to provide information on the characteristics of current jet fuels. In addition to information on fuel properties, discussions are presented on fuel specifications, the variations among fuels supplied under a given specification, fuel composition, and the pertinence of fuel composition and physical properties to fuel system design. In some instances the influence of variables such as pressure and temperature on physical properties is indicated. References are cited to provide fuel system designers with sources of information containing more detail than is practicable in the present report.

Barnett, Henry C↗

NASA NTRS2004

Analysis of Fuel Vaporization, Fuel-Air Mixing, and Combustion in Integrated Mixer-Flame Holders

Requirements to limit pollutant emissions from the gas turbine engines for the future High-Speed Civil Transport (HSCT) have led to consideration of various low-emission combustor concepts. One such concept is the Integrated Mixer-Flame Holder (IMFH). This report describes a series of IMFH analyses performed with KIVA-II, a multi-dimensional CFD code for problems involving sprays, turbulence, and combustion. To meet the needs of this study, KIVA-II's boundary condition and chemistry treatments are modified. The study itself examines the relationships between fuel vaporization, fuel-air mixing, and combustion. Parameters being considered include: mixer tube diameter, mixer tube length, mixer tube geometry (converging-diverging versus straight walls), air inlet velocity, air inlet swirl angle, secondary air injection (dilution holes), fuel injection velocity, fuel injection angle, number of fuel injection ports, fuel spray cone angle, and fuel droplet size. Cases are run with and without combustion to examine the variations in fuel-air mixing and potential for flashback due to the above parameters. The degree of fuel-air mixing is judged by comparing average, minimum, and maximum fuel/air ratios at the exit of the mixer tube, while flame stability is monitored by following the location of the flame front as the solution progresses from ignition to steady state. Results indicate that fuel-air mixing can be enhanced by a variety of means, the best being a combination of air inlet swirl and a converging-diverging mixer tube geometry. With the IMFH configuration utilized in the present study, flashback becomes more common as the mixer tube diameter is increased and is instigated by disturbances associated with the dilution hole flow.

Deur, J. M.↗

DOE OSTI2021

Fuel properties effects on wall-wetting and fuel-in-lube dilution under stochastic pre ignition prone conditions

Fuel-engine interactions have been shown to influence stochastic pre-ignition (SPI), however there is uncertainty on the root causes, participially if effects are primarily physical or chemical in nature. To better delineate the physical and chemical dependencies of fuel properties on SPI, this work studies interactions between aromatics, distillation, and particle matter index on SPI with a laser induced fluorescence (LIF) diagnostic to observe wall wetting. Fuels with high aromatic components or higher distillation temperatures tend to increase SPI events, but it is not well understood if the increased fuel dilution or a chemical aspect of this process is the primary mechanism for SPI. By employing the novel LIF in this work we measure fuel dilution in real-time in a running single cylinder research engine operated at SPI conditions. Three fuels were used in the present work, with the LIF diagnostic. Each fuel was operated at two injection timings, generating fuel specific effects on wall wetting. The LIF measurements are coupled with engine combustion measurements and SPI event counts. Results enable a deconvolution of fuel physical and chemical properties on SPI propensity, providing unique and novel insights into the dominant fuel effects affecting SPI.

Splitter, Derek↗

DOE OSTI2022

Advanced Characterization of Fuel-cladding Chemical Interaction between U-10Zr Fuel and HT9 Cladding Tested in Fast Flux Test Facility

Fuel cladding chemical interaction (FCCI) can greatly accelerate the cladding failure. However, due to the limited space in a fuel cladding assembly, it is historically challenging to gain an mechanistical understanding of the formation mechanism of FCCI and its influence on fuel and cladding performance. With the imminent need to qualify U-10Zr based metallic fuel cladded by HT-9 for advanced reactors demonstration project, it is of vital importance to use advanced characterization method to study FCCI in a unprecedent detailed manner and gain better mechanism understanding of FCCI. Mechanistic Fuel Failure (MFF) series of prototypic fuel elements irradiated in FFTF [1, 2] provides the best samples to study FCCI since the MFF-series assemblies had an axial fuel height the same as proposed length by industry partners. Jason et al. [3] has performed preliminary post-irradiation examination on a MFF fuel pin sample, which was extracted from the HT9 cladded U-10at.%Zr MFF-3 pin MFF-3 pin (#193045) at an axial location of X/L = 0.98. This sample has a peak burnup of 5.7 at.% and peak inner cladding temperature (PICT) of around 615 °C during in-core testing. Scanning electron microscope examination has identified visible FCCI region on more than half of the HT9 circumference [3]. The most striking feature are grain boundary attacking by apparently lanthanides (Lns) rich phase. However, SEM cannot provide accurate assessment of phase and concentration of grain boundary phases and prevented a better understanding of the formation mechanism of such attach. This study, by pairing transmission electron microscope (TEM) characterization and atom probe tomography (APT) techniques with in-situ micro-tensile testing in scanning electron microscope (SEM), aims at gaining in-depth understanding on the formed FCCI region. The identified FCCI region roughly consists of multilayers as illustrated in Figure 1 (c). The main findings are: (1) layer-B shows observable lanthanides (Lns) infiltration along grain boundaries and mechanical softening due to FCCI- and irradiation-induced microstructural and microchemistry changes, particularly the recovery of martensitic lath structure and dissolution of pre-existing M23C6 together with the formation of coarsened Laves phases, (Fe, Cr)2(Mo, W); (2) layer-C is Fe depleted but Lns significantly enriched, becoming very brittle; (3) layer-D is mainly composed of UFe2 and Lns; (4) three FCCI-induced intermetallic U-Fe-Zr phases, ? (Fe0.5Zr0.32U0.18), e (Fe0.3Zr0.4U0.3), ? (Fe0.06Zr0.23U0.71), were identified near layer-E; (5) the ? (Fe0.5Zr0.32U0.18) phase was characterized to be a face centered cubic (FCC) crystal structure. These results will help to better understanding the governing mechanism of FCCI and facilitating the development of theoretical model for assessing the performance of metallic fuel and cladding integrity.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Advanced Fuel Cycle Cost Basis Report: Module D1-7 Contact-Handled Pelletized Pressurized Heavy Water (PHWR) UOX Fuel Fabrication (Rev.1)

In addition to literature-based pressurized heavy-water reactor (PHWR) fuel price information in the 2017 AFC-CBR, the what-it-takes (WIT) unit cost data in this update is informed by new analysis and escalation of the 1978 PHWR-UOX fuel life cycle cost (LCC) data from ORNL reports prepared for the 1977–1980 Nonproliferation Alternative Systems Assessment Program (NASAP). (These reports are referenced and summarized in detail in Module D1-PR.) The PHWR fuel fabrication LCC data in these reports is scaled from a bottom-up cost estimate for a reference technology pressurized-water reactor (PWR)—uranium oxide (UOX) fuel fabrication plant by using algorithms that consider the manufacturing process complexity, fuel design complexity, plant floor space requirements, and the radiation and health, safety, and environmental (HS&E) regulatory environment of PHWR-UOX fuel production vis-à-vis light-water reactor (LWR)-UOX production (PWR fuel in this case). The module name has been changed from “Canadian Deuterium Uranium (CANDU)” to the more generic PHWR fuel fabrication in recognition that not all power reactors that might use this fuel type are considered. Unfortunately, the detailed algorithms and their design bases were not archived at the end of the NASAP effort of the commercial CANDU concept specifically developed in the middle of the last century by Atomic Energy of Canada Limited (AECL).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗