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At least 1,261 records · Page 70

Sister Rod Destructive Examinations (FY2021)

As a part of DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. This report documents the status of the ORNL Phase 1 DEs of 7 sister rods and outlines the DE tasks performed and the data collected to date, as guided by the sister rod test plans.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Sister Rod Destructive Examinations (FY2021) Appendix F: Cyclic Integrated Reversible-Bending Fatigue Tests

As a part of DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. This appendix documents the status of the ORNL Phase 1 DE activities related to tests of the sister rods using the Cyclic Integrated Reversible-Bending Fatigue Tester (CIRFT) in Phase 1 of the sister rod test program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Sister Rod Destructive Examinations (FY2020) Appendix I: SNF Aerosols Released During Rod Fracture

As a part of the DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin Zirc-4, ZIRLO, and M5. This report documents the status of the ORNL Phase 1 DE activities related to the collection of SNF aerosol particles released during fuel rod fracture in four-point bending in Phase 1 of the sister rod test program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Sister Rod Destructive Examinations (FY2021) Appendix C: Rod Internal Pressure, Void Volume, and Gas Transmission Tests

As a part of the DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWD/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called the sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. This Appendix C documents the status of the ORNL Phase 1 DE activities [C-2, C-3] related to rod internal pressure and void volume measurement techniques, fission gas stack flow measurements applied to selected sister rods, and fission gas release calculations in Phase 1 of the sister rod test program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Report Summarizing Progress in Digital Image Correlation Analysis of Burst Phenomenon

This report is an update on the progress made towards utilizing in-situ methods to observe and quantify Zry-4 deformation behavior during burst testing. A heavily modified burst test was developed that allows both digital image correlation and infrared thermography to be utilized during testing to quantify strain and axial thermal gradient data during burst. A variety of tests ranging from 6.2-15.9 MPa internal pressure and utilizing both constant and transient pressure conditions were conducted and presently reported on. The test modifications, which are detailed extensively in a previous report, are effectively found to have no discernible impact on burst temperatures when compared to historical Zircaloy burst data. To support future modeling studies, the IR thermography data was used to approximate the thermal gradient down the axial length at burst for all the claddings. Then, DIC is first correlated to thermocouple temperature for a 10.3 MPa Transient pressure test, and then DIC correlated to IR thermal gradient data down the axial length of a 8.2 MPa Transient pressure test at several points.

36 MATERIALS SCIENCE↗

Application of Laser Powder Bed Fusion for Transformational Challenge Reactor Core

The following report focuses on the utility of Laser Powder Bed Fusion (LPBF) for the construction of components for the Transformational Challenge Reactor (TCR) core. Multiple additive manufacturing processes are under investigation to evaluate the advantages and viability of each process for direct manufacturing of complex structures needed for future nuclear reactors. Technologies under investigation include binder jet, direct energy deposition (DED), electron beam powder bed fusion (EBPBF), and laser powder bed fusion (LPBF). Each process has advantages and disadvantages. For the core design, two manufacturing approaches are under consideration—one involving the exclusive use of LPDF to fabricate the entire core and the other consisting of integration of LPBF and DED where LPBF is used for the core’s top and bottom manifolds (where complexity is high) and DED is used for the manufacture of the cladding where complexity is still high but geometric variability, size, and speed are better suited for DED. For both approaches, LPBF research has focused on processing parameter development, core design, and manufacturing tolerances for integration of fuel elements. The following report highlights reactor core design as it relates to LPBF and experimental validation of test components necessary for finalizing the core design.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Fundamental Studies of Tritium Formation and Diffusivity in Pure and Defective Zircaloy-4 Getters

Zirconium (Zr) and its alloys are used as fuel cladding in nuclear reactors. These materials have their low absorption cross-section for thermal neutrons and have good mechanical and thermal properties. In addition, they are used as tritium getters in tritium-producing burnable absorber rods (TPBARs), in the form of nickel-plated Zircaloy-4 tubes. To produce 3 H, the breading blankets such as lithium aluminate are irradiated in pressurized water. 3 H produced in this process is captured by the getter and 3 H reacts chemically with Zr to form metal hydride (ZrTx). The precipitation of metal hydride results in not only the volume increase and hydrogen embrittlement of zircaloy but also changes in getter’s chemical properties. This degrades the getter’s performance. Therefore, understanding the behavior of 3 H (such as diffusion and solubility) in zircaloy is important to understand getter performance.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Response of a Pressurized Water Reactor Dashpot Region to Commercial Drying Cycles

The purpose of this report is to document updates to the simulation of commercial vacuum drying procedures at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates additional, well-designed investigations of drying process efficacy and water retention. Scaled tests that incorporate relevant physics and well-controlled boundary conditions are essential to provide insight and guidance to the simulation of prototypic systems undergoing drying processes. This report documents testing updates for the Dashpot Drying Apparatus (DDA), an apparatus constructed at a reduced scale with multiple Pressurized Water Reactor (PWR) fuel rod surrogates and a single guide tube dashpot. This apparatus is fashioned from a truncated 5×5 section of a prototypic 17×17 PWR fuel skeleton and includes the lowest segment of a single guide tube, often referred to as the dashpot region. The guide tube in this assembly is open and allows for insertion of a poison rod (neutron absorber) surrogate.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A User Guide to PARET/ANL

PARET was originally created in 1969 at what is now Idaho National Laboratory (INL), to analyze reactivity insertion events in research and test reactor cores cooled by light or heavy water, with fuel composed of either plates or pins. The use of PARET is also appropriate for fuel assemblies with curved fuel plates when their radii of curvatures are large with respect to the fuel plate thickness. The PARET/ANL version of the code has been developed at Argonne National Laboratory (ANL) under the sponsorship of the U.S. Department of Energy/NNSA since the inception of the Reactor Conversion Program. Since Reduced Enrichment for Research and Test Reactors (RERTR) began in 1978, PARET/ANL has been benchmarked to experimental data including SPERT testing, and used to determine the expected transient behavior of a large number of reactors regardless of enrichment both inside and outside the Reactor Conversion Program. This document provides the pertinent information for the use of PARET/ANL Version 7.6. PARET/ANL models the various fueled regions of a reactor core as channels. Each of these channels consists of a single flat fuel plate/pin (including cladding and, optionally, a gap) with water coolant on each side. In slab geometry the coolant channels for a given fuel plate are of identical dimensions (mirror symmetry), but they can be of different thickness in each channel. There can be many channels, but each channel is independent and coupled only through reactivity feedback effects to the whole core. The time-dependent differential equations that represent the system are replaced by an equivalent set of finite-difference equations in space and time, which are integrated numerically. PARET/ANL uses fundamentally the same numerical scheme as RELAP5 for the time-integration of the point-kinetics equations. The one-dimensional thermal-hydraulic model includes temperature-dependent thermal properties of the solid materials, such as heat capacity and thermal conductivity, as well as the transient heat production and heat transfer from the fuel meat to the coolant. Temperature- and pressure-dependent thermal properties of the coolant such as enthalpy, density, thermal conductivity, and viscosity are also used in determining parameters such as friction factors and heat transfer coefficients. The code first determines the steady-state solution for the initial state. Then the solution of the transient is obtained by integration in time and space. Multiple heat transfer, DNB and flow instability correlations are available. The code was originally developed to model reactors cooled by an open loop, which was adequate for rapid transients in pool-type cores. An external loop model appropriate for Miniature Neutron Source Reactors (MNSR’s) was also added to PARET/ANL to model natural circulation within the vessel, heat transfer from the vessel to pool and heat loss by evaporation from the pool. PARET/ANL also contains models for decay heat after shutdown, control rod reactivity versus time or position, time-dependent pump flow, and loss-of-flow event with flow reversal as well as logic for trips on period, power, and flow. Feedback reactivity effects from coolant density changes and temperature changes are represented by tables. Feedback reactivity from fuel heat-up (Doppler Effect) is represented by a four-term polynomial in powers of fuel temperature. Photo-neutrons produced in beryllium or in heavy water may be included in the point-kinetics equations by using additional delayed neutron groups.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

FY23 Post-LOCA Characterization of Irradiated Fuel (NSUF Award 17-12985)

This report summarizes the sample preparation and data collection on fuel pins following integral LOCA testing in the Severe Accident Test Station at Oak Ridge National Laboratory. The test sample cross-sections show post-transient fragmentation behavior of UO 2 commercially irradiated above 67 MWd/kgU. Ring compression testing and hydrogen measurements were collected on the cladding segments.

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Mach Conference, 2022.

There has been considerable interest in chemical vapor infiltration (CVI) manufactured silicon carbide fiber and silicon carbide matrix (SiC/SiC) composite tubes due to their superior mechanical properties. The SiC/SiC tubes are known to remain stable even after prolonged exposure to radiation. However, there are many variables in the manufacturing of SiC/SiC composite tubes such as elastic constants of constituent SiC fiber and SiC matrix, braiding angle, porosity, and others whose values vary over a range. The intention is to identify the distribution of elastic constants of SiC/SiC tubes which would help model the performance of the novel cladding material. To do so, a sensitivity analysis will be carried out to determine the dominant variables that influence the elastic constants of SiC/SiC tubes. A chosen number of combinations of dominant variables will be sampled through the Latin hypercube sampling (LHS) method. The elastic constants of composite tube namely Young's moduli in the circumferential and longitudinal direction, Poisson's ratio, and shear modulus will be calculated at sampled points through finite element (FE) analysis. A polynomial response surface (PRS) will be built for each of the elastic constants to be used as a surrogate to FE analysis. Once the predictive accuracy of PRS is verified at the validation set of data points, the PRS will be invoked 105 times in Monte Carlo simulations (MCS). The uncertainty can be quantified by calculating the coefficient of variation (CV) based on MCS-generated data which will be presented at the conference.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Disassembly of Capsules after Irradiation of Prototype Metal and Nanocomposite Specimens in the High Flux Isotope Reactor

This report summarizes the disassembly, thermometry (TM) analysis, and future post-irradiation examination of irradiation capsules that contain nanodispersion-strengthened materials for the improved neutron irradiation resistance of fuel cladding and reactor core materials. All six capsules were successfully disassembled, and all TM was shipped to the Low Activation Materials Development and Analysis Laboratory for further analysis. The results of this project will support the development of new radiation-resistant materials by helping researchers understand the mechanism of defect evolution at interfaces in nanodispersion-strengthened materials.

36 MATERIALS SCIENCE↗

Transformative Building Envelope Retrofit Using Insulation-Inflatable Walls Assisted by Automation

This work highlights the effort to develop a low-cost envelope retrofit for homes built prior to the implementation of energy conservation measures established by the Department of Energy. Inflatable structures were constructed to conform to the exterior envelope (a corner wall construction with a fenestration was used as a prototype). The structures were then filled with spray polyurethane foam insulation. The flexibility in construction and the ability to fill with spray polyurethane foam insulation were demonstrated. In addition, hygrothermal simulations showed that the installation of these systems does not compromise the moisture durability of uninsulated and insulated building envelopes across eight climate zones from hot humid to subarctic. Preliminary cost estimates, based on retail pricing, of the inflatable retrofit including 3 inches of spray foam insulation (insulation value of approximately R 20) is $\$ 4.25$ per square foot uninstalled. The installed cost was calculated using two labor rates, the labor rate for the installation of a weather resistive barrier and the installation of spray foam insulation. Aggregating those values into one labor rate results in an installed cost between $\$ 11$ and $\$ 28$ per square foot. The low end includes the installation of vinyl siding as the exterior cladding. The higher value includes an exterior stucco finish.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Measurement of radiolytic hydrogen generation from surrogate zr-based materials in a "mini-canister"

This report describes a test campaign to investigate radiolytic hydrogen generation from surrogate materials resembling the (Zr-based) cladding of commercial spent nuclear fuel (SNF) with an inventory of residual water post-dryout. The radiolytic hydrogen generation rates from residual waters in the SNF-in-canister system are important for predicting the in-canister environment for sealed SNF dry storage canisters over time and the impact to continued safe dry storage.

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Progress on Demonstration of a MOOSE-Based Coupled Capability for Hot Channel Factors in Fast Reactors

Hot channel factors (HCFs) are computed values that account for the impact on predicted peak fuel, cladding, and coolant temperatures due to uncertainties in the as-built reactor’s material properties and geometry as well as uncertainties due to modeling approximations. Reduction in computed HCF values via reduction or elimination of modeling approximations may translate to significant economic savings if the reactor power can be raised due to the extra temperature margin gained. While limited historical datasets exist for sodium-cooled fast reactors (SFRs), there are no available HCF data for lead-cooled fast reactors (LFRs) outside of work generated previously within NEAMS. The computation of HCFs involves insights from reactor physics, thermal fluids and heat conduction calculations to determine how the peak temperatures respond to various uncertainties in the design. Due to the significant advantages for multi-physics coupling offered by the MOOSE framework, Griffin (MOOSE-based reactor physics code), MOOSE Heat Conduction Module, and Cardinal (MOOSE-wrapped multi-physics application which includes the NekRS thermal fluids code) are being coupled together using the MOOSE MultiApp System to develop a highfidelity multi-physics modeling capability for HCF simulations. This high-fidelity coupling workflow may also be beneficial for other fast reactor applications in the future. In previous work, Griffin and NekRS were individually assessed to ensure the necessary capabilities were in place. This work describes initial efforts to couple the codes (including folding in the MOOSE Heat Conduction Module) and determining the workflow for the perturbed calculations which will leverage the Stochastic Tools Module (STM). To our knowledge, this is the first coupling of Griffin and NekRS as well as the first exploratory use of Stochastic Tools Module for Cardinal. In this report, the neutronics code Griffin, the heat conduction solver in MOOSE, and the MOOSE-wrapped application containing NekRS (Cardinal) are linked together to demonstrate the coupled capability. Griffin and Cardinal are linked dynamically by specifying shared libraries. Different coupling hierarchies are tested for selecting the most appropriate coupling strategy. A coupling scheme is selected based on the efficiency of calculation and ease of data communication. Multiple tests are performed to choose suitable mesh structure, model configurations, scheme setup and boundary conditions to avoid loss of energy due to data interpolation between different modules or weak imposition of fluxes in finite element codes. Computational experiments are performed to study the tolerance control of each type of iteration to avoid false convergence. The coupled capability is demonstrated in both single pin and 7-pin models based on LFR materials and geometry. The study finds that the use of too large a time step size in the heat conduction module can lead to temperature oscillation even though the heat conduction equation does not have a time-derivative kernel, but only the time-dependent boundary condition. A 7-pin model without duct region achieved good convergence in the coupled calculation while a 7 pin model with duct region experienced data communication issues which need to be resolved.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Ageing Management for Extended Long-Term Dry Storage of Spent Nuclear Fuel and Transportation

The principal objectives of the Coordinated Research Project (CRP) and CRADA were to (1) investigate how ageing effects leading to degradation of materials used in the spent fuel dry storage systems could be managed by ageing management programs (AMPs) and (2) using existing AMPs as a basis, establish guidance on how to develop, generate, and maintain AMPs for dry storage systems of spent nuclear fuel (SNF) that can be accomplished in various ways. The PI (Dr. Liu) is an internationally recognized expert on ageing management for license renewal of nuclear power plants and independent spent fuel dry storage installations. Dr. Liu was invited by IAEA to participate in this CRP and served as Chair of the Working Group, supporting the IAEA CRP Lead, with other members from Argentina, the Czech Republic, France, Germany, Hungary, Japan, Pakistan, Spain, Switzerland, United Kingdom, and the United States of America. Argonne’s scope of work in the CRADA for the CRP included (1) ageing management guidance documents developed by Argonne for DOE and used by the Nuclear Regulatory Commission (NRC) and industry and (2) research leveraged from the DOE Office of Nuclear Energy on the mechanical properties of high-burnup fuel cladding and the ARG-US remote monitoring systems technology developed for the DOE Packaging Certification Program, Office of Packaging and Transportation, Office of Environmental Management.

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Application of Directed Energy Deposition for Transformational Challenge Reactor Core

The following report focuses on utilizing directed energy deposition (DED) for constructing the Transformational Challenge Reactor core. Multiple additive manufacturing processes are under investigation to evaluate the advantages and viability of each process for direct manufacturing of complex structures needed for future nuclear reactors. Technologies under investigation include binder jet, laser powder bed (LPB) fusion, electron beam powder bed fusion, and DED. Each process has advantages and disadvantages. For the core design, the current manufacturing approach consists of integrating LPB with DED. This hybrid manufacturing approach uses LPB for the core’s top and bottom manifold (where complexity is high) and DED for the manufacture of the cladding, where complexity is still high but geometric variability, size, and speed are better suited for DED. Research has focused on processing parameter development, evaluation of toolpath generation algorithms, core designs suitable for DED, manufacturing tolerances for integration of fuel elements, and seamless calibration and integration of LPB components into a DED build volume to create monolithic structures based on integrating these technologies. The following report highlights reactor core design as it relates to DED and experimental validation of test components necessary for finalizing the core design.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

FY2022 Progress Report for Advanced Re-fabrication/Re-instrumentation Capability Development

In support of performing follow-on irradiation experiments with previously irradiated materials, the Halden Reactor Project developed unique and state of the art capabilities to refabricate and re-instrument previously irradiated materials. Such materials were used in in-pile tests at the Halden reactor, and out-of-pile tests for example using furnaces as a heat source. The decision to close the Halden Reactor Project results in the loss of this refabrication and re-instrumentation capability. As a result, the United States (U.S.) Department of Energy (DOE) has determined to develop refabrication and re-instrumentation capability at the unique shielded facilities at Idaho National Laboratory (INL). The development of refabrication capability has been completed and demonstrated. This report focuses on the complementary aspects of reinstrumentation and the progress to-date. Halden spent nearly 30 years developing both refabrication and re-instrumentation. Collaboration with Halden is allowing Idaho National Laboratory (INL) to develop this capability much more rapidly. In FY-21 the results include development of the capability to drill annular center holes in ceramic UO2 fuel pellets, development of fuel rod end caps with feedthroughs for centerline instrumentation inside the rodlet, The procurement of both fuel drilling and welding demonstration equipment from Halden, evaluation of surface thermocouple attachments to support better understanding of temperature measurement uncertainties, and finally, the conceptual design of a new shielded enclosure where advanced refabrication and re-instrumentation equipment can be housed. In FY-22, the results include; Completing set up of the drilling and welding modules procured from Halden, and early experimental trials using that equipment.; Completing set up of an out-of-cell circumferential weld system to allow for further weld development to take place and support fabrication of fuel for fresh fuel experiments.; Evaluation of the Hot Fuel Examination Facility (HFEF) infrastructure to support future installation of advanced re-fabrication/re-instrumentation equipment, specifically related to necessary infrastructure for cryo-drilling.; Developments in dry-drilling alternative. Including experimental studies showing cordierite is the most suitable surrogate for UO 2 for performing drilling studies. That drilling performance is enhanced when a fuel-clad bonding condition is simulated.; Conceptual design completed for attaching surface thermocouples to irradiated fuel in support of TWIST capsule experiments. The authors would like to thank the numerous colleagues at INL and Halden who provided support in accomplishing this work. Their support both material and intellectual is invaluable in advancing the state of the art and establishing the capabilities for refabrication and re-instrumentation at INL.

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