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High-fidelity forced convection simulations of the University of Wisconsin–Madison air-cooled reactor cavity cooling system

Among the various types of advanced nuclear technologies that exist, high-temperature gas-cooled reactors (HTGRs) stand out for their co-generation capabilities and exceptional passive safety systems. HTGRs rely on a reactor cavity cooling system (RCCS) to remove decay heat from the reactor pressure vessel (RPV) during the course of long-term transients. Several studies have focused on experimental and numerical modeling of the RCCS; however, the literature reveals a notable gap when it comes to high-fidelity simulations such as direct numerical simulations (DNS) or large eddy simulation (LES) models of the RCCS. An LES model was developed for forced convection inside the RCCS so as to obtain a high-fidelity representation of the RCCS at a scale never before attempted. Furthermore, the LES model was compared against three different Reynolds-averaged Navier–Stokes (RANS) models (Realizable k − ϵ, k − ω SST, and Reynolds stress model [RSM]). This comparison verified the robustness and accuracy of the turbulence modeling approach of the RANS models for the RCCS. Finally, based on the comparison between the LES and the RANS models, the k − ω SST RANS model of the experimental facility was developed and compared against the available experimental data.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Nuclear Data Impact Assessment for the HTR-10 Pebble-Bed Reactor Using SCALE

The HTR-10 was used as a representative pebble-bed high-temperature gas-cooled reactor in this assessment of nuclear data’s impact on important reactor and spent fuel metrics, including safety-related quantities such as the effective multiplication factor (k eff ), temperature reactivity feedback, spent fuel inventory, and decay heat. Using the SCALE code system tools and ENDF/B-VII.1 nuclear data libraries, we quantify the effect of nuclear data uncertainties on these key performance metrics for both fresh fuel and equilibrium core configurations. For reactor core key parameters, important contributors to uncertainty include reactions of 235 U [$\bar{v}$, fission, (n, γ)], 238 U [elastic, (n, γ)], and graphite [elastic, (n, γ)]. Additional important contributors for the equilibrium core include reactions of higher actinides ( 239 Pu, 240 Pu) and fission products ( 135 Xe, 149 Sm). For spent fuel analysis, most nuclide inventory uncertainties remain below 5%. Higher uncertainties up to 11% are being observed for minor actinides like 243 Am and 244 Cm. Additionally, fission product uncertainties in 155 Eu and 155 Gd, of 25% and 23% respectively, are also significant and have implications for burnup credit applications. 110m Ag also shows high uncertainty of up to 11%, mainly due to fission product yield uncertainties. Decay heat relative uncertainties remain below 0.6% up to 10 years’ cooling time after fuel discharge. The highest relative uncertainty of 1.5% occurs at 500 years of cooling; however, because the decay heat value is very low at that time, the absolute uncertainty is not significant. This work demonstrates that extending assessments beyond fresh fuel k eff to include irradiated cores, nuclide inventories, and decay heat is essential in understanding the behavior of uncertainties as a function of fuel burnup and can support improvements of safety margins and spent fuel management.

Nuclear data impact↗

NEET Enhanced Micro-Pocket Fission Detector for High Temperature Reactors - FY16 Status Report

A collaboration between the Idaho National Laboratory (INL), the Kansas State University (KSU), and the French Atomic Energy Agency, Commissariat à l'Énergie Atomique et aux Energies Alternatives, (CEA), has been initiated by the Nuclear Energy Enabling Technologies (NEET) Advanced Sensors and Instrumentation (ASI) program for developing and testing High Temperature Micro-Pocket Fission Detectors (HT MPFD), which are compact fission chambers capable of simultaneously measuring thermal neutron flux, fast neutron flux and temperature within a single package for temperatures up to 800 °C. The MPFD technology utilizes a small, multi-purpose, robust, in-core fission chambers and thermocouple. As discussed within this report, the small size, variable sensitivity, and increased accuracy of the MPFD technology represent a revolutionary improvement over current methods used to support irradiations in US Material Test Reactors (MTRs). Previous research conducted through NEET ASI1-3 has shown that the MPFD technology could be made robust and was successfully tested in a reactor core. This new project will further the MPFD technology for higher temperature regimes and other reactor applications by developing a HT MPFD suitable for temperatures up to 800 °C. This report summarizes the research progress for year two of this three year project. Highlights from research accomplishments include: • Continuation of a joint collaboration between INL, KSU, and CEA. Note that CEA is participating at their own expense because of interest in this unique new sensor. • An updated parallel wire HT MPFD design was developed. • Program support for HT MPFD deployments was given to Accident Tolerant Fuels (ATF) and Advanced Gas-cooled Reactor (AGR) irradiation test programs. • Quality approved materials for HT MPFD construction were procured by irradiation test programs for upcoming deployments. • KSU improved and performed electrical contact and fissile material plating. • KSU delivered fissile HT MPFD parts to INL for final construction of HT MPFD prototype. • A prototype HT MPFD was constructed and analyzed at INL. • The HT MPFD has been modeled in MCNP to optimize the amount of fissile material deposition. • The HT MPFD has been modeled in MCNP to optimize the sensor location in the irradiation test. • The fissile material deposition is undergoing independent verifications. • Detector amplifier electronics have been revised and tested by KSU. • Several project meetings were held at INL and KSU to discuss the roles and responsibilities between INL, KSU, and CEA for development and deployment of the HT MPFDs. As documented in this report, FY16 funding has allowed the project to meet year two planned accomplishments to develop a HT MPFD. In addition, the accomplishments of this project have attracted independent funding from other Department of Energy Office of Nuclear Energy (DOE-NE) programs for MTR irradiations of the MPFD technology. These are significant opportunities for this NEET Enhanced Micro-Pocket Fission Detector for High Temperature Reactors project because the irradiation expense of these experiments could not be included in the original project scope.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

SPOUTED BED DESIGN CONSIDERATIONS FOR COATED NUCLEAR FUEL PARTICLES

High Temperature Gas Cooled Reactors (HTGRs) are fueled with tristructural isotropic (TRISO) coated nuclear fuel particles embedded in a carbon-graphite fuel body. TRISO coatings consist of four layers of pyrolytic carbon and silicon carbide that are deposited on uranium ceramic fuel kernels (350µm – 500µm diameters) in a concatenated series of batch depositions. Each layer has dedicated functions such that the finished fuel particle has its own integral containment to minimize and control the release of fission products into the fuel body and reactor core. The TRISO coatings are the primary containment structure in the HTGR reactor and must have very high uniformity and integrity. To ensure high quality TRISO coatings, the four layers are deposited by chemical vapor deposition (CVD) using high purity precursors and are applied in a concatenated succession of batch operations before the finished product is unloaded from the coating furnace. These depositions take place at temperatures ranging from 1230°C to 1550°C and use three different gas compositions, while the fuel particle diameters double, their density drops from 11.1 g/cm3 to 3.0 g/cm3, and the bed volume increases more than 8-fold. All this is accomplished without the aid of sight ports or internal instrumentation that could cause chemical contamination within the layers or mechanical damage to thin layers in the early stages of each layer deposition. The converging section of the furnace retort was specifically designed to prevent bed stagnation that would lead to unacceptably high defect fractions and facilitate bed circulation to avoid large variability in coating layer dimensions and properties. The gas injection nozzle was designed to protect precursor gases from becoming overheated prior to injection, to induce bed spouting and preclude bed stagnation in the bottom of the retort. Furthermore, the retort and injection nozzle designs minimize buildup of pyrocarbon and silicon carbide on the retort wall and manage nozzle orifice accretions. The equipment and operating methods have yielded very good reproducibility in the TRISO coated particles batches.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Studies of the use of high-temperature nuclear heat from an HTGR for hydrogen production

The results of a study which surveyed various methods of hydrogen production using nuclear and fossil energy are presented. A description of these methods is provided, and efficiencies are calculated for each case. The process designs of systems that utilize the heat from a general atomic high temperature gas cooled reactor with a steam methane reformer and feed the reformer with substitute natural gas manufactured from coal, using reforming temperatures, are presented. The capital costs for these systems and the resultant hydrogen production price for these cases are discussed along with a research and development program.

Peterman, D. D.↗

Experimental study of forced convection heat transfer during upward and downward flow of helium at high pressure and high temperature

Fundamental high pressure/high temperature forced convection experiments have been conducted in support of the development of a Very High Temperature Reactor (VHTR) with a prismatic core. The experiments utilize a high temperature/high pressure gas flow test facility constructed for forced convection and natural circulation experiments. The test section has a single 16.8 mm ID flow channel in a 2.7 m long, 108 mm OD graphite column with four 2.3kW electric heater rods placed symmetrically around the flow channel. This experimental study presents the role of buoyancy forces in enhancing or reducing convection heat transfer for helium at high pressures up to 70 bar and high temperatures up to 873 degrees K. Wall temperatures have been compared among 10 cases covering the inlet Re numbers ranging from 500 to 3,000. Downward flows display higher and lower wall temperatures in the upstream and downstream regions, respectively, than the upward flow cases due to the influence of buoyancy forces. In the entrance region, convection heat transfer is reduced due to buoyancy leading to higher wall temperatures, while in the downstream region, buoyancyinduced mixing causes higher convection heat transfer and lower wall temperatures. However, their influences are reduced as the Reynolds number increases. This experimental study is of specific interest to VHTR design and validation of safety analysis codes.

Buoyancy↗

Fiber-Based Distributed Hydrogen Measurement at High Temperatures

In this work, we discuss the implementation of evanescent field optical fiber sensors for distributed gas sensing of H2, focusing on results using a Ni / Gd-doped CeO2 nanocomposite sensing material for detection of low levels of H2 (0-4%) at 700 °C. This approach utilizes sensors prepared using a low-cost, wet chemical deposition process, in conjunction with a custom-built interrogator system leveraging optical time domain reflectometry (OTDR). Using a specially designed dual-gas flow reactor system, the sensor is tested by establishing a controlled equilibrium gradient of gas concentration. Initial results are shown using silica fiber, but provides a pathway for utilization with high temperature stable single crystal optical fiber for operation at higher temperatures and higher levels of H2 relevant for solid oxide fuel cell (SOFC) operating conditions.

Wuenschell, Jeffrey↗

ELECTRIC FIELD-ASSISTED DIFFUSION WELDING TO FABRICATE ALLOY 617 COMPACT HEAT EXCHANGERS

Compact heat exchangers are of interest for a number of applications including advanced reactors. Alloy 617 is one of the top candidate materials for the gas-cooled reactor intermediate heat exchanger. Previous endeavors to diffusion weld Alloy 617 utilized hot pressing (HP). It was reported that grain boundary migration across the interface was hindered by extensive precipitation. Bonds of this nature have been observed to reduce the elevated-temperature mechanical properties compared to the wrought-product form. It was hypothesized that the electric current applied during electric-field-assisted sintering (EFAS) can overcome these challenges, resulting in improved diffusion welding (DW). This study investigated DW of Alloy 617 via EFAS. Stacks composed of three sheets that were 20 mm in diameter were welded using EFAS. Specimens were welded with an applied electric current, a pressure of 30 MPa, hold time of 30 min, and temperatures of 1050°C, 1100°C, and 1150°C. DW using HP as the zero-current analog of EFAS was also performed at the most promising EFAS conditions. Results revealed that both the applied electric current and temperature played a key role in precipitation and grain boundary migration in diffusion-welded Alloy 617. Precipitates were observed at the interface of the hot-pressed samples which limited grain boundary migration. Electric current was found to prevent precipitate formation along the interface at 1150°C. The electric current coupled with a temperature of 1150°C during EFAS resulted in significant grain boundary migration across the interface.

36 - MATERIALS SCIENCE↗

A physics study for negative void reactivity in compact supercritical CO{sub 2}-cooled fast reactor

A compact S-CO{sub 2}-cooled fast reactor which has negative Coolant Void Reactivity (CVR) has been investigated. A negative CVR is important for the gas cooled fast reactor as an inherent safety mechanism to prevent the sudden positive reactivity insertion when the loss of coolant accident happens. An alternative solution to reduce the CVR is investigated in this study by using O-17 instead of O-16 in UO{sub 2} fuel. By using O-17 in the fuel, it is found that the CVR can even be negative. Impacts of the radial reflector on the CVR are also evaluated for the small SCO{sub 2} cooled fast reactor in this study. We have considered a pure lead (Pb) reflector and a lead magnesium eutectic (LME) reflector as alternative radial reflectors of the S-CO 2-cooled fast reactor. It has been shown that, with the LME radial reflector, the CVR can be negative, while the pure lead reflector provides a slightly positive CVR. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Janus Reactors with Highly Efficient Enzymatic CO 2 Nanocascade at Air–Liquid Interface

Though enzymatic cascade reactors have been the subject of intense research over the past few years, their application is still limited by the complicated fabrication protocols, unsatisfactory stability and lack of effective reactor designs. In addition, the spatial positioning of the cascade reactor has so far not been investigated, which is of significant importance for biphase catalytic reaction systems. Inspired by the Janus properties of the lipid cellular membrane, in this paper we show a highly efficient Janus gas–liquid reactor for CO 2 hydration and conversion. Within the Janus reactor, nanocascades containing the nanoscale compartmentalized carbonic anhydrase and formic dehydrogenase were positioned at a well-defined gas–liquid interface, with a high substrate concentration gradient. The Janus reactor exhibited 2.5 times higher CO 2 hydration efficiency compared with the conventional gas–liquid contactor with pristine membranes, and the formic acid conversion rate can reach approximately 90%. Finally, through this work, we provide evidence that the spatial arrangement of the nanocascade is also crucial to efficient reactions, and the Janus reactor can be a promising candidate for the biphase catalytic reactions in environmental, biological and energy aspects.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Improving Thermal Model Prediction Through Statistical Analysis of Irradiation and Post-Irradiation Data from AGR Experiments

As part of the High Temperature Reactors (HTR) R&D program, a series of irradiation tests, designated as Advanced Gas-cooled Reactor (AGR), have been defined to support development and qualification of fuel design, fabrication process, and fuel performance under normal operation and accident conditions. The AGR tests employ fuel compacts placed in a graphite cylinder shrouded by a steel capsule and instrumented with thermocouples (TC) embedded in graphite blocks enabling temperature control. While not possible to obtain by direct measurements in the tests, crucial fuel conditions (e.g., temperature, neutron fast fluence, and burnup) are calculated using core physics and thermal modeling codes. This paper is focused on AGR test fuel temperature predicted by the ABAQUS code's finite element-based thermal models. The work follows up on a previous study, in which several statistical analysis methods were adapted, implemented in the NGNP Data Management and Analysis System (NDMAS), and applied for qualification of AGR-1 thermocouple data. Abnormal trends in measured data revealed by the statistical analysis are traced to either measuring instrument deterioration or physical mechanisms in capsules that may have shifted the system thermal response. The main thrust of this work is to exploit the variety of data obtained in irradiation and post-irradiation examination (PIE) for assessment of modeling assumptions. As an example, the uneven reduction of the control gas gap in Capsule 5 found in the capsule metrology measurements in PIE helps identify mechanisms other than TC drift causing the decrease in TC readings. This suggests a more physics-based modification of the thermal model that leads to a better fit with experimental data, thus reducing model uncertainty and increasing confidence in the calculated fuel temperatures of the AGR-1 test.

99 GENERAL AND MISCELLANEOUS↗

Validation of Wichner Predictive Model for Chronic Oxidation by Moisture of Nuclear Graphite

This document reports the results of multi-year extensive research on chronic oxidation of nuclear graphite by traces of moisture that might be present in the helium coolant of high-temperature gas-cooled reactors (HTGRs). The research focuses on four grades of nuclear graphite that are considered potential candidates for component fabrication in advanced nuclear reactors. The four grades are (1) PCEA (medium-fine grain, extruded, manufactured by GrafTech Inc., USA); (2) NBG-17 (medium-fine grain, vibrationally molded, manufactured by SGL Carbon, Germany/France); (3) IG-110 (microfine grain, isostatically molded, manufactured by Toyo Tanso, Japan); and (4) 2114 (microfine grain, isostatically pressed, manufactured by Mersen, USA). The experimental part of this research comprised three objectives that were consistently pursued for each graphite material: (1) accelerated oxidation tests in well-controlled conditions (temperature, gas composition) and analysis of chemical kinetic models and of their parameters for each graphite grade; (2) measurements of water vapor transport rates from H 2 O/He mixtures through thin graphite slabs for estimation of the water effective diffusivity specific to each material; (3) controlled oxidation of graphite specimens in H 2 O/He mixtures and characterization of the effects of oxidation temperatures on the density profiles of oxidized layers. These three groups of experimental results were interpreted using the model developed by Wichner et al. for predicting the penetration depth of oxidants (moisture or oxygen) as a function of oxidation conditions. Basically, starting from the kinetic and transport properties of each graphite grade, the ultimate goal was predicting the stable density profile in the oxidized layer and its dependence on the oxidation temperature. The profiles obtained this way were then compared against direct observations of oxidized layers in specimens obtained in well-controlled oxidation conditions. The general agreement between predictions and observations validated the general applicability of the Wichner model. The results obtained in this project were presented at annual Department of Energy–Advanced Reactor Technologies program reviews and at specialist meetings and conferences and were published in Oak Ridge National Laboratory (ORNL) reports and in professional journals. The results published in 2018 had an immediate impact in 2019, when a group from three US universities used ORNL kinetic data as input information in a complex simulation of chronic oxidation by moisture using the same graphite grades during long-time operation in a modular high-temperature gas-cooled reactor. Their conclusion, in line with the conclusions obtained at the end of this project, was that chronic graphite oxidation by moisture during normal operation conditions of an HTGR will be limited to a thin surface layer of graphite blocks at the reactor bottom, where the highest temperatures are. That will not affect the integrity of graphite components and reactor safety, provided the impurity concentration in the helium coolant is rigorously controlled and maintained at the design specifications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Cardinal: A Lower-Length-Scale Multiphysics Simulator for Pebble-Bed Reactors

This paper demonstrates a multiphysics solver for pebble-bed reactors, in particular, for Berkeley’s pebble-bed -fluoride-salt-cooled high-temperature reactor (PB-FHR) (Mark I design). The FHR is a class of advanced nuclear reactors that combines the robust coated particle fuel form from high-temperature gas-cooled reactors, the direct reactor auxiliary cooling system passive decay removal of liquid-metal fast reactors, and the transparent, high-volumetric heat capacitance liquid-fluoride salt working fluids (e.g., FLiBe) from molten salt reactors. This fuel and coolant combination enables FHRs to operate in a high-temperature, low-pressure design space that has beneficial safety and economic implications. The PB-FHR relies on a pebble-bed approach, and pebble-bed reactors are, in a sense, the poster child for multiscale analysis. Relying heavily on the MultiApp capability of the Multiphysics Object-Oriented Simulation Environment (MOOSE), we have developed Cardinal, a new platform for lower-length-scale simulation of pebble-bed cores. The lower-length-scale simulator comprises three physics: neutronics (OpenMC), thermal fluids (Nek5000/NekRS), and fuel performance (BISON). Cardinal tightly couples all three physics and leverages advances in MOOSE, such as the MultiApp system and the concept of MOOSE-wrapped applications. Moreover, Cardinal can utilize graphics processing units for accelerating solutions. In this paper, we discuss the development of Cardinal and the verification and validation and demonstration simulations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Deployment of the Finite Volume Method in Pronghorn for Gas and Salt cooled Pebble Bed Reactors

This report summarizes the activities related to ”Complete FHR and HTGR pebble bed simulator, including initial validation” funded by the NEAMS thermal-hydraulics focus area. The activity revolves around the coarse-mesh thermal-hydraulics code Pronghorn and its application to gas and salt cooled Pebble bed reactor (PBR). The main difference between gas and salt cooled PBR from a thermal-hydraulics perspective is the fluid. To address the difference in fluid behavior, two separate approaches are implemented in the MOOSE Navier Stokes module: 1) a Boussinesq approximation and 2) a fully compressible formulation. The developed finite volume method capabilities are used for improving pre-existing gas-cooled and salt-cooled pebble-bed reactor models. A steady-state, multiphysics gas-cooled pebble-bed reactor model is created that couples the equilibrium core depletion capability developed in previous work, and the finite volume method capability developed for this report. The salt-cooled pebble-bed reactor model is upgraded to use the incompressible finite volume method capability and then extended to three spatial dimensions. Finally, several verification-and-validation exercises performed with Pronghorn are documented using the verification-and-validation report of the MooseDoc system. The goal of this effort to document the verification-and-validation level of Pronghorn and improve stakeholder confidence in the results obtained with Pronghorn.

97 MATHEMATICS AND COMPUTING↗

Coated particle fuel: Historical perspectives and current progress

We report that coated particle fuel concepts date back some 60 years, and have evolved significantly from the relatively primitive pyrocarbon-coated kernels envisioned by the first pioneers. Improvements in particle design, coating layer properties, and kernel composition have produced the modern tristructural isotropic (TRISO) particle, capable of low statistical coating failure fractions and good fission product retention under extremely severe conditions, including temperatures of 1600 °C for hundreds of hours. The fuel constitutes one of the key enabling technologies for high-temperature gas-cooled reactors, allowing coolant outlet temperatures approaching 1000 °C and contributing to enhanced reactor safety due to the hardiness of the particles. TRISO fuel development has taken place in a number of countries worldwide, and several fuel qualification programs are currently in progress. Here, we discuss the unique history of particle fuel development and some key technology advances, concluding with some of the latest progress in UO 2 and UCO TRISO fuel qualification.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

UMo Solutions Processing in La Hague Cold Crucible Induction Melter: the Feedback From the First Years of Operation - 16376

250 cubic meters of high-level liquid waste from reprocessed U-Mo-Sn-Al spent fuel, used in Gas Cooled Reactors (GCR), were produced during the mid-1960's at La Hague facility. These 'UMo' solutions are less radioactive than the current fission product concentrates coming from ongoing reprocessing activities, but are very rich in molybdenum and phosphorus whose contents make the molten glass quite corrosive and require a high-temperature glass formulation to obtain sufficiently high waste loading factors (12% in molybdenum oxide). Hence the use of the Cold Crucible Induction Melter (CCIM) technology to process such solutions has been deemed a good opportunity for AREVA to meet its performance expectations. In addition to being very corrosive, the UMo waste is quite challenging to process as the molybdenum has a strong tendency to stick in the calciner and causes clogging issues in off-gas treatment equipment. Therefore, the process and technological qualifications were deployed in order to address these specific issues. UMo solutions processing in the La Hague CCIM has started in January 2013 and is currently ongoing. During this period (from 2013 to 2015), many data have been collected to confirm the process parameters that were defined during the qualification of this innovating process. Even if some difficulties occurred, operations teams experience along with engineering and R and D support allowed managing them. This paper presents the start-up methodology and the feedback from the first years of UMo solutions processing with the CCIM technology at La Hague site. Lessons learned are presented with the difficulties encountered and the solutions implemented, emphasizing the benefits of a close integration between R and D, engineering and operations teams. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Numerical Analysis of an Impinging Jet Reactor for the CVD and Gas-Phase Nucleation of Titania

We model a cold-wall atmospheric pressure impinging jet reactor to study the CVD and gas-phase nucleation of TiO2 from a titanium tetra-iso-propoxide (TTIP)/oxygen dilute source gas mixture in nitrogen. The mathematical model uses the computational code FIDAP and complements our recent asymptotic theory for high activation energy gas-phase reactions in thin chemically reacting sublayers. The numerical predictions highlight deviations from ideality in various regions inside the experimental reactor. Model predictions of deposition rates and the onset of gas-phase nucleation compare favorably with experiments. Although variable property effects on deposition rates are not significant (approximately 11 percent at 1000 K), the reduction rates due to Soret transport is substantial (approximately 75 percent at 1000 K).

Gokoglu, Suleyman A.↗