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Synthesis and electrochemical characterization of Ti{sub x}Ta{sub y}Al{sub z}N{sub 1-δ}O{sub γ} for fuel cell catalyst supports

Quinary Ti{sub x}Ta{sub y}Al{sub z}N{sub 1-δ}O{sub γ} of various compositions have been prepared by a co-precipitation method followed by ammonolysis. The nitride samples were examined as potential catalyst supports in polymer electrolyte membrane fuel cells. The nitride products crystallized in the rock salt (NaCl) structure over a wide range of compositions. The addition of Ta and Al was highly beneficial towards improving the chemical and electrochemical stability of TiN, without a significant loss of electrical conductivity. Platinum particles were successfully deposited on the (oxy)nitride samples, and the composite samples at some compositions were found to be comparable to Pt/carbon in their stability and catalytic activity even without optimizing the Pt deposition and dispersion processes. - Graphical abstract: The effect of additions of Ta and Al into TiN structure. Shifts the lattice constant, and increases its chemical stability in acidic environment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

ORIGEN-based Nuclear Fuel Inventory Module for Fuel Cycle Assessment: Final Project Report

The goal of this project, “ORIGEN-based Nuclear Fuel Depletion Module for Fuel Cycle Assessment" is to create a physics-based reactor depletion and decay module for the Cyclus nuclear fuel cycle simulator in order to assess nuclear fuel inventories over a broad space of reactor operating conditions. The overall goal of this approach is to facilitate evaluations of nuclear fuel inventories for a broad space of scenarios, including extended used nuclear fuel storage and cascading impacts on fuel cycle options such as actinide recovery in used nuclear fuel, particularly for multiple recycle scenarios. The advantages of a physics-based approach (compared to a recipe-based approach which has been typically employed for fuel cycle simulators) is in its inherent flexibility; such an approach can more readily accommodate the broad space of potential isotopic vectors that may be encountered under advanced fuel cycle options. In order to develop this flexible reactor analysis capability, we are leveraging the Origen nuclear fuel depletion and decay module from SCALE to produce a standalone “depletion engine” which will serve as the kernel of a Cyclus-based reactor analysis module. The ORIGEN depletion module is a rigorously benchmarked and extensively validated tool for nuclear fuel analysis and thus its incorporation into the Cyclus framework can bring these capabilities to bear on the problem of evaluating long-term impacts of fuel cycle option choices on relevant metrics of interest, including materials inventories and availability (for multiple recycle scenarios), long-term waste management and repository impacts, etc. Developing this Origen-based analysis capability for Cyclus requires the refinement of the Origen analysis sequence to the point where it can reasonably be compiled as a standalone sequence outside of SCALE; i.e., wherein all of the computational aspects of Origen (including reactor cross-section library processing and interpolation, input and output processing, and depletion/decay solvers) can be self-contained into a single executable sequence. Further, to embed this capability into other software environments (such as the Cyclus fuel cycle simulator) requires that Origen’s capabilities be encapsulated into a portable, self-contained library which other codes can then call directly through function calls, thereby directly accessing the solver and data processing capabilities of Origen. Additional components relevant to this work include modernization of the reactor data libraries used by Origen for conducting nuclear fuel depletion calculations. This work has included the development of new fuel assembly lattices not previously available (such as for CANDU heavy-water reactor assemblies) as well as validation of updated lattices for light-water reactors updated to employ modern nuclear data evaluations. The CyBORG reactor analysis module as-developed under this workscope is fully capable of dynamic calculation of depleted fuel compositions from all commercial U.S. reactor assembly types as well as a number of international fuel types, including MOX, VVER, MAGNOX, and PHWR CANDU fuel assemblies. In addition, the Origen-based depletion engine allows for CyBORG to evaluate novel fuel assembly and reactor design types via creation of Origen reactor data libraries via SCALE. The establishment of this new modeling capability affords fuel cycle modelers a substantially improved ability to model dynamically-changing fuel cycle and reactor conditions, including recycled fuel compositions from fuel cycle scenarios involving material recycle into thermal-spectrum systems.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

BWR Spent Nuclear Fuel Acquisition and Testing to Support DOE-NE High Burnup Spent Fuel Data Project

The Office of Spent Fuel and Waste Disposition (SFWD) within the US Department of Energy (DOE) Office of Nuclear Energy (NE) established the Spent Fuel and Waste Science and Technology (SFWST) campaign to conduct research and development (R&D) activities related to the storage, transportation, and disposal of spent nuclear fuel (SNF) and high-level radioactive waste. The SFWST program was created within SFWD to address issues of extended or long-term SNF storage and transportation. Some near-term objectives of SFWST are to use a science-based, engineering-driven approach to: Support the enhancement of the technical bases to support the continued safe and secure dry storage of SNF for extended periods; Support the enhancement of the technical bases for retrieving SNF after extended dry storage; Support the enhancement of the technical bases for transporting high burnup (HBU) fuel and transporting low burnup fuel and HBU fuel after dry storage DOE-NE, in partnership with the Electric Power Research Institute, developed the High Burnup Spent Fuel Data Project to perform a large-scale demonstration and laboratory-scale testing of HBU pressurized water reactor (PWR) fuels (exceeding 45 gigawatt-days per metric ton of uranium [GWd/MTU]). Under this project, 25 sister rods—which are rods that have the same design, power histories, and other characteristics—were removed from assemblies at the North Anna Nuclear Power Station and sent to Oak Ridge National Laboratory (ORNL) in January 2016. ORNL performed detailed nondestructive examination (NDE) on all 25 rods. The NDE consisted of visual examinations, gamma and neutron scanning, profilometry and rod length measurements, and eddy current examinations. After completing the NDE, 10 of the sister rods were delivered to Pacific Northwest National Laboratory (PNNL) in a NAC International, Inc. legal-weight truck cask in September 2018 for destructive examination (DE). To date, SFWD work has focused on the PWR fuel that is part of the Sister Rod Test program. No boiling water reactor (BWR) fuel has been tested in the program, and the data needs that were identified for the PWR fuel have not been collected for BWR fuel. The goal to obtain six to nine BWR rods and test them at ORNL will support closing this important data gap. BWR fuel comprises approximately 56% of the total fuel assemblies currently in storage at nuclear power plants in the United States. BWR nuclear fuel and cladding designs and manufacturing are significantly different from PWRs. Differences include the following: BWR fuel pellets are larger than PWR pellets; Variations of Zircaloy-2 (including liners) are used instead of the Zircaloy-4 cladding materials used in PWRs; Clad manufacturing and stress-relief processes are different between PWRs and BWRs; The fuel rod dimensions are different because larger rod diameters and thicker cladding are used in BWRs; BWR fuel typically has lower internal rod pressures and sees vastly different operating conditions than PWR fuel (i.e., two-phase flow); BWR assemblies are “canned,” meaning each assembly is surrounded by a metal fuel channel; BWR cladding is often composed of an inner pure Zr liner that has widely different mechanical properties than the Zircaloy-2 alloy and exhibits a stronger affinity for hydrogen; The BWR SNF generally has more total hydrogen in the cladding/liner than typical PWR fuel; The construction of the PWR and BWR assemblies is vastly different; BWR rods are solidly attached to the assembly nozzles and experience a much different vibration and shock load than PWR rods, which are “floating” within a grid system attached to guide tubes, and the rods sit loosely on the bottom end plates. These numerous differences will affect the way the BWR SNF responds under dry storage preparation processes (e.g., vacuum drying) and during transportation. The results collected in the PWR experimental program must be compared with a subset of similar data collected on BWR SNF to establish a technical basis for whether the larger PWR database is sufficient to bound the BWR SNF end-of-life conditions as is currently assumed for several fuel/clad properties. Changes that occur in both fuel types at HBU could exacerbate any mechanical property differences. As the fuel burnup increases, several changes occur that might affect the performance of the fuel, cladding, and assembly hardware in storage and transportation. These changes include increased cladding corrosion layer thickness, increased cladding hydrogen content, increased cladding creep strains, increased fission gas release, and the formation of the HBU structure at the surface of the fuel pellets. The Nuclear Regulatory Commission (NRC) limits the current maximum rod-averaged burnup to 62 GWd/MTU due to these changes and the lack of data at higher burnups.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Fuel utilization effects on system efficiency in solid oxide fuel cell gas turbine hybrid systems

Here, a computational analysis was conducted to optimize the design of a solid oxide fuel cell - gas turbine hybrid power generator, focusing on the impact that fuel utilization within the fuel cell has on system efficiency and installed costs. This is the first ever design-study considering the effect of fuel utilization on performance, as well as on the optimum power split. This hybrid system attained high electric generation efficiencies (>70%) over a wide range of operating conditions (60% < fuel utilization < 90%) while the fuel cell stack size decreased in proportion to decreasing the fuel utilization. A one-dimensional fuel cell model was used to simulate the fuel cell while GateCycle® was used to simulate the performance of the associated recuperated turbine and various subsystems necessary for thermal management. For each test case, the size of the solid oxide fuel cell, gas turbine, and recuperator, as well as the fuel and air flow rates, hot-air bypass set point, and heat exchange effectiveness in the solid oxide fuel cell manifold were varied to obtain 550 MWe output. In addition, anode recycle, turbomachinery efficiency, and various thermal management options were tested. The maximum system efficiency (75.6%) was attained for the single-pass solid oxide fuel cell with highly efficient turbomachinery when the solid oxide fuel cell used 80% of the incoming fuel. Efficiency was essentially flat from 75% fuel utilization through 85% fuel utilization. Employing anode recycle starting at 65% resulted in roughly 1 percentage point efficiency decrease for each percent increase in fuel utilization. For minimized solid oxide fuel cell degradation, a near 50:50 power split case was studied resulting in 68.6% efficiency and the solid oxide fuel cell using 55% of the incoming fuel. Because of shifting half of the power generation to the gas turbine, the size of the fuel cell stack was reduced by 25% as compared to that at maximum efficiency (80% fuel utilization).

42 ENGINEERING↗

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

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

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Fuel Performance Modeling Results for Representative FCRD Irradiation Experiments: Projected Deformation in the Annular AFC-3A U-10Zr Fuel Pins and Comparison to Alternative Designs

The objective of the present study was to predict the outcome of the AFC-3A annular U-10Zr fuel irradiation experiment. Specifically, the study attempted to predict whether the annular fuel will swell inward and fill the annulus, or swell outward resulting in an undesirable cladding deformation. It was predicted that both 55% and 75% annular fuels operating at 350 W/cm for 201 days will swell inward and partially fill the annulus which signifies a positive outcome of the experiment. The driving mechanism for such behavior is the fuel creep under the compressive stress exerted on the fuel by the cladding as a result of the fuel cladding mechanical interaction. Comparison with the solid fuel revealed that the annular fuel is expected to swell less early in life due to the mechanical constraint provided by the cladding. Furthermore, mechanical constraint is expected to yield a marked reduction of the axial elongation of the annular fuel as compared to the solid fuel. The prediction is based on the assumption that the annular fuel is not capable of moving axially relative to the cladding after the two come in contact. Post irradiation examination results would be very useful to assess the validity of this assumption. Specifically, underprediction of the axial growth would point to the fact that some slippage of the fuel relative to the cladding occurs after the onset of the FCMI. As fuel creep plays the major role in the deformation of the annular fuel, the contributions from the thermal and irradiation induced creep to the total creep rate of fuel were examined to provide guidance for possible creep testing experiments of the fuel (separate effect tests). It was found that irradiation induced creep dominates deformation of the fresh fuel at low temperatures. At high temperatures, and in the case of porous fuel, the thermal creep of the fuel becomes dominant and irradiation induced creep can be neglected. Fission gas induced porosity seems to accelerate fuel creep drastically. Recognizing the sensitivity of the fuel creep to the porosity, additional studies exploring this phenomenon and verifying published equations either experimentally or through computation may benefit the understanding of the annular fuel behavior.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

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

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

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

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

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

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

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

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

30 DIRECT ENERGY CONVERSION↗

Fuel Safety Research Plan for Accident Tolerant Fuels

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

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Fuel Pond Sludge - Lessons Learned from Initial De-sludging of Sellafield's Pile Fuel Storage Pond - 12066

The Pile Fuel Storage Pond (PFSP) at Sellafield was built and commissioned between the late 1940's and early 1950's as a storage and cooling facility for irradiated fuel and isotopes from the two Windscale Pile reactors. The pond was linked via submerged water ducts to each reactor, where fuel and isotopes were discharged into skips for transfer along the duct to the pond. In the pond the fuel was cooled then de-canned underwater prior to export for reprocessing. The plant operated successfully until it was taken out of operation in 1962 when the First Magnox Fuel Storage Pond took over fuel storage and de-canning operations on the site. The pond was then used for storage of miscellaneous Intermediate Level Waste (ILW) and fuel from the UK's Nuclear Programme for which no defined disposal route was available. By the mid 1970's the import of waste ceased and the plant, with its inventory, was placed into a passive care and maintenance regime. By the mid 1990s, driven by the age of the facility and concern over the potential challenge to dispose of the various wastes and fuels being stored, the plant operator initiated a programme of work to remediate the facility. This programme is split into a number of key phases targeted at sustained reduction in the hazard associated with the pond, these include: - Pond Preparation: Before any remediation work could start the condition of the pond had to be transformed from a passive store to a plant capable of complex retrieval operations. This work included plant and equipment upgrades, removal of redundant structures and the provision of a effluent treatment plant for removing particulate and dissolved activity from the pond water. - Canned Fuel Retrieval: Removal of canned fuel, including oxide and carbide fuels, is the highest priority within the programme. Handling and export equipment required to remove the canned fuel from the pond has been provided and treatment routes developed utilising existing site facilities to allow the fuel to be reprocessed or conditioned for long term storage. - Sludge Retrieval: In excess of 300 m{sup 3} of sludge has accumulated in the pond over many years and is made up of debris arising from fuel and metallic corrosion, wind blown debris and bio-organic materials. The Sludge Retrieval Project has provided the equipment necessary to retrieve the sludge, including skip washer and tipper machines for clearing sludge from the pond skips, equipment for clearing sludge from the pond floor and bays, along with an 'in pond' corral for interim storage of retrieved sludge. Two further projects are providing new plant processing routes, which will initially store and eventually passivate the sludge. - Metal Fuel Retrieval: Metal Fuel from early Windscale Pile operations and various other sources is stored within the pond; the fuel varies considerably in both form and condition. A retrieval project is planned which will provide fuel handling, conditioning, sentencing and export equipment required to remove the metal fuel from the pond for export to on site facilities for interim storage and disposal. - Solid Waste Retrieval: A final retrieval project will provide methods for handling, retrieval, packaging and export of the remaining solid Intermediate Level Waste within the pond. This includes residual metal fuel pieces, fuel cladding (Magnox, aluminium and zircaloy), isotope cartridges, reactor furniture, and miscellaneous activated and contaminated items. Each of the waste streams requires conditioning to allow it to be and disposed of via one of the site treatment plants. - Pond Dewatering and Dismantling: Delivery of the above projects will allow operations to progressively remove the radiological inventory, thereby reducing the hazard/risk posed by the plant. This will then allow subsequent dewatering of the pond and dismantling of the structure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

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

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

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Titanium and/or Aluminum Rod-Replacement Experiments in Fully-Reflected Water-Moderated Square-Pitched U(6.90)O 2 Fuel Rod Lattices with 0.67 Fuel to Water Volume Ratio (0.800 CM Pitch)

The US Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories. The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5% 235 U. The 7uPCX assembly is a water-moderated and -reflected array of aluminum-clad square-pitched UO2 fuel rods. The uranium is enriched to 6.90% by mass. Sets of 36 titanium and aluminum experiment rods with the same nominal outside diameter as the fuel rods were fabricated and used as replacements for fuel rods in the array. The twenty-four 7uPCX critical experiments reported here compare the effects of the titanium and aluminum replacement rods on nearly critical fuel rod arrays. The fuel used in these experiments was fabricated using unirradiated UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The nominal outside diameter of the fuel pellets is 0.207 in (0.52578 cm). The nominal outside diameter of the fuel rod cladding is 0.250 in (0.635 cm). The distance between the fuel rods in the square-pitched array is 0.315 in (0.8001 cm). This geometry gives a fuel-to-water volume ratio of 0.67 in the array. The twenty-four critical experiments in this series were performed in 2015 and 2016 at the Sandia Critical Experiments Facility. The first of the experiments had no replacement rods in the array and was intended to provide a baseline against which the experiments containing replacement rods could be compared. Eight critical experiments had titanium replacement rods in various numbers and arrangements near the center of the fuel array. Eight critical experiments had aluminum replacement rods in the same numbers and arrangements as in the eight experiments containing titanium experiment rods. In the final four experiments, fuel rods were removed from a central region of the array so that the pitch of the fuel rods in this part of the array was effectively doubled. This softened the neutron spectrum in the central part of the fuel array. Thirty-six replacement rods in different combinations of titanium and/or aluminum were placed in the interstices created in the center of the array. All twenty-four critical experiments are judged to be acceptable as benchmark experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

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

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

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Fuel Economy and Emissions of a Vehicle Equipped with an Aftermarket Flexible-Fuel Conversion Kit

The U.S. Environmental Protection Agency (EPA) grants Certificates of Conformity for alternative fuel conversion systems and also offers other forms of premarket registration of conversion kits for use in vehicles more than two model years old. Use of alternative fuels such as ethanol, natural gas, and propane are encouraged by the Energy Policy Act of 1992. Several original equipment manufacturers (OEMs) produce emissions-certified vehicles capable of using alternative fuels, and several alternative fuel conversion system manufacturers produce EPA-approved conversion systems for a variety of alternative fuels and vehicle types. To date, only one manufacturer (Flex Fuel U.S.) has received EPA certifications for ethanol fuel (E85) conversion kits. This report details an independent evaluation of a vehicle with a legal installation of a Flex Fuel U.S. conversion kit. A 2006 Dodge Charger was baseline tested with ethanol-free certification gasoline (E0) and E20 (gasoline with 20 vol % ethanol), converted to flex-fuel operation via installation of a Flex Box Smart Kit from Flex Fuel U.S., and retested with E0, E20, E50, and E81. Test cycles included the Federal Test Procedure (FTP or city cycle), the highway fuel economy test (HFET), and the US06 test (aggressive driving test). Averaged test results show that the vehicle was emissions compliant on E0 in the OEM condition (before conversion) and compliant on all test fuels after conversion. Average nitrogen oxide (NO X ) emissions exceeded the Tier 2/Bin 5 intermediate life NO X standard with E20 fuel in the OEM condition due to two of three test results exceeding this standard [note that E20 is not a legal fuel for non-flexible-fuel vehicles (non-FFVs)]. In addition, one E0 test result before conversion and one E20 test result after conversion exceeded the NO X standard, although the average result in these two cases was below the standard. Emissions of ethanol and acetaldehyde increased with increasing ethanol, while nonmethane organic gas and CO emissions remained relatively unchanged for all fuels and cycles. Higher fraction ethanol blends appeared to decrease NO X emissions on the FTP and HFET (after conversion). As expected, fuel economy (miles per gallon) decreased with increasing ethanol content in all cases.

02 PETROLEUM↗

Fuel Cycle System Analysis Implications of Sodium-Cooled Metal-Fueled Fast Reactor Transuranic Conversion Ratio

If advanced fuel cycles are to include a large number of fast reactors (FRs), what should be the transuranic (TRU) conversion ratio (CR)? The nuclear energy era started with the assumption that they should be breeder reactors (CR > 1), but the full range of possible CRs eventually received attention. For example, during the recent U.S. Global Nuclear Energy Partnership program, the proposal was burner reactors (CR < 1). Yet, more recently, Massachusetts Institute of Technology's "Future of the Nuclear Fuel Cycle" proposed CR [approximately] 1. Meanwhile, the French company EDF remains focused on breeders. At least one of the reasons for the differences of approach is different fuel cycle objectives. To clarify matters, this paper analyzes the impact of TRU CR on many parameters relevant to fuel cycle systems and therefore spans a broad range of topic areas. The analyses are based on a FR physics parameter scan of TRU CR from 0 to [approximately]1.8 in a sodium-cooled metal-fueled FR (SMFR), in which the fuel from uranium-oxide-fueled light water reactors (LWRs) is recycled directly to FRs and FRs displace LWRs in the fleet. In this instance, the FRs are sodium cooled and metal fueled. Generally, it is assumed that all TRU elements are recycled, which maximizes uranium ore utilization for a given TRU CR and waste radiotoxicity reduction and is consistent with the assumption of used metal fuel separated by electrochemical means. In these analyses, the fuel burnup was constrained by imposing a neutron fluence limit to fuel cladding to the same constant value. This paper first presents static, time-independent measures of performance for the LWR [right arrow] FR fuel cycle, including mass, heat, gamma emission, radiotoxicity, and the two figures of merit for materials for weapon attractiveness developed by C. Bathke et al. No new fuel cycle will achieve a static equilibrium in the foreseeable future. Therefore, additional analyses are shown with dynamic, time-dependent measures of performance including uranium usage, TRU inventory, and radiotoxicity to evaluate the complex impacts of transition from the current uranium-fueled LWR system, and other more realistic impacts that may not be intuited from the time-independent steady-state conditions of the end-state fuel cycle. These analyses were performed using the Verifiable Fuel Cycle Simulation Model VISION. Compared with static calculations, dynamic results paint a different picture of option space and the urgency of starting a FR fleet. For example, in a static analysis, there is a sharp increase in uranium utilization as CR exceeds 1.0 (burner versus breeder). However, in dynamic analyses that examine uranium use over the next 1 to 2 centuries, behavior as CR crosses the 1.0 threshold is smooth, and other parameters such as the time required outside of reactors to recycle fuel become important. Overall, we find that there is no unambiguously superior value of TRU CR; preferences depend on the relative importance of different fuel cycle system objectives.

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

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

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗