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Computational model development and validation of fuel dispersal phenomena

As the US nuclear industry is renewing efforts to extend the rod average burnup limits in existing pressurized water reactors, it becomes imperative to investigate the safety implications associated with high burnup fuel fragmentation and the potential dispersal of fragmented fuel into the reactor coolant system. Additionally, as there is a growing interest in transitioning to new nuclear fuel designs to accommodate higher fuel burnup levels, it becomes essential to conduct studies on fuel behavior during design basis accident scenarios, particularly during a postulated loss-of-coolant accident, in order to ensure the safe operation of light-water reactors. The present study develops a computational model to simulate the complex three-phase flow of the fuel dispersal phenomena that occur following a breach in the cladding, when the stream of solid fuel particles and carrier fission gas stream may interact with the surrounding liquid medium. Furthermore, the proposed framework considers the solid phase as discrete Lagrangian particles while the interpenetrating gas–liquid continuum is modeled using a Eulerian framework. The developed simulation framework is validated with experimental results performed in a separate-effect test facility by comparing predicted particle settlement locations with the experimental observations reported in the literature. Key highlights of this study include the interpretation of the high-pressure boundary conditions and the three-phase flow coupling strategy. Also discussed are the gas–liquid hydrodynamics and the behavior of particles as they are transported through the gas and liquid phases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Irradiation performance of a U-7Mo in Al-Si matrix dispersion full-size fuel plate assembly

The Korea Atomic Energy Research Institute (KAERI) is leading the Ki-Jang Research Reactor (KJRR) project with the intent to develop a new reactor for medical isotope production and other nuclear research purposes. The KJRR core is designed to use high density fuel system where uranium alloyed with 7 wt% molybdenum (U-7Mo) particles are dispersed in a matrix of aluminum alloyed with 5 wt% silicon (Al-5Si) and clad in aluminum alloy 6061 (Al-6061) to form fuel plates. KAERI developed a fabrication facility to construct KJRR fuel assemblies and partnered with the Idaho National Laboratory (INL) to irradiate a full-size fuel assembly, with 21 total fuel plates, in the Advanced Test Reactor (ATR). Irradiation testing and subsequent Post Irradiation Exam (PIE) campaigns were performed successfully over a multi-year project. Monte Carlo neutronic calculations, coupling with a depletion code, were performed based on ATR’s as-run power history which showed that the highest power plate (plate 20) reached 83.1 % end-of-life (EOL) local burnup based on initial 235 U content. Additionally, finite element thermal modeling was performed based as-run power history which showed a beginning-of-life (BOL) peak local heat flux of 184 W/cm 2 . No anomalous fuel performance was observed during the irradiation and target test conditions were achieved. PIE showed favorable performance of the fuel assembly regarding all important phenomena. This paper describes the KJRR fuel assembly irradiation conditions and PIE data to support the conclusion that it performed well, without evidence of unexpected or problematic fuel performance, within an irradiation test designed to bound the KJRR design environment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A knowledge gap analysis for transient CHF prediction within RELAP5-3D

Here we compare several experimental pool and flow boiling critical heat flux experiments with corresponding computational models developed with RELAP5-3D. Encompassed within this paper are several sensitivity analyses for the boiling heat transfer correlations, critical heat flux (CHF) prediction within RELAP5-3D and the thermal properties of the cladding for experiments in the Transient Reactor Test Loop (TRTL) and Transient Reactor Test (TREAT) facilities. The sensitivity analyses were consistent in determining that there is a large contribution from the critical heat flux multiplier which in this application, accounts for the effects of power transient critical heat flux. Comparison to experimental results of both the TREAT CHF-SERTTA experimental campaign and a University of New Mexico (UNM) pool boiling experimental campaign demonstrate both the under-prediction of transient CHF and nucleate boiling heat transfer. To address the gaps in knowledge regarding the transient heating effect for both boiling heat transfer and CHF prediction, we present an experimental test matrix for the TRTL facility that will isolate the power transient effect under PWR relevant operational conditions. The test matrix will incorporate 6 power pulses with a constant energy deposition and a timescale that spans over several orders of magnitude, including a steady state test with an exponential period of 10 s.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Dispersal of high-burnup fuel fragment surrogate particles during and after loss-of-coolant accident tests

The issue of fuel fragmentation, relocation, and dispersal is critical in the licensing and use of high-burnup (>62 GWd/MTU) nuclear fuel in light water reactors (LWRs). In this work, two test series are reported that examine the fragment dispersal during a burst event and an additional dispersal following the burst due to vibrations in the rod, such as those induced by accident recovery systems. To examine dispersal during the balloon and burst portion of a Loss-of-Coolant Accident event, HfO 2 fragments and yttria-stabilized zirconia pellets were filled into an as-fabricated cladding tube, which was then pressurized and subjected to loss-of-coolant accident testing in steam. Results from this test were found to be highly non-prototypic, and dispersal was both significantly more violent and significantly greater in magnitude than identified for actual fuel tests. These findings were attributed to the conservative (more dispersive) nature of the particles chosen for dispersal and to the details of the test conditions used that led to particularly wide bursts. Further, the second set of tests examined dispersal following the burst when vibrations were induced in the rod, primarily via recovery activities such as Emergency Core Cooling System actuation leading to rapid water addition. Post-burst dispersal testing was performed by inducing sinusoidal oscillations with 2–25 nm peak-to-peak amplitude and 2–5 Hz frequencies in pre-burst rods that had been refilled with HfO 2 fragments or high-burnup fragment surrogate mixture of HfO 2 fragments and yttria-stabilized zirconia sands. Testing revealed that rods with large burst openings (7 mm wide in this work) led to unmitigated dispersal from above the burst zone but that smaller bursts (5 mm wide), although still much larger than the mean fragment size of 3 mm, led to effectively no dispersal because of interparticle locking. Additionally, mixture and moisture were found to impact the amount of dispersal: mixtures increased dispersal, and moisture drastically reduced it. The implications of these findings on likely dispersal from actual fuel are discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

The liquid-conduction, vapor-flow heat pipe model in Sockeye

A single-phase heat pipe flow model implemented in the heat pipe application Sockeye is described. This model solves one-dimensional, compressible flow equations for the vapor phase in the center of a heat pipe, which are coupled to the two-dimensional heat conduction equation for the wick, liquid, and cladding, as well as to an ordinary differential equation tracking the working fluid inventory in the evaporator section of the heat pipe. This model is demonstrated with several test problems, including comparisons to analytic solutions for the vapor flow fields, analytic curves for sonic and capillary limitations of heat pipe operation, and some experimental data. The numerical solution gives excellent agreement for verification problems and good agreement with experimental results. Also, demonstrations show that the model is very robust, allowing for full simulations of heat pipe transients, including frozen startup, sonic-limited (supersonic) flow, and heat pipe shutdown.

42 ENGINEERING↗

Flow reversal benchmark of a one-sided heated narrow rectangular channel with CATHARE and RELAP5

Flow reversal in narrow coolant channels can be a crucial phenomenon for the safety of research reactors with a downward nominal flow direction. During a loss of forced flow accident, the downward flow stagnates briefly before transitioning into an upward natural circulation flow. The fuel may be damaged if dryout occurs and threshold fuel and/or cladding temperatures are exceeded. A comprehensive study is provided for flow reversal in narrow rectangular channels by examining experimental data and conducting software model analyses. The literature on flow reversal was reviewed, and selected experimental datasets were used to benchmark against CATHARE and RELAP5 models and also compare the code calculations with each other. The experimental data comes from flow reversal tests conducted with a narrow rectangular channel with one-sided heating. The results were compared with experimental data for successful flow reversal tests and predicted dryout power for dryout conditions. Also, the study examined the effects of the pump coastdown period, inlet liquid temperature, system pressure, and localized pressure drops. The experimental results showed that shorter coastdown periods, reduced pressure drops, and lower coolant inlet temperatures increased the dryout power. However, the system pressure did not noticeably affect the results. The simulation results showed that both CATHARE and RELAP5 agreed with experimental data, capturing the trends of the experimental results. Slight differences between each code calculation, as well as the predicted and measured dryout powers, were attributed to experimental uncertainties and the modeling of physical phenomena such as wall nucleation, interfacial heat transfer, drag coefficients, and critical heat flux. Overall, this study provides an understanding of flow reversal and the prediction capabilities of thermal-hydraulics software models. In conclusion, a future study of the flow reversal benchmark of a narrow rectangular channel with two-sided heating may provide additional valuable insights.

CATHARE↗

Modeling and design of a separate effects irradiation test targeting fission gas release from Cr-doped UO 2

Fission gas release (FGR) from nuclear fuel during operation can diminish heat transfer properties across the pellet-cladding gap and increase the fuel rod internal pressure, thereby posing a concern to fuel reliability and safety during an accident. Enlarging the fuel grain size, which has been shown to improve fission gas retention, can be achieved by doping the fuel feedstock prior to sintering. In this work, the BISON fuel performance code was used to predict FGR from undoped and chromia-doped UO 2 (referred to as Cr-doped UO 2 ) fuel specimens with different grain sizes and across various temperatures. The BISON models identified the irradiation conditions for which FGR is most significant, and a separate effects irradiation experiment in the High Flux Isotope Reactor (HFIR) was then developed targeting those conditions. Further, the experiment leveraged the MiniFuel irradiation capability at Oak Ridge National Laboratory and consisted of 12 fuel specimens of varying grain size and Cr content. A coupling scheme between BISON FGR results and the ANSYS finite element thermal model used for experiment design was formulated to predict cumulative FGR from each fuel specimen based on expected irradiation temperature histories. The fuel samples were fabricated and characterized as a part of this work, and the fuel compositions modeled in BISON were representative of the specimens used in the experiment. This combined modeling and experimental effort aims to study the effect of fuel grain size and Cr content on FGR and to provide simulated BISON FGR results that can be used for future model validation activities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

International fuel performance study of fresh fuel experiments for PCMI effects during RIA experiments

This paper presents the results of High-burnup Experiments for Reactivity-initiated Accident (HERA) Modeling & Simulation (M&S) exercise. The HERA project under the Nuclear Energy Agency (NEA) Second Framework for Irradiation Experiments (FIDES-II) program is focused on studying Light Water Reactor (LWR) fuel behavior during Reactivity-Initiated Accident (RIA) conditions. The Part I M&S cases are based on a series of tests in the Transient Reactor Test (TREAT) facility in the United States and the Nuclear Safety Research Reactor (NSRR) in Japan. The purpose of this work is to evaluate the test design to accomplish its goals in establishing clearer understanding of the effects of power pulse width during RIA conditions. Further, the blind predictions using various computational tools have been performed and compared amongst to interpret the behaviors of high burnup fuels during RIA. While many international participants evaluate the thermal–mechanical behavior of fuel rod under different conditions, a considerable scatter of outputs comes out for the cases due to the disparity between codes in predicting mechanical behaviors. In general, however, the results of thermal–mechanical analysis elaborate that nominal design conditions the shorter pulse width tests in NSRR should cause cladding failures while the TREAT tests appear to have more split prediction of failure or not. Furthermore, the sensitivity analysis varying key testing parameters reveals the considerable effect of power pulse width and total energy deposition on prediction of fuel rod failure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Sensitivity study of hydrogen Soret transport in yttrium Hydride-Based nuclear fuel

Yttrium hydride is an excellent solid neutron moderator material for high temperature nuclear reactor applications due to its high hydrogen density and exceptional hydride stability at high temperatures. Despite these attractive characteristics, the details of how hydrogen behaves within yttrium hydride while temperature gradients exist are still not well understood. The evolution of the hydrogen composition profile resulting from a temperature gradient requires knowledge of hydrogen’s heat of transport, a critical parameter that has not yet been measured for this material. In this work, we perform hydride redistribution, hydrogen dissociation, and hydrogen leakage calculations while varying the Soret heat of transport of hydrogen in yttrium hydride to elucidate the sensitivity of hydride stability under temperature gradients to this parameter. This study analyzes hydride stability of a hypothetical uranium-yttrium hydride nuclear fuel design during operation of a high temperature liquid metal-cooled nuclear reactor. Assuming U-YH x could be fabricated in a physically stabilized manner, this fuel system can likely maintain hydride stability while operating at very high power densities and temperatures. We find that even though the hydrogen dissociation pressure in the gas gap does vary by several percent as the heat of transport temperature parameter is varied, the hydrogen content in the U-YH x fuel meat is relatively insensitive to this parameter over the course of a high burnup fuel cycle; this is due to yttrium hydride’s excellent hydrogen retention under the high temperature conditions considered here. Here, this suggests that hydride stability analyses are insensitive to the value of the Soret heat of transport in U-YH x under steady state liquid metal-cooled reactor conditions. However, the susceptibility to internal gas overpressurization-induced stress-rupture of the cladding during a high temperature transient is more sensitive to this parameter due to the non-linear dependence of hydrogen gas dissociation pressure vs. composition and temperature.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A strategy for automated core design to increase economic viability and minimize fuel fragmentation, relocation, and dispersal susceptibility in high-burnup cores

The nuclear industry aims to increase the cycle length of pressurized water reactors from 18 to 24 months to increase power plant capacity factors and economic viability. These cycle length extensions will inherently require fuel rods to exceed the current peak rod average burnup limit of 62 GWd/MTU. A chief concern of operating beyond the current burnup limit is the fuel fragmentation, relocation, and dispersal (FFRD) phenomenon in which pulverized fuel fragments can axially relocate and escape through a burst in the cladding formed during a loss-of-coolant accident. In this work, we demonstrate an approach for automating core design employing an optimization tool based on a penalty-free, parallel simulated annealing algorithm to produce pressurized water reactor core designs with two different optimization objectives. The two objectives were to produce core designs with (1) mitigated FFRD susceptibility while achieving 24-month cycle lengths (2) maximum cycle length with no regard for the likelihood of FFRD. Batch size was considered in tandem with both cases to maximize economic viability. The PARCS nodal model was the primary reactor physics tool used in the optimizations and used nuclear cross sections calculated with 2D Polaris lattice physics models. Reactor performance and safety characteristics of the optimized cores were verified using high-fidelity Virtual Environment for Reactor Applications models. The core designs produced by the optimization tool are compared with each other and to a high-burnup core design produced and analyzed in previous works to highlight the fuel management strategies that may enhance high-burnup reactor safety and economic viability. The optimized cores satisfied their respective objective functions, producing a maximum cycle length of 720 effective full-power days in one core design and one that may reduce FFRD susceptibility by up to 50% based on the first-order approximation to FFRD risk formulated in this work. The optimized cores met most constraints but exceeded the hot channel factor limit, especially in FFRD cases where fresh fuel carried more power. Furthermore, this highlights the need for future lattice-level optimizations and broader assembly options.

Cycle length↗

Estimation of post-burst vibration-induced fuel dispersal thresholds following LOCA-simulant testing

The nuclear industry intends to increase burnup past the regulatory limit of 62 GWd/MTU, and to be successful, the dispersal behavior of fragmented high-burnup fuel during loss-of-coolant accidents must be better understood. Part of this behavior is fuel fragmentation, relocation, and dispersal. This work reports on testing concerning the dispersal of fuel from rods following burst and pressure blowdown through the burst. The Fuel Relocation Induced by Accident Recovery (FRIAR) system was used to examine surrogate material and pre-burst cladding specimens to evaluate the effects of vibrational loading, mixture composition, and burst size on post-burst dispersal. Vibrational loading resulted in maximum dispersal around 15 Hz when the loading was performed with peak-to-peak oscillation amplitudes at 0.5 and 1 mm. Here, under this aggressive vibrational loading, dispersal was found to become significant as burst widths increased to approximately 5 mm and larger. However, below 4 mm widths, little material dispersed out of the opening, even at 1 mm amplitudes and for more dispersive mixtures (smaller average fragments). At and above 7 mm widths, dispersal was rapid for all mixtures. Finally, dispersal in the threshold region (4–5 mm wide bursts) strongly depended on the mixture. For mixtures with large fragments, dispersal was minimized to a few fragments, as the large fragments proved to be effective at minimizing dispersal. Conversely, mixtures with smaller fragments showed increased dispersal in this region.

Burst geometry↗

Photovoltaic windows cut energy use and CO 2 emissions by 40% in highly glazed buildings

Buildings account for 30% of global energy use. The architectural trend across building sectors is toward more glass despite higher energy use and carbon emissions than opaque cladding alternatives. Numerous window technologies - low-emissivity coatings, triple glazing, dynamic tinting, and the more recently developed photovoltaic glass - have emerged in the last two decades as approaches to reduce building energy. However, a comprehensive understanding of where and how these window technologies can be installed to enable optimal energy savings under different climate conditions remains limited. Here we test window technologies using thousands of macroscale building-energy simulations for different climate zones and building designs to evaluate the associated net energy use and carbon-emissions reduction potential. Novel window technologies, especially photovoltaic windows with high thermal performance, offer energy savings in all climates, ranging from 10,000-40,000 GJ per year over substandard windows for a typical office building, resulting in up to 2,000 tons of annual CO 2 emissions reduction. Highly glazed, net-zero buildings are achievable via photovoltaic windows when combined with careful geometric considerations.

14 SOLAR ENERGY↗

Additive manufacturing of cobalt-based alloy on tool steel by directed energy deposition

Cladding hard-surfacing alloys on tool steel is an effective approach to enhance the surface properties of tool steel. In this study, a Co-based alloy was deposited on tool steel by Directed Energy Deposition (DED) following a three-factor three-level design of experiment matrix with varied laser power, scan speed, and powder flow rate. The microstructure of the deposits was characterized using scanning electron microscopy (SEM). The residual stress on the surface of the samples was measured by the X-ray diffraction (XRD) sin2? technique. The parameters that produced promising deposits were used to fabricate samples for tensile test, four-point bending test, Charpy impact test, and hardness measurement. Our result reveals that the processing parameters have a significant role in the residual stress of the coatings. Residual stress reduces with the increase of laser energy density. Cracks were found at samples with energy density below a threshold. Tensile testing of the coating/substrate combined structure reveals fracture at the coatings with an ultimate tensile strength of 633.9 ± 54.7 MPa. The bi-material interface survived the tensile test, indicating a strong interfacial bond. The four-point bending test of coating/substrate laminates shows an ultimate flexure strength of 860.6 ± 36.9 MPa. Cracks initiated from the coatings ignored the interface and penetrated the substrate, suggesting a solid bi-material bond. Charpy impact test shows the absorbed energy of coating/substrate laminates is more than doubled that of the substrate.

36 MATERIALS SCIENCE↗

Preliminary conceptual design of fast neutron spectrum nuclear thermal rocket cores using monolithic uranium nitride fuel

This paper presents a few nuclear thermal rocket (NTR) reactor core preliminary conceptual designs based on the use of monolithic uranium nitride (UN) fuel plates or pins clad with tungsten (W), alloyed or unalloyed as needed. High-assay low-enriched uranium (HALEU) as well as high-enriched uranium (HEU) are considered. Nominal core thermal powers are between 300 and 1100 MW corresponding to thrusts between 66 kN and 240 kN. The estimated thrust-to-reactor-weight ratios (T/WRx) achievable with the HEU plate and pin configurations are between 3.8 and 10.9. The T/WRx achievable with the HALEU plate and pin configurations are lower, 1.9–4.0, than those achievable with HEU. It is noteworthy that even a relatively modest increase in fuel enrichment above the HALEU limit enables a significant increase in T/WRx. It must be emphasized that these results do not yet account for uncertainties and that the appropriateness of the assumed fuel thermal design limits for normal operation (i.e., peak centerline temperature of 3100 K) will need to be confirmed. Finally, just like for the other UN-based fuels currently considered for NTR applications (i.e., CERMET and CERCER), the proposed UN fuel systems need significant testing in prototypic conditions to confirm the appropriate performance for safe NTR applications. However, the monolithic fuel systems may have, overall, a higher technology readiness level (TRL), and, consequently, shorter fuel development and validation time may result.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Prospects for additive manufacturing of nuclear fuel forms

Additive manufacturing (AM) is viewed as a critical enabling technology for achieving superior performance and improved economics across many sectors. Although the past decade has seen increased application of AM methods to nuclear reactor cladding and structural materials, exploration of AM as applied to the uranium-bearing nuclear fuel forms has been limited. The two major families of nuclear fuel forms (monolithic, particle/dispersion) are utilized with their own set of core objectives in mind, and their differences require distinct fabrication infrastructures. These reference fabrication methods impose many limitations on nuclear fuels. Further, both currently operating reactors and future concepts have the potential for improved performance if these accepted limitations are relaxed or removed entirely. The primary limitations of reference fabrication processes for the common nuclear fuel forms are outlined in this paper. This groundwork is then used to identify avenues of fuel performance specific to each of these fuel architectures that could be exploited if the restrictions of conventional fuel fabrication are removed. Moreover, multiple targets for AM studies are laid out for each of the major nuclear fuel variants. Finally, key strategic components to guide research activities in AM of nuclear fuels are outlined, with an emphasis on use of modeling and simulation to motivate research aims and embrace of an accelerated testing methodology to screen and quality new fuel forms.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Particulate plutonium released from the Fukushima Daiichi meltdowns

Traces of Pu have been detected in material released from the Fukushima Daiichi Nuclear Power Plant (FDNPP) in March of 2011; however, to date the physical and chemical form of the Pu have remained unknown. Here we report the discovery of particulate Pu associated with cesium-rich microparticles (CsMPs) that formed in and were released from the reactors during the FDNPP meltdowns. The Cs-pollucite-based CsMP contained discrete U(IV)O 2 nanoparticles, <~10 nm, one of which is enriched in Pu adjacent to fragments of Zr-cladding. The isotope ratios, 235 U/ 238 U, 240 Pu/ 239 Pu, and 242 Pu/ 239 Pu, of the CsMPs were determined to be ~0.0193, ~0.347, and ~0.065, respectively, which are consistent with the calculated isotopic ratios of irradiated-fuel fragments. Thus, considering the regional distribution of CsMPs, the long-distance dispersion of Pu from FNDPP is attributed to the transport by CsMPs that have incorporated nanoscale fuel fragments prior to their dispersion up to 230 km away from the Fukushima Daiichi reactor site.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Deformation mechanism in nanolaminate FeCrAl alloys by ,em>in situ micromechanical strain rate jump tests at elevated temperatures

FeCrAl alloys have attracted extensive attention as one of the potential cladding materials for the commercial light water reactors. Although the creep behaviors of coarse-grain FeCrAl alloys have been investigated at elevated temperatures, little is known on the deformation mechanism of fine-grain FeCrAl alloys. We performed surface mechanical grinding treatment to fabricate nanolaminated ferritic FeCrAl alloys. In situ micropillar compression tests were applied to determine the underlying deformation mechanism of nanolaminated FeCrAl alloys at elevated temperatures. The strain rate sensitivity and activation energy for the dominant deformation mechanism were estimated considering the presence of a threshold stress.

36 MATERIALS SCIENCE↗

In-situ synchrotron X-ray investigation of phase evolution in gas atomized powder enabling manufacturing of nanoscale oxide-dispersion strengthened ferritic steels

Here, we present an investigation of Fe-14Cr-3W-0.4Y-0.4Zr-0.18Ti (wt.%) as a reduced-activation oxide-dispersion strengthened (ODS) ferritic steel, an alternative to the “14YWT” structural alloys designed for nuclear energy applications. Gas atomization reaction synthesis (GARS) was used to produce these Zr-modified powders with a non-equilibrium (metastable) phase that enable a heat treatment (delayed) route for producing nanoscale oxide-dispersion strengthening. In situ synchrotron X-ray diffraction and transmission electron microscopy were used to analyze phase evolution as a function of temperature and time, revealing formation of highly dispersed oxide nanoprecipitate phases at temperatures above those needed for powder consolidation and shaping of components. This would allow fabrication of net-shape parts using conventional powder-processing methods prior to thermal activation of a reaction producing nanocrystalline Y-(Ti, Zr)-O particles, with a size of 20 ± 7 nm. These results can inform processing of tubes, cladding, sheets, and plates for use in advanced fission and fusion reactors.

In-situ synchrotron X-ray diffraction↗