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3D CFD Model Validation Using Benchmark Data of 1/16th Scaled VHTR Upper Plenum and Development of Wall Heat-Transfer Correlation For Laminar Flow

With support from the U.S. Department of Energy-Office of Nuclear Energy’s (DOE-NE’s) Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, an effort has been pursued to support high-temperature gas-cooled reactor (HTGR) technology development and its modeling and simulation needs. There is a particular need for advanced modeling and simulation tools to predict thermal-fluid behavior in the nuclear reactor primary system, especially in the core and the lower and upper plena, during safety-related transients. In this report, two main such activities are presented relevant to the HTGRs: (1) three-dimensional (3D) computational fluid dynamics (CFD) validation using benchmark data from the upper plenum of Texas A&M University’s 1/16th scaled very-high-temperature gas-cooled reactor (VHTR), and (2) development of wall heat-transfer correlation for laminar flow in a wall-heated pipe. The CFD tool validation exercises can be helpful to choose the models and CFD tools to simulate and design specific components of the HTRGs such as upper plenum where jet mixing is a complex phenomenon. In a loss of forced circulation event, the laminar flow can be observed during the development of natural circulation flow. This work includes the development and validation of heat transfer correlations for laminar flow using the Nek5000 CFD code due to limited available experimental data for laminar flow conditions to guide low-order models (1D). In this report, the flow characteristics of a single isothermal jet discharging into the upper plenum was investigated using the Nek5000 Large-Eddy Simulation (LES) CFD tool. Several numerical simulations were performed for various jet-discharged Reynolds numbers ranging from 3,413 to 12,819. A grid-independent study was performed. The numerical results of mean velocity, root-mean-square fluctuating velocity, and Reynolds stress were compared against the benchmark data. Good agreement was obtained between simulated and measured data for axial mean velocities, except near the upper plenum hemisphere. The maximum predicted errors for axial mean velocities at various normalized coolant channel diameter heights of 1, 5, and 10 are 1.56%, 1.88%, and 3.82%, respectively. In addition, the predicted root-mean-square fluctuating velocity and Reynolds stress are qualitatively in agreement with the experimental data. The Nek5000 code was used to develop wall-heat transfer correlation for laminar flow in a cylindrical tube. Several simulations were performed for various Reynolds flow and wall-heat fluxes. A new heat transfer correlation was developed using data from Nek5000 simulation results and regression functions in Matlab. The developed heat transfer correlation is valid for various Reynolds flows from 200 to 2000. The predicted R² value for model fit was 0.875, which ensures that 87.5% of the model data lies on the Nek5000 data. Moreover, a machine learning (ML) tool was used to train and test the Nek5000 data. A good fit of the ML-based model was observed with the test data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Representativity error scaling of models of the high temperature test facility

Error scaling is a critical step toward the validation of modeling capabilities for high-temperature gas-cooled reactors (HTGRs). Extensive effort is being made to bring HTGRs into the validation basis of numerous thermal-hydraulics codes. Here, this paper demonstrates how systems-level codes can be leveraged to perform error scaling analyses between an experimental facility and a plant-to-be facility. Specifically, we focus on two conduction cooldown experiments from the High Temperature Test Facility (HTTF) and the General Atomics 350 MW th modular high-temperature gas-cooled reactor (MHTGR-350). The error scaling methodology employed in this study is representativity, which in the context of this work was used to quantify how well experiments captured the physics of the plant facility by comparing sensitivity vectors between the two facilities. In addition, two different RELAP5–3D models of the HTTF were included in the comparison to determine if modeling methodologies notably impact the representativity results. The key figures of merit are the maximum block temperature and the coolant outlet temperature. The time-dependent maximum block temperature had a low representativity of below 0.1 for both models across both transients. The coolant outlet temperature had a higher representativity of around 0.6 for both models during the pressurized conduction cooldown, but it was below 0.2 for the depressurized conduction cooldown. Overall, the HTTF experiments were not representative of the transients in the MHTGR-350. However, these results can play a significant role in informing future potential experiments for HTGR systems that iterate on what the HTTF accomplished.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Study on Water-ingress Accident during the Initial Core and the Running-in Phase of HTR-PM - 18429

Water ingress accident is one of the typical accidents with potential hazard to the high temperature gas-cooled reactor (HTGR), which will cause reactivity introduction, as well as the chemical corrosion of the graphite fuel elements and reflector structure material. Besides, increase of the primary pressure may result in the opening of the safety valves, consequently leading the release of radioactive isotopes. Therefore high attention has been paid to water ingress phenomenon during the design of the HTGR to verify its inherent safety characteristics. The online continuous discharge and multi-pass of the fuel elements is another important characteristics for the pebble-bed HTGR which can effectively increase the reactor operation availability. From the initial core, a long period of time, namely the running-in phase, is needed to reach the final long-term stable equilibrium core. During this period of time, the core states are totally different, including the number of the fuel elements, the fuel enrichment, the accumulation of the fission product, the temperature feedback coefficient of the reactivity, and so on. In this paper, based on the design of 250 MW Pebble-bed Module High Temperature gas-cooled Reactor (HTR-PM) and a candidate proposal for its initial core and running-in phase, considering three typical states during the running-in phase, the design basis accident of a double-ended guillotine break of one heating tube has been analyzed with the TINTE code, and the results are compared with that of the equilibrium core. Some important parameters during the transient process, including the power, the temperature of the fuel element, the pressure of the primary coolant, as well as the graphite corrosion rate, are studied. To a certain extent, the results can verity the design of the initial core and the running-in phase, and also further prove the safety feature of the HTR. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Development of an Improved RELAP5-3D Model for the High Temperature Test Facility

High-temperature gas-cooled reactors (HTGRs) are rapidly approaching deployment. Confidence in transient analysis of these systems requires modeling and simulation tools that have been validated against data relevant to HTGR conditions. The High Temperature Test Facility (HTTF) is an integral effects thermal hydraulics test facility for prismatic HTGRs. In spring and summer of 2019, HTTF was used for a series of experiments that now serve as the basis for the Organization of Economic Cooperation and Development / Nuclear Energy Agency Thermal Hydraulic Code Validation Benchmark for High Temperature Gas-Cooled Reactors using HTTF Data (HTGR T/H Benchmark). Previous analyses as part of the HTGR T/H benchmark used a RELAP5-3D model developed at Idaho National Laboratory (INL) and demonstrated an ability to reproduce trends in the measured data but difficulties reproducing experimental values within their uncertainty. These difficulties were largely attributed to assumptions made during the development of the initial RELAP5-3D model, which predated the HTTF experiments. A significant cause of difficulty reproducing the measured temperatures may be the radial nodalization of the previous RELAP5-3D model. In this paper, we present a new RELAP5-3D model of HTTF with finer radial nodalization built to assess the impact of radial heat transfer. We describe the new model and compare it against the old one at full-power steady state and for the pressurized conduction cooldown (PCC) transient. These analyses are based on the code-to-code comparison exercise for the PCC problem of the HTGR T/H benchmark. We compare maximum block temperature as the primary figure of merit and include discussion on intracore natural circulation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Implementation of a Drift-Flux Model in SAM for Modeling of Passively Transported GAS in Molten Salt Reactors

The Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is further developing the Multiphysics Object Oriented Simulation Environment (MOOSE) system thermal hydraulics (T/H) code, System Analysis Module (SAM), to include modeling of molten salt reactor (MSR) designs. MSR designs in which the fuel is dissolved in the salt coolant poses unique modeling and simulation (M&S) challenges because fission products—some of which will be noncondensable gasses—travel with the coolant, thus allowing for deposition and interaction throughout the entire system flow loop. This behavior must be modeled to successfully understand MSR system behavior during normal and off-normal operation events. In past work, SAM has been extended to include a passive species transport capability for modeling of MSR fission products that travel with the salt coolant. This work extends the model to include a drift-flux model to capture the tendency of the gas phase to move at a different velocity than the bulk liquid. Additional constitutive models have also been added for calculation of gas volume fraction, bubble radius, and interfacial area, which will be important for calculation of species phase migration in future coupling activities. Testing has been performed to ensure that the new model agrees with expected values for several simple models, but additional future work will be required to test the model for more complex geometries that will be needed for full-scale MSR simulations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Final report on assessment of molten salt corrosion testing of unirradiated and ion irradiated advanced manufactured high entropy alloys

Generation IV reactors and future fusion reactor designs have led to more demanding materials performance requirements due to their increased operating temperatures, corrosive coolants, and increased radiation doses compared to the current light-water reactor fleet. Among the innovative nuclear technologies under development, molten salt reactors stand out for their potential to offer superior fuel utilization, intrinsic safety characteristics, and economic viability. Of the proposed Generation IV designs, the gas fast reactor operates at 450 to 850°C and the molten salt reactor operates at 565 to 850°C, with the molten salt reactor design needing molten salt corrosion resistant materials [1, 2]. These increased temperatures and more extreme corrosion environments necessitate higher material performance, such as creep strength, radiation-tolerant microstructures, corrosion resistance, and high-temperature tensile properties. Hastelloy-N, a nickel-based alloy with additions of molybdenum and chromium, has been successfully employed to contain molten fluoride salt at temperatures up to 705°C. However, Hastelloy-N becomes embrittled upon neutron irradiation, primarily due to the accumulation of helium produced by (n,a) transmutation reactions. Furthermore, the corrosive nature of molten fluoride and chloride salts presents a formidable challenge, as these salts can react with and dissolve alloying elements such as Cr, Mo, and Fe, leading to selective leaching, loss of protective oxide layers, and accelerated degradation. High entropy alloys (HEAs) and refractory high entropy alloys (RHEAs) have emerged as a prominent area of interest, due to their ability to achieve tailored chemical compositions for specific applications. Unlike conventional alloys, HEAs are characterized by having multiple principal elements in equimolar or near equimolar ratios, leading to an unconventional alloying strategy [3]. This alloying strategy is believed to promote unique properties, such as single-phase stabilization of chemically compatible elements, lattice distortion effects due to atomic radius differences, and proposed sluggish diffusion effects. For extreme-environment applications, RHEAs have garnered much research interest because of the possibility of creating relatively ductile materials that can operate in extremely high-temperature environments, beyond the operating temperatures where other Ni-based superalloys begin to lose strength [4-6]. Idaho National Laboratory (INL) initiated a joint international effort with the Czech Republic to explore the feasibility of manufacturing HEAs for high-temperature nuclear applications using advanced manufacturing. This effort was funded at INL by the United States Department of Energy's Office of Nuclear Energy under the Advanced Reactor Technologies and Advanced Materials and Manufacturing Technologies (AMMT) Program. The HEAs were specifically designed for the corrosive and irradiation environments experienced in gas-cooled fast reactors, molten salt reactors, and fusion power. These alloys have been manufactured by multiple processes to determine the impact of manufacturing processes on the performance of the alloys in corrosive and irradiation environments. Preliminary molten salt corrosion testing showed that equimolar MoNbTiV and MoNbTi alloys exhibit exceptional performance, with arc-melted variants demonstrating only minimal degradation after 1000 hours of exposure to molten chloride salt at 700°C. Conversely, Nb2TiVZr2 showed significant molten salt corrosion susceptibility and microstructural instability during high-temperature molten salt exposures, and was, therefore deemed unfit for molten salt reactor applications. The MoNbTiV, MoNbTi, and Nb2TiVZr2 alloys were further evaluated through ion irradiation experiments conducted at the Michigan Ion Beam Laboratory at the University of Michigan. The microstructural stability and the evolution of irradiation-induced defects were characterized to assess the irradiation resistance of each of these alloys.

36 - MATERIALS SCIENCE↗

NGNP Program 2013 Status and Path Forward

High temperature gas-cooled reactor (HTGR) technology can play an important role in the energy future of the United States by extending the use of nuclear energy for non-electricity energy production missions, as well as continuing to provide a considerable base load electric power generation capability. Extending nuclear energy into the industrial and transportation sectors through the coproduction of process heat and electricity provides safe, reliable energy for these sectors in an environmentally responsible manner. The modular HTGR provides a substantial improvement in nuclear plant safety for the protection of the public and the environment, and supports collocation of the HTGRhigh temperature gas-cooled reactor with major industrial facilities. Under U.S. Department of Energy direction since 2006, the Next Generation Nuclear Plant Project at Idaho National Laboratory has been working toward commercializing the HTGR technology. However, a recent decision by the Secretary of Energy to reduce the scope of the Next Generation Nuclear Plant Project to a research and development program, considerable realignment has taken place. This report: (1) summarizes the accomplishments of the Next Generation Nuclear Plant Program from FY2011 through FY2013; (2) lays out the path forward necessary to achieve the ultimate objective of commercializing HTGR technology; and (3) discusses ongoing technical, licensing, and evaluation activities under the realigned Next Generation Nuclear Plant program considered important to preserve the significant investment made by the government to-date and to maintain some progress in meeting the objectives of the Energy Policy Act of 2005 (EPAct2005).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

RELAP5-3D validation studies based on the High Temperature Test facility

In the spring and summer of 2019, experiments were conducted at the High Temperature Test Facility (HTTF) that form the basis of an upcoming high-temperature gas-cooled reactor (HTGR) thermal hydraulics (T/H) benchmark. HTTF is an integral effects test facility for HTGR T/H modeling validation. This paper presents RELAP5-3D models of two of those experiments: PG-27, a pressurized conduction cooldown (PCC); and PG-29, a depressurized conduction cooldown (DCC). These models used the RELAP5-3D model of HTTF originally developed by Paul Bayless as a starting point. The sensitivity analysis and uncertainty quantification code, RAVEN was used to perform calibration studies for the steady-state portion of PG-27. Here we developed four PG-27 calibrations based on steady-state conditions. These calibrations all used an effective thermal conductivity equal to 36 % of the measured thermal conductivity, but they differed with respect to the frictional pressure drops and radial conduction models. These models all captured the trends in steady-state temperature distributions and transient temperature behavior well. All four calibrations show room for improvement in predicting the transient temperature rise. The smallest error in temperature rise during the transient was a 21 % underprediction, and the largest was a 48 % underprediction. The errors in transient temperature rise are largely a result of a mismatch in power density between the RELAP5-3D model and the experiment due to the location of active heater rods along the boundary between heat structures in the model. The best of these calibrations was applied to PG-29 to model the DCC. Once again, temperatures during the transient were underpredicted but trends in temperature were captured. The RELAP5-3D model captured trends in the data but could not reproduce measured temperatures exactly. This result is not attributed to deficiencies in the experimental data or to RELAP5–3D itself. Rather, this result likely arises due to the some of the assumptions and decisions made when the RELAP5-3D model was first developed, prior to the execution of HTTF experiments. An agreement in prediction of temperature trends but challenges reproducing HTTF temperatures within measurement uncertainty is consistent with previous analyses of HTTF in the literature. Future RELAP5-3D validation activities centered around HTTF may be able to provide greater insight into the code’s capabilities for HTGR modeling with a more finely nodalized model.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

OECD/NEA COUPLED NEUTRONIC/THERMAL-FLUIDS BENCHMARK OF THE MHTGR-350 MW CORE DESIGN: RESULTS FOR PHASE-I EXERCISE 1

This report presents the results from code-to-code comparisons for a prismatic modular high-temperature gas-cooled reactor 350-MW design for steady-state neutron transport calculations. Integral parameters as well as power and flux distributions are provided. Differences between solutions from diffusion and transport operators are analysed. Effects of control rod homogenization between full block and one sixth block are discussed.

42 ENGINEERING↗

Particulates for additive manufacturing techniques

A method of making a particulate for an additive manufacturing technique includes receiving particulate at a chemical vapor deposition (CVD) reactor, flowing a hydrocarbon gas into the CVD reactor, decomposing the hydrocarbon gas in the CVD reactor, and depositing a carbonaceous coating on the particulate using a product of the decomposed hydrocarbon gas. The coating deposited over the particulate has a reflectivity that is lower than the reflectivity the underlying particulate body to reduce an energy input requirement for purposes of fusing the particulate into a layer of an article using an additive manufacturing technique. In embodiments, the coated particulate can be received at an additive manufacturing apparatus and fused into a layer of an article as a metallic-carbon composite using a high-density energy source.

42 ENGINEERING↗

Application of Combined Sustained and Cyclic Loading Test Results to Alloy 617 Elevated Temperature Design Criteria

Alloy 617 is a reference structural material for very high temperature components of advanced-gas cooled reactors with outlet temperatures in the range of 900-950°C . In order for designers to be able to use Alloy 617 for these high temperature components, Alloy 617 has to be approved for use in Section III (the nuclear section) of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. A plan has been developed to submit a draft code for Alloy 617 to ASME Section III by 2015. However, the current rules in Subsection NH for the evaluation of strain limits and creep-fatigue damage using simplified methods based on elastic analysis have been deemed inappropriate for Alloy 617 at temperatures above 1200°F (650°C). The rationale for this exclusion is that at higher temperatures it is not feasible to decouple plasticity and creep deformation, which is the basis for the current simplified rules. This temperature, 1200 °F, is well below the temperature range of interest for this material in High Temperature Gas Cooled Reactor (HTGR) applications. The only current alternative is, thus, a full inelastic analysis which requires sophisticated material models which have been formulated but not yet verified. To address this issue, proposed code rules have been developed which are based on the use of elastic-perfectly plastic (EPP) analysis methods and which are expected to be applicable to very high temperatures.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Report on FY15 Two-Bar Thermal Ratcheting Test Results

Alloy 617 is a reference structural material for very high temperature components of advanced-gas cooled reactors with outlet temperatures in the range of 900-950°C. In order for designers to be able to use Alloy 617 for these high temperature components, Alloy 617 has to be approved for use in Section III (the nuclear section) of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. A plan has been developed to submit a draft code for Alloy 617 to ASME Section III by 2015. However, the current rules in Subsection NH* for the evaluation of strain limits and creep-fatigue damage using simplified methods based on elastic analysis have been deemed inappropriate for Alloy 617 at temperatures above 1200°F(650°C). The rationale for this exclusion is that at higher temperatures it is not feasible to decouple plasticity and creep deformation, which is the basis for the current simplified rules. This temperature, 1200°F(650°C), is well below the temperature range of interest for this material in High Temperature Gas Cooled Reactor (HTGR) applications. The only current alternative is, thus, a full inelastic analysis which requires sophisticated material models which have been formulated but not yet verified. To address this issue, proposed code rules have been developed which are based on the use of elastic-perfectly plastic (EPP) analysis methods and which are expected to be applicable to very high temperatures. These newly proposed rules also address a long-term objective to provide an option for more simple, comprehensive and easily applied rules than the current so called “simplified” rules.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Catalyzed oxidation of nuclear graphite by simulated fission products Sr, Eu, and I

The influence of three fission products Sr, Eu, and I on the oxidation of IG-110 nuclear graphite was studied in the temperature range of 400 to 1000 °C. Sr and Eu were introduced as chlorides, and I was introduced as NaI. The temperature dependence of both CO 2 and CO production during the graphite oxidation measured with mass spectroscopy and infrared spectrometry shows that the introduction of these three compounds to graphite significantly decreases the onset temperature for the oxidation of graphite. Among the three compounds, NaI is the most active towards the oxidation reaction, characterized by a significant decrease of the onset temperature from approximately 650 to 400 °C before and after its introduction to graphite. Separate measurements of CO 2 and CO concentration at varying temperatures enable the calculation of the activation energy for the formation of CO 2 and CO. The activation energies for the oxidation of pure and fission product-impregnated graphite samples decrease in the following order: standard IG-110 graphite, EuCl 3 -impregnated IG-110, SrCl 2 -impregnated IG-110, and NaI-impregnated IG-110. This trend indicates that the three compounds catalyze the oxidation of graphite at temperatures relevant to the operation of high-temperature gas-cooled reactors. Furthermore, it is found that the three compounds can also affect the molar ratio of reaction products CO 2 and CO, and the rates of the graphite oxidation. At temperatures higher than about 850 °C, the impregnated samples exhibit lower CO 2 : CO ratios than the pure graphite. Different from EuCl 3 and NaI, the introduction of SrCl 2 decreases the graphite oxidation rates at temperatures higher than about 770 °C. Their catalytic mechanism can be understood based on a redox cycle of the intermediate active species, promoting the dissociation of molecular oxygen and transfer to the carbon.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Direct Numerical Simulation of the Flow through a Randomly Packed Pebble Bed

The proposition for molten salt and high-temperature gas-cooled reactors has increased the focus on the dynamics and physics in randomly packed pebble beds. Research is being conducted on the validity of these designs as a possible contestant for the fourth-generation nuclear power systems. A detailed understanding of the coolant flow behavior is required in order to ensure proper cooling of the reactor core during normal and accident conditions. In order to increase the understanding of the flow through these complex geometries and enhance the accuracy of lower-fidelity modeling, high-fidelity approaches such as direct numerical simulation (DNS) can be utilized. Nek5000, a spectral-element computational fluid dynamics (CFD) code, was used to develop DNS fluid flow data. The flow domain consisted of 147 pebbles enclosed by a bounding wall. In the work presented, the Reynolds numbers ranged from 430 to 1050 based on the pebble diameter and inlet velocity. Characteristics of the flow domain such as volume averaged porosity, axial porosity, and radial porosity were studied and compared with correlations available in the literature. Friction factors from the DNS results for all Reynolds numbers were compared with correlations in the literature. The first- and second-order statistics show good agreement with the available experimental data. Turbulence length scales were analyzed in the flow. Reynolds stress anisotropy was characterized by utilizing invariant analysis. Overall, the results of the analysis in this study provide deeper understanding of the flow behavior and the effect of the wall in packed beds.

Yildiz, Mustafa Alper↗

Rapid depletion analysis of flowing-pebble reactor systems at equilibrium using SCALE

Several high-temperature gas-cooled reactor concepts (and more recently, salt-cooled designs such as the fluoride salt-cooled high-temperature reactor) feature core designs employing continuously circulating fuel pebbles. These reactor designs permit both continuous online refueling of fuel elements as well as higher overall achievable discharge burnups. However, rapid calculation of time-dependent fuel isotopic inventories proves challenging for this class of dynamic systems with current analysis tools. While iterative approaches employing coupled neutron transport have been developed to solve this issue, rapid depletion analysis techniques are needed to calculate time-dependent inventories for individual pebbles and batches (and thus the construction of full- core inventory at equilibrium). We propose a depletion analysis strategy for this type of system for cores at equilibrium. Drawing upon previous neutronic analysis of the PBMR-400 equilibrium core, we demonstrate the viability of developing collapsed one-group cross section libraries suitable for performing rapid depletion analyses with SCALE. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Transportable NPP with Open and Closed Gas-Turbine Cycle

Information on advancements made in small transportable NPP with HTGR and gas-turbine cycles as the source of energy for supplying electricity and heat in remote regions is presented and the possibility of their development at the current stage is analyzed. This pertains especially to the remote regions of the Far North with extreme climatic conditions: ambient air temperature –50–35°C in the absence of water for dumping unused heat. The possibilities of developing a small transportable nuclear power plant based on schematic and structural engineering studies performed at OKBM Afrikantov with high-temperature gas-cooled reactor and different variants of energy conversion systems are analyzed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗