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Status Report on Design of In-situ Thermomechanical Testing at LANSCE

Nuclear fuel encounters severe thermomechanical environments in which its mechanical response is determined by its microstructure, temperature and stress level histories. Simulating the response of such microstructures is crucial for predicting both performance and transient fuel mechanical responses and experimental verification of such predictions is therefore of great interest. While most of the deformation in a nuclear fuel rod occurs in the cladding, deformation of the fuel itself is still of interest with deformation mechanisms at operating temperature and above including creep, swelling, cracking as well as pellet-clad interaction. Characterization of these properties and understanding of the underlying deformation phenomena at operating or excursion temperatures is therefore of great importance for development and ultimately licensing of improved and novel nuclear fuel forms. Diffraction techniques offer unique insight on the atomistic (e.g. crystal structure) and microstructure (e.g. phase transformations, texture, defects) length scales and have a long history of providing unique data to inform relevant deformation models that enable the required predictive capabilities. For example, dislocations lead to diffraction peak broadening that can be characterized to estimate the dislocation density and study the role of dislocations on the deformation while measuring lattice strains allows to studie load sharing in two phase materials. In this report the requirements for a sample environment for high temperature deformation of nuclear fuels are defined. The HIPPO neutron time-of-flight diffractometer at LANSCE will host this sample environment and is also described. This instrument covers diffraction angles from 140° to 40° and is also equipped with an event-mode neutron imaging detector system, enabling energy-resolved neutron imaging in parallel with the diffraction that could measure sample temperature from Doppler broadening of neutron absorption resonances or measure pore densities from changes in the attenuation. Designs of devices to characterize thermomechanical properties of nuclear fuel without diffraction are also considered to guide the design. While this report is focused on applications for nuclear fuels, the device can also characterize cladding, moderator or structural materials and therefore contribute to other fields of research and development for advanced reactors. The temperatures planned to be reached are above 2000℃, thus enabling characterization of LWR reactor fuels under accident scenarios but also reaching temperatures of fuels developed for nuclear thermal propulsion and providing opportunities to characterize those. In conjunction with the energy-resolved neutron imaging detector, this setup would allow to measure neutron cross-sections at high temperatures, filling a gap towards development of reactors operating at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Initial Evaluation of Fuel-Reactor Concepts for Advanced LEU Fuel Development

The National Nuclear Security Administration (NNSA) Office of Defense Nuclear Nonproliferation R&D has commenced a project to evaluate and develop low-enriched uranium (LEU) fuel systems, materials, and fabrication technologies that could be used for compact, advanced LEU (aLEU) fuel, power-producing, high-burnup reactor applications. Potential applications are intended to be off-grid power sources for ship-borne systems and transportable systems to fixed locations, e.g., to a remote base or to a seawater desalination service location. Reactors with these qualities and fuel enrichments between 5 and 20% are atypical. The aLEU Fuel for Nonproliferation Applications Project addresses this technology gap.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Comparison of Fission Product Release Predictions using PARFUME with Results from the AGR-2 Irradiation Experiment

The PARFUME (PARticle FUel ModEl) code was used to predict fission product release from tristructural isotropic (TRISO) coated fuel particles and compacts during the second irradiation experiment (AGR-2) of the Advanced Gas Reactor Fuel Development and Qualification Program. The PARFUME model for the Advanced Gas reactor (AGR)GR-2 experiment used the fuel compact volume average temperature for each of the 560 days of irradiation to calculate the release of fission products of silver, cesium, and strontium from a representative particle for a select number of AGR -2 compacts. In addition, safety tests were performed on 15 compacts ranging from 1500 to 1800°C to determine fission product release at temperatures that bound reactor accident conditions. PARFUME was used to calculate the fission product release of silver, cesium, strontium, and krypton during these safety tests. Post-irradiation examination (PIE) measurements provided the data on release of fission products from the fuel compacts and fuel particles, and retention of fission products in the compacts outside the silicon carbide (SiC) layer. The predicted fraction release from PARFUME was then compared to PIE measurements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Utilization of the LMP Methodology in Support of the VTR Conceptual Safety Design Report

The Versatile Test Reactor (VTR) is a fast spectrum test reactor currently being developed in the United States under the direction of the US Department of Energy (DOE), Office of Nuclear Energy. The VTR is utilizing a risk-informed performance-based (RIPB) approach for design support and authorization by the DOE, derived from recent efforts by the US industry led Licensing Modernization Project (LMP). This document contains an overview of the implementation of the LMP approach in support of the VTR Conceptual Safety Design Report (CSDR). The work reported here is the result of studies supporting a VTR conceptual design, cost, and schedule estimate for DOE-NE to make a decision on procurement. As such, it is preliminary. The VTR RIPB authorization approach utilizes information from the probabilistic risk assessment (PRA), coupled with deterministic analyses, to aid in decision-making regarding the identification and categorization of safety basis events (SBEs), the classification of structures, systems, and components (SSCs), and the evaluation of defense-in-depth (DID) adequacy. As part of initial reactor design efforts, a VTR conceptual design PRA was developed to support the RIPB process, which focused on at-power internal events, with scoping analyses for seismic and sodium fire hazards. In addition to supporting numerous design studies, preliminary results from the RIPB approach and the VTR conceptual design PRA were utilized as the basis of the VTR CSDR. The initial identification and categorization of SBEs, SSC classification, and DID evaluation were contained within the CSDR, which was submitted to DOE in 2019 as part of the CD-1 submittal package. Following review, DOE approved the CSDR in April 2020 and the CD-1 package in late 2020. Valuable experience was gained through the implementation of the RIPB approach for design and authorization during the VTR conceptual design phase, which is summarized in this document. To the extent possible, this experience has been shared with the advanced reactor industry, through publications and participation in licensing tabletops, in addition to informing DOE:NE advanced reactor regulatory development efforts. Furthermore, the approval of the CSDR by the DOE as part of CD-1 represents a significant milestone in the use of RIPB approaches for advanced reactor licensing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Non-LWR Regulatory Framework FY20 Status Report

This report provides an end-of-year summary that reflects progress and status of INL’s activities concerning advanced reactor regulatory framework development and implementation in the U.S. This work was done in FY20 and supported regulatory development for the U.S. Department of Energy (DOE) Advanced Reactor Technologies (ART) Program. These activities are managed by Idaho National Laboratory on behalf of the U.S. DOE.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Non-LWR Regulatory Framework Modernization

This report provides an end-of-year summary that reflects the progress and status of Idaho National Laboratory’s (INL) activities concerning the development of advanced reactor (AR) regulatory framework and its implementation in the United States (U.S.). The report also provides recommendations for work to be performed in Fiscal Year 2025 (FY-25) and beyond. This work was completed in Fiscal Year 2024 (FY-24) and was supported by the U.S. Department of Energy (DOE) Regulatory Development sub-program. These activities are managed by INL on behalf of DOE.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Report on Year-3 of Water NSTF Matrix Testing: Two-Phase Parametric Test Series

The Natural convection Shutdown heat removal Test Facility (NSTF) is large scale test facility constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactor concepts. With support from the Department of Energy (DOE) offices of Advanced Reactor Technologies (ART) and Advanced Reactors Regulatory Development (RD), this facility reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems. Since the facility also retains all aspects common to a fundamental boiling water thermosiphon, the generated experimental data sets are well poised to advance the understanding of fundamental natural circulation boiling and two-phase flow phenomena.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

One-Step Ahead Prediction of Thermal Mixing Tee Sensors with Long Short Term Memory (LSTM) Neural Networks

High-temperature advanced reactors under development, such as sodium fast reactors (SFR) and molten salt cooled reactors (MSCR), are expected to offer lower levelized cost of energy (LCOE) compared to existing light water reactor (LWR’s). In the existing light water reactors (LWR’s), operation and maintenance (O&M) expenses constitute the largest fraction of the total operating cost. Some of the O&M costs are related maintenance of sensors which can fail due to exposure to harsh environment in a reactor. The O&M costs of Advanced Reactor (AR)’s are expected to constitute a significant fraction of the total cost as well, because of high temperature and radiation level in AR are likely to cause material fatigue and premature failure of sensors and components. The O&M costs in AR’s could be reduced through integration of advanced informatics of performance-related sensors into a digital twin designed for reactor monitoring. For example, machine learning (ML) could be employed for real-time validation and correction of performance-related sensors, and reducing the number of performance-related physical sensor units through virtual sensing. As part of the effort, we investigate real-time validation of thermal hydraulic sensors through one-step ahead forecasting of sensor values using long short-term memory (LSTM) recurrent neural networks (RNN). The sensors are installed in a flow loop containing a thermal mixing tee, which is a common experimental model to study thermal fatigue in a thermal hydraulic loop. In addition, nonlinear transients generated in a thermal mixing tee constitute a good challenge data set for training and validation of ML algorithms. Sensors in this study include thermocouples, flow meters, and optical fibers for distributed temperature sensing. In one experiment, measurement data sets were obtained for a loop was filled with water, and in another experiment, measurements were performed on a loop filled with liquid metal Galinstan. We have also conducted preliminary investigation of one-step ahead prediction of fiber optics-based distributed temperature sensing with LSTM networks. In predicting fiber-based temperature measurements, we treated each gauge pitch of the fiber as an independent sensor. Accuracy of one-step ahead forecasting was estimated by calculating root mean square error (RMSE) for the test segment of time series of each sensor. RMSE’s for temperature sensors in water loop were, for the most part, lower than for the same sensors in Galinstan loop. The RMSE’s for flow meters were similar for both loops. The RMSE’s for distributed temperature measured with the fiber optic sensor were similar to those of the point sensors. Results of this study demonstrated the capability of LSTM one-step ahead forecasting with RMSE comparable to uncertainty in sensor measurements.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Leveraging the High Flux Isotope Reactor for nuclear fuel development: a review of experiments, facilities, and capabilities

Materials testing reactors (MTRs) have been used to develop in-core nuclear fuels and materials since the outset of the nuclear power industry. However, the closure of prominent MTRs worldwide and protracted construction timelines for new facilities have increased reliance on existing infrastructure for near-term irradiation testing needs. One facility that can support these needs is the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory. HFIR boasts the highest steady-state neutron flux in the Western Hemisphere and, among other roles, has been used to rapidly administer high fluences on fuels and materials for fission and fusion reactor applications. This paper reviews HFIR facilities and infrastructure, fuel-bearing irradiation experiments conducted in HFIR, and select nonfueled experiments that demonstrate advanced techniques transferable to fuels experiments. Collectively, these examples underscore HFIR's potential role as a nuclear fuels testbed supporting both the existing reactor fleet and advanced reactor fuel development.

Fuel qualification↗

Idaho national laboratory to demonstrate collaboration first versus competition to accelerate achieving a secure clean energy future by 2031

Idaho National Laboratory (INL) announced at COP27 it would reach net zero greenhouse gas (GHG) emissions by 2031. As a Nuclear, Energy and Environment, and National Homeland Security laboratory, the predominant solution to closing the clean energy gap will include nuclear as a safe, clean, reliable and affordable electricity source with the additional benefit of producing heat and hydrogen to fuel INL’s large transportation fleet. INL’s collaboration first vs. competition is essential to the program’s success. The focused actions in INL’s Nuclear Roadmap include: Infrastructure, Licensing/Regulatory, Financial, Time to Market, Fuel Cycle and Public Confidence/Communications. The roadmap also includes nuclear technology innovations and creative partnerships with utility providers, regulators, businesses, community members, and Indigenous Peoples to accelerate deployment of advanced reactors. Through development of the Net-Zero Nuclear Roadmap, INL will offer a model to provide safe and secure energy for the nation and the world by: (1) establishing the necessary infrastructure on its 890-square mile site to support demonstration, (2) showing proven pathways through the licensing and regulation process, (3) partnering with utilities to ensure commercial application, and (4) collaborating with industry to site new technologies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Bayesian calibration of irradiated graphite property models under high temperatures

Graphite under high temperatures and irradiation is central to advanced reactors. We develop a Bayesian calibration framework for graphite property models that explicitly represents model-data mismatch via a Gaussian-process discrepancy. The approach propagates uncertainty from parameters, experimental noise, and model form, with a hierarchical variance structure to capture group and cross-group noise. Using two predictive models across five grades (IG-110, NBG-18, PCEA, NBG-17, 2114) and four properties-irradiation-induced dimension change, creep, Young’s modulus change ratio, and coefficient of thermal expansion change ratio-we obtain average predictive-error reductions of 54%, 65%, 17%, and 17% when discrepancy is included. We illustrate engineering impact with a multiphysics model of a very-high-temperature reactor prismatic reflector brick, analyzing stresses under high fluence and temperature. Accounting for model discrepancy markedly improves predictive accuracy and provides a robust basis for reliable graphite component design in advanced reactors.

36 - MATERIALS SCIENCE↗

Meta-Analysis of Advanced Nuclear Reactor Cost Estimations

Supporting Data can be downloaded at: https://gain.inl.gov/content/uploads/4/2024/06/INL-RPT-24-77048-R1.xlsx Nuclear energy is a critical cornerstone of the current United States clean energy supply and may play a larger role in the future in support of a transition to a net-zero economy. The current fleet of nuclear reactors predominantly consists of large light-water reactors (LWRs), while many of the reactor designs under consideration are smaller and/or different technologies. Because these new designs have not yet been built, there is a high degree of uncertainty associated with their cost. This complicates energy-planning efforts because cost projections are not always standardized, consistent, and centralized in an easily accessible location. To help support energy planning in the US, this report provides advanced nuclear cost ranges using a transparent methodology along with other relevant information that can be used to help support decision making and energy planning. The purpose of this work was to conduct a methodical process for cost evaluation using only public information that was vetted with the end-goal to provide reference cost projections for nuclear energy. To provide a solid basis for these values, the approach and assumptions are explicitly laid out throughout the report allowing any user of the data to challenge or reconsider them. Because future US nuclear-reactor costs are still unknown due to little recent observed data, the report opted to compile a comprehensive list of bottom-up estimates and evaluate averages/trends within the data to identify reference ranges. This was deemed preferable to opining on the robustness or validity of one cost estimation versus another. To that end, the work evaluated thousands of lines of cost subaccounts from several bottom-up cost estimates. A wide variety of different reactor types captured in the data are of various sizes and technologies. Some of these reactors will be representative of advanced reactors under development while others will not. Thus, the results here are dependent on the data that are available and the accuracy of the estimates that are used. Each bottom-up estimate was reviewed to determine whether it was complete. Incomplete data sets were corrected to ensure an adequate basis of cross-comparison. The report is not without limitations and should be interpreted as an initial step to develop cost ranges for nuclear technology. Ultimately, future work can build upon the methodology with refined cost estimates to reduce uncertainty. US-based overnight capital cost (OCC) estimates were compiled from extensive data sets into ranges for both large and small reactor sizes for 2030. To project the cost declines over time, learning rates were sampled from literature sources. No SMRs were previously built; hence, learning rates based on bottom-up approaches (e.g., by quantifying the impact stemming from fabrication of different components, modular work, site construction, commissioning) were prioritized. For larger reactors, actual learning rates from deployments were used to project future costs (adjusted to account for standardization or lack thereof between designs). Other costs included are fixed and variable operations and maintenance costs. The final variables were capacity factors and ramp rates to support energy planning.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Draft Summary Report on Irradiated Fuel Handling and Management for LOTUS

The National Reactor Innovation Center (NRIC) has conceptualized the design of the Laboratory for Operation and Testing in the United States (LOTUS) test bed to provide the United States Department of Energy (DOE) with the infrastructure necessary to make advanced reactor designs available for commercial developers. LOTUS will provide a test bed to developers with the capabilities of supporting a wide range of experiment design possibilities. Upon completion of the developers’ operations and experiments within the test bed, the irradiated fuel, reactor components, and other experiment materials must be removed. Idaho National Laboratory (INL) possesses significant capabilities for radioactive material handling such as casks, carts, and forklifts. However, given the unique environment presented by the NRIC-LOTUS test bed, located inside the Zero Power Physics Reactor (ZPPR) Perimeter Intrusion Detection and Assessment System (PIDAS) area at the Materials and Fuels Complex (MFC) and the complexity of novel removal activities of recently operated reactor experiments through the new proposed access tunnel. The efficacy was not apparent for existing equipment to provide all the needed capability. To bridge the potential gaps in cask designs, storage, and transportation, NRIC requested the development of trade studies for the transfer, handling, and storage requirements of irradiated fuel salts and other radioactive materials. NRIC directed Boston Government Services, LLC (BGS) to perform the trade studies and develop a report analyzing alternatives. In addition to the BGS reports, the Idaho National Lab’s (INL), provided by the first potential user’s Advanced Reactor Development (ARD) team, prepared a feasibility study for the storage of specific irradiated fuel within the existing ZPPR vault.This summary report is intended to present the trade studies, options, and alternatives that were investigated. The maturity level of LOTUS, the reactor, fuel salt containers, gloveboxes, and reactor testing campaign and concept of operations were not at a level sufficient to base critical decisions on. This report is not intended to present a final recommendation. The final recommendations for fuel storage location, transport, handling equipment, and operations will be made in FY 2024 and will be based on known materials, test campaign requirements, funding, and final analysis of the fuel and equipment to be used.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Accelerated statistical failure analysis of multifidelity TRISO fuel models

Statistical nuclear fuel failure analysis is critical for the design and development of advanced reactor technologies. Although Monte Carlo Sampling (MCS) is a standard method of statistical failure analysis for fuels, the low failure probabilities of some advanced fuel forms and the correspondingly large number of required model evaluations limit its application to low-fidelity (e.g., 1-D) fuel models. In this paper, we present four other statistical methods for fuel failure analysis in Bison, considering tri-structural isotropic (TRISO)-coated particle fuel as a case study. The statistical methods considered are Latin hypercube sampling (LHS), adaptive importance sampling (AIS), subset simulation (SS), and the Weibull theory. Using these methods, we analyzed both 1-D and 2-D representations of TRISO models to compute failure probabilities and the distributions of fuel properties that result in failures. The results of these methods compare well across all TRISO models considered. Overall, SS and the Weibull theory were deemed the most efficient, and can be applied to both 1-D and 2-D TRISO models to compute failure probabilities. Moreover, since SS also characterizes the distribution of parameters that cause TRISO failures, and can consider failure modes not described by the Weibull criterion, it may be preferred over the other methods. Finally, a discussion on the efficacy of different statistical methods of assessing nuclear fuel safety is provided.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Technology Enabling Zero-EPZ Micro Modular Reactors: Fabrication of Zirconium Hydride with Controlled Hydrogen Loading

This report completes Milestone M2.2.2 - ZrH pellet fabricated with controlled hydride loading: ZrH1.5±0.1 single phase pellets fabricated with controlled and thermally stable hydride loading. Hydrogen content to be quantified and single-phase confirmed by X-ray diffraction. In this milestone, we report the successful fabrication of delta-phase zirconium hydride pellets using the ORNL bulk metal hydriding system. The successful deployment of zirconium hydride moderator in advanced reactors requires development of a consistent and affordable production pathway along with implementation of a hydrogen retention solution throughout the reactor life. Fabrication of delta-phase zirconium hydride is challenging since the absorption of a large amount of hydrogen into alpha-zirconium induces significant volume expansion and the present hydrogen concentration gradient results in cracking. A fully programmable hydriding system with continuous hydrogen partial pressure and flow control to facilitate processing of massive metal hydride has been developed at ORNL. In this report, the working principle of the hydriding system will be introduced. Characterization of the produced zirconium hydride includes X-ray powder diffraction to identify the present phases and X-ray Computed Tomography to visualize the internal microstructure (including cracks). The results indicate that single delta-phase zirconium hydride pellets with various sizes have been successfully produced.

36 MATERIALS SCIENCE↗

Domestic MC&A Recommendations for Liquid-Fueled MSRs

Investments by the US Department of Energy (DOE) are providing opportunities for vendors and developers of advanced reactor technologies to move toward experimental reactor systems, leading to commercial scale facilities. One facet of complementary research under the Advanced Reactor Safeguards program in the DOE Office of Nuclear Energy (NE-5) is motivated to assist vendors in licensing under the existing US (domestic) regulatory body’s federal regulations. This report provides concepts, approaches, and recommendations for liquid-fueled molten salt reactor (MSR) vendors to meet the material control and accountability (MC&A) and licensing requirements set forth by the US Nuclear Regulatory Commission (NRC) to possess and handle special nuclear material.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Engagement opportunities in OECD NEA benchmark development

A myriad of opportunities is available to collaborate via international benchmark exercises and experimental data preservation activities. Many such opportunities abound under the auspices of the Nuclear Science Committee of the Organisation for Economic Co-operation and Development Nuclear Energy Agency (NEA). Key projects and activities of relevance to the development of advanced reactors design include the International Criticality Safety Benchmark Evaluation Project (ICSBEP), the International Reactor Physics Experiment Evaluation Project (IRPhEP), the International Assay Data of Spent Nuclear Fuel Database (SFCOMPO), the Shielding Integral Benchmark and Archive Database (SINBAD), and The International Experimental Thermal HYdraulicS Database (TIETHYS), and various cooperative benchmark exercises. Interested participants are encouraged to contact the leadership and secretariat of the various Technical Working Groups and Working Parties to become more engaged. This paper provides a summary of the current benchmark exercises and experimental databases available for international participation.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

Digital Twin Framework for the Resilient Remote Monitoring and Operation of Nuclear Microreactors

The nuclear industry is developing new advanced reactor technologies, and many companies are conceptualizing designs for microreactors, a class of nuclear reactor with a sub-20 MWth power output designed to be factory fabricated, easily transportable, and simple to control. Microreactors offer promising solutions to several use cases for which large-scale plants would not be suitable, and conventional power generation means, notably diesel electric generators, are expensive and logistically difficult. Many of the potential use cases are in isolated locations such as arctic communities, remote mines, and military installations. Therefore, the cost of microreactor deployment and traditional onsite operations pose a challenge that requires new technical solutions to address. One solution that has the potential to greatly improve economics is to operate and monitor microreactors remotely from a centralized location. Remote monitoring and operation are novel concepts to the nuclear industry and will greatly alter the tasks and responsibilities associated with current commercial nuclear power plant operators. As such, it is important to perform research on potential technological solutions and the impacts those solutions have on operations with end-goal of defining a safe and effective remote concept of operations. This paper proposes a framework for resilient remote operation of microreactors enabled by a novel digital twin implementation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗