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At least 1,261 records · Page 70

Pulsed Infrared Thermography Nondestructive Imaging of SiC-SiC f Composite Cladding Architectures; Understanding the Performance of SiC-SiC f Composite Cladding Architectures with Cr Coating in Normal Operating and Accident Conditions in LWRs and Advanced Reactors

SiC-SiC f composites, consisting of silicon carbide fibers embedded in a silicon carbide matrix, are advanced materials with high thermal conductivity, temperature stability, and resistance to radiation damage. Traditional methods for quality control of fabricated SiC-SiC f composites involve nondestructive evaluation (NDE) with X-ray computed tomography (XCT). However, XCT imaging of typical SiC-SiC f structures for cladding applications can involve several hours. In this project, we investigate an alternative approach to NDE of SiC-SiC f composites that involves rapid (on the order of seconds) imaging with Pulsed infrared thermography (PIT). PIT images of a planar SiC-SiC f specimen show the structure of the surface monolith layer and internal SiC f structures. The capability of PIT imaging in visualizing SiC f structures is qualitatively confirmed by observing similarity in the PIT and X-ray transmission images of the same specimen. Computer vision analysis of defects in the PIT image of the monolith was performed with thresholding followed by topological structural analysis that computed geometric descriptors, including major/minor axes of fitted ellipses, area, perimeter, Feret diameter, circularity, roundness, and solidity.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Sensitivity analysis of thermal contact conductance modeling to inform MiniFuel irradiation capsule designs

The MiniFuel irradiation platform has been developed by Oak Ridge National Laboratory as a flexible, high-throughput separate effects testing capability within the High Flux Isotope Reactor (HFIR). Finite element thermal models are relied upon to design MiniFuel experiments to achieve a specific time-averaged irradiation temperature for experimental objectives. A previous study identified that uncertainty in the component heat generation rates and thermal contact conductance (TCC) model are the most significant contributors to predicted fuel temperature variance. To address both sources of uncertainty, this work performs sensitivity analysis on the TCC model to identify high-impact, high-uncertainty parameters that contribute to fuel temperature variance. The TCC model is analyzed in increasing detail, first using a standalone Python code, then again after coupling Python to the BISON fuel performance code. Furthermore, the parameters with the largest contributions to fuel temperature variance which can be reduced through design changes are identified as the initial subcapsule gas pressure, contact pressure between the fuel and dish, and the effective surface roughness of the interface. A set of design recommendations for future capsule designs has been established and applied to reduce the previously quantified average fuel temperature uncertainty ranges of ± 40 °C in the HFIR vertical experiment facilities (VXF) and ± 80 °C in the removable beryllium (RB) reflector to approximately ± 32 °C and ± 53 °C, respectively. This equates to a 21 % and 33 % reduction in the uncertainty range of the average fuel temperature for VXF and RB, respectively.

BISON↗

Reduction of Ultrafine Hematite for a Spouting Bed Chemical Looping Process - Presentation

Chemical looping combustion research has been a topic of great interest since the mid-1990s, although the concept can be traced much further back. It is a combustion technology for fuel utilization that uses a two-reactor system to produce a carbon free effluent stream from the air reactor and a carbon dioxide rich stream from the fuel reactor with oxygen shuttled between the reactors with an oxygen carrier. Chemical looping combustion has been studied extensively because of this inherent separation of the carbon dioxide combustion product from the atmospheric nitrogen over that past 25 years with hundreds of research papers and tens of books. The oxygen carrier is, in general, a solid such as naturally occurring hematite or an engineered carrier like a copper and iron oxide supported on alumina. System technical and economic research activities conducted at the National Energy Technology Laboratory have shown that the costs associated with the carrier, initial and replacement, are a significant factor in the economic viability of the technology. To overcome this economic challenge, the work reported on in this paper investigates the use of a waste iron oxide as the chemical looping oxygen carrier. This waste material is quite unique as it has a particle size of 0.7 um. Given the particle size, the reactions are quite fast. However, the development of a contactor reactor to mix the fuel with the carrier is a fluidization challenge as the material is a Geldart group C material and highly cohesive. Normally, Geldart group C materials are fluidized with either a vibrating bed. This technique is acceptable for low temperature pharmaceuticals production but does not lend itself to much larger reactors used for power production or operation at temperatures in the order of 1100 to 1200 C. Therefore, a hydrodynamic solution was needed to break up the cohesive structures to replace the vibration. In this instance, it was hypothesized that a spouting bed of large Geldart group B or Geldart group D particles could provide the necessary energy to break up the cohesive structures of the Geldart group C material. This paper presents the reduction performance for this novel carrier material in a laboratory spouting bed reactor.

Breault, Ronald↗

Under the microscope: Reduced activation ferritic martensitic steel Eurofer-97 following ion-Irradiation and high-temperature high-pressure water exposure

Here, this study is designed to characterise the microstructural behaviour of Eurofer-97 steel under ion irradiation and subsequent exposure to high-temperature high-pressure (HTHP) water. Eurofer-97, a ferritic-martensitic steel, has been developed to withstand the conditions of fusion reactors in the locations in contact with coolant with an elevated level of neutron flux, such as the breeder-wall blanket. The material has been studied after self-ion irradiation (using Fe ions) simulating the microstructural effects of neutron irradiation limited to the subsurface layer. The corrosion properties of the Eurofer-97 steel were studied by exposure to HTHP water up to 331 °C. Advanced microstructural characterisation using scanning, transmission electron and focused ion beam microscopy was performed on the as-received microstructure and after ion irradiation. This was then characterised after exposure for 240 h in high-temperature water. Eurofer-97 had a dense, columnar Cr-rich inner oxide, followed by a Fe-rich outer oxide layer. In the irradiated condition the grain structure and oxide itself was less ordered. No appreciable difference in oxide thickness was identified between the irradiated and unirradiated specimens after this short exposure time.

36 MATERIALS SCIENCE↗

High Temperature Sodium Submersible Flowmeter Design and Analysis

This work details the design and analysis of a permanent magnet flowmeter designed to be submerged in a pool type sodium fast reactor environment. Recently developed Samarium Cobalt rare earth magnets were utilized that have demonstrated resilience to temperature and neutron flux up to 550 °C and 10 18 n/cm 2 , respectively. This paper will discuss the theory, design, calibration and uncertainty quantification of the flowmeter. The flowmeter was calibrated over a flowrate range of 11.4 - 90.9 LPM at temperatures of 220 and 400 °C, yielding an uncertainty in calibration of 2-3.6%. Here, a finite element model was developed and validated experimentally, yielding <; 3.2% error.

47 OTHER INSTRUMENTATION↗

Plastic waste upgrade to olefins via mild slurry microwave pyrolysis over solid acids

Chemical upcycling technologies are emerging as the most viable to combat plastic waste accumulation. Among them, catalytic pyrolysis is very promising as it is feedstock agnostic. However, the high energy demand associated with pyrolysis can lead to significant carbon dioxide production. In this work, we demonstrate that coupling microwave heating with suitable solid acid promoters in a slurry reactor coupled with a distillation unit can overcome the energy-related challenge of conventional pyrolysis, by operating at modest temperatures (350–375 °C), enhancing transport, and furnishing high yields of olefins (~88 %) in seconds, with medium-sized olefins (>75 %) composing a significant fraction. Reduced thermal gradients minimize coke formation, further improving the performance. Techno-economic analysis and life cycle assessment indicate the potential of the technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

High-temperature steam oxidation study of irradiated FeCrAl defueled specimens

Post irradiation examinations (PIE) were performed on irradiated iron-chromium-aluminum (FeCrAl) specimens. These FeCrAl specimens were fabricated at the US Department of Energy's Oak Ridge National Laboratory (ORNL). The experimental setup involved subjecting FeCrAl cladding, along with UO 2 pellets, to irradiation in the Idaho National Laboratory Advanced Test Reactor (ATR). In parallel, the FeCrAl alloy tubing without UO 2 pellets was irradiated at ORNL's High Flux Isotope Reactor (HFIR). After irradiation, the ATR-irradiated rodlet was transported to an ORNL hot cell, where it was sectioned into multiple samples for the PIE and severe-accident testing. The sectioning process revealed that the fuel was not bonded to the cladding and could be easily detached from sectioned cladding slices. Microstructural analysis of the fuel cross sections demonstrated no significant interaction between the fuel and the cladding. Additionally, high-temperature steam oxidation tests on defueled cladding segments showed minimal oxygen uptake even at 1200 °C. Here, the ATR-irradiated specimens began to exhibit signs of enhanced oxidation upon reaching a temperature of 1300 °C. Furthermore, enhanced oxidation was observed on the inner surface of the ATR-irradiated FeCrAl specimen, which had been subjected to 1300 °C for a duration of 1 min. By contrast, high-temperature steam oxidation experiments indicated that the HFIR-irradiated FeCrAl cladding provided good thermal stability when exposed to 1300 °C for up to 4 h. Comparative analysis encompassing the oxidation behavior of the ATR-irradiated fueled FeCrAl, HFIR-irradiated unfueled FeCrAl, and unirradiated FeCrAl suggests that the fuel–cladding interaction, although not visible via standard microscale electron microscopy measurements, may accelerate the deterioration of FeCrAl cladding in beyond-design-basis accident scenarios.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Laser-based Adhesion Strength Measurements for Advanced Manufactured Sensor Adhesion Characterization

As part of the advanced manufacturing (AM) focus of the Nuclear Energy Enabling Technologies (NEET) Advanced Sensors and Instrumentation (ASI) Program, new in-house capabilities to fabricate and test novel active and passive in-pile sensors are being developed at the Idaho National Laboratory (INL). These advanced-manufactured sensors, such as peak temperature monitors and strain gauges, must be miniaturized and be able to provide real-time feedback, all while withstanding the coupled extremes of temperature and radiation typically observed in the environment of a nuclear test reactor. Fabricating durable and robust in-pile sensors with high fidelity requires a fundamental understanding of the optimal process parameters required in the AM technique, as well as the effect of deviations from optimal process parameters on the sensor-substrate adhesion and the ultimate robustness of the sensor. This report presents the use of a laser-based, non-contact approach for characterizing the adhesion of sensors manufactured using aerosol jet printing (AJP) that comprise of silver nanoparticle inks deposited and sintered on austenitic stainless steel (SS) 316L substrates. The effect of substrate surface roughness, surface energy, ink sintering time and sintering temperature on the printed sensor topography and the sensor-substrate adhesion has been systematically investigated. The sensor-substrate interfacial adhesion strength was determined from the critical laser pulse energy required to ablate/ detach the printed sensor from the substrate. Measurements of the sensor topography using optical profilometry revealed that post-deposition sintering at 400°C for 60 minutes resulted in a reduced sensor thickness, while plasma treating the substrate prior to printing yielded sensors with uniform thickness profiles transverse to the print direction. Sintering temperature and time were found to be the dominant parameters that affected sensor-substrate adhesion, followed by substrate surface roughness. The laser-based and locally-destructive approach for adhesion strength measurements shows promise in overcoming the challenges and limitations of current standardized peel tests and can be developed into a post-fabrication process control protocol for evaluating the durability of AM printed sensors in a high throughput fashion. Future studies will investigate the use of laser-induced spallation techniques as well as non-destructive laser ultrasonic methods for sensor-substrate adhesion characterization on sensors manufactured using AJP and other AM techniques such as plasma jet printing (PJP).

42 ENGINEERING↗

Conversion of CO 2 into Synthetic Graphite

Carbon Dioxide (CO 2 ) can be utilized as a source for producing synthetic graphite. Our method converts CO 2 into solid carbon. These CO 2 -sourced solid carbon have an anisotropic property that allow them to be graphitized into synthetic graphite. Our patented thermal catalytic process uses carbon dioxide and hydrogen as the feedstocks for the reaction, producing solid carbon material, with distilled water as the sole byproduct. The process is designed as a closed loop, where all feedstock gases entering the reactor are converted into durable bulk carbons and water, with no emissions. These carbons materials can be sintered into a solid structure and then thermally annealed, taking the carbon atoms from a disordered state to a highly ordered state of graphitic material – producing synthetic graphite structures. Phase 1 will prove that these bulk carbons can be sintered into a machinable solid carbon structure, which will then be annealed into a fully graphitic solid structure. Standard analytics will be done to verify the extent of graphitization (Raman, XRD). Proving this CO 2 -sourced carbon pathway to synthetic graphite structures will give the US a domestic supply route for this critical material and remove reliance on foreign sources. In addition, since the synthetic graphite structure is made from CO 2 -sourced carbon, this is also a method to mitigate CO 2 . Graphite structures are used in high temperature and high friction applications, for example, as anodes for steel refining, for brake pad linings, as neutron reflectors in nuclear reactors.

36 MATERIALS SCIENCE↗

Systems Biology-Based Optimization of Extremely Thermophilic Lignocellulose Conversion to Bioproducts

This was a collaborative project involving researchers at the University of Georgia, North Carolina State University, Sanford‐Burnham‐Prebys Med. Discovery Institute and the University of Rhode Island. The over-arching goal was to demonstrate that non-model microorganisms, specifically extreme thermophiles, can be a strategic metabolic engineering platform for industrial biotechnology. We engineered the most thermophilic lignocellulose-degrading organism known, Caldicellulosiruptor bescii (Cbes) , which grows optimally near 80°C, and the most thermophilic fermentative organism known, Pyrococcus furiosus (Pfu) , which grows optimally at 100°C, to produce several key industrial chemicals. This work leveraged recent breakthrough advances in the development of molecular genetic tools for these organisms, complemented by a deep understanding of its metabolism and physiology gained over the past decade of study in the PIs’ laboratories. We applied the latest metabolic reconstruction and modeling approaches to optimize biomass to product conversion. Bio-processing above 70°C can have important advantages over near-ambient operations. Highly genetically-modified microorganisms usually have a fitness disadvantage and can be easily overtaken in culture when contaminating microbes are present. The high growth temperature of extreme thermophiles precludes growth or survival of virtually any contaminating organism or phage. This reduces operating costs associated with reactor sterilization and maintaining a sterile facility. In addition, at industrial scales, heat production from microbial metabolic activity vastly outweighs heat loss through bioreactor walls such that cooling is required. Extreme thermophiles have the advantage that non-refrigerated cooling water can be used if needed, and heating requirements can be met with low-grade steam typically in excess capacity on plant sites. We assembled a highly interdisciplinary team that brought together all of the expertise for the project to have successful outcomes. This project also built upon and utilized extensive information already available in the PIs’ labs for both Cbes and Pfu to develop models that provide a comprehensive description of these organisms’ physiology and metabolism that were utilized to inform metabolic engineering strategies. The models were validated with experimental data and the results demonstrated that unpretreated lignocellulose has the potential to be converted into value-added industrial chemicals at high loading at bioreactor scale. The data generated from this research were published in twenty-one peer-reviewed papers in international journals with online access.

60 APPLIED LIFE SCIENCES↗

Controlled Dy-doping to nickel-rich cathode materials in high temperature aerosol synthesis

Layered nickel-rich materials are promising next-generation cathode materials for lithium ion batteries due to their high capacity and low cost. However, the poor thermal stability and longtime cycling performance hinders the commercial applications of high nickel materials. Doping with heteroatoms has been an effective approach for improving electrochemical performance of cathode materials. Controlling doping concentration and geometrical distribution is desired for optimal electrochemical performance, but it is challenging in traditional co-precipitation methods. In this work, controlled dysprosium (Dy) doping to NCM811 was studied in an aerosol synthesis method by controlling the precursor concentrations and heating parameters. The obtained materials were characterized by SEM, XRD, and XPS, and their electrochemical properties and thermal stability were evaluated. By controlling the doping concentration (1.5%), Dy-doped NCM811 was improved simultaneously in long-term cycling and high-rate performance. Here, the thermal-chemical stability of the Dy-doped cathode materials was examined in a microflow reactor with a mass spectrometer. The results showed that Dy-doping shifted the O 2 onset temperature to a higher temperature and reduced O 2 release by 80%, thus dramatically increasing the thermal-chemical stability and improving the fire safety of cathode materials. Since high temperature aerosol synthesis is a low-cost and scalable method, the findings in this work have broad implications for commercial synthesis of novel materials with controlled doping modification to achieve high electrochemical performance and safety in lithium ion batteries.

25 ENERGY STORAGE↗

High temperature inelastic constitutive models for the ASME Section III, Division 5 Class A materials

This report describes the exploration of a universal high temperature inelastic constitutive model for use with the ASME Boiler & Pressure Vessel Code Section III, Division 5, Class A design rules. The idea, developed based on feedback from reactor vendors, is to simplify the current bespoke material models for Grade 91, 316H, and Alloy 617 and the new model for Alloy 800H into a simple, single model form. The report describes a new parallel time integration technique implemented in the pyoptmat package which allowed us to explore a wide variety of model forms, searching for a suitable common model. The report then describes preliminary work on models for monontonic deformation and then the development of a set of models suitable for capturing high temperature cyclic deformation. These models are suitable for use with the ASME design rules, except potentially for a narrow, material-specific band of temperatures at the edge of the creep regime. An incremental improvement the current models could overcome this discrepancy and provide a new, simpler set of constitutive model for all four materials.

36 MATERIALS SCIENCE↗

Rapid Gamma Simulations of TRISO Fuel Elements

As energy demand rises, nuclear energy, particularly from reactors that use tristructural isotropic (TRISO) fuels, has gained attention due to the fuel’s enhanced resistance to radiation damage and high temperatures. This report investigates the modeling capabilities of the Gamma Detector Response and Analysis Software (GADRAS) for TRISO fuels, focusing on the gamma signatures of TRISO particles, which have not been extensively explored. Using the Monte Carlo N-Particle (MCNP) code as a benchmark, we developed both homogeneous and heterogeneous models of TRISO pebbles to analyze gamma spectra. Our findings reveal that the homogeneous and heterogeneous models produced different gamma signatures. Additionally, the GADRAS heterogeneous model significantly reduces computation times compared to MCNP, enabling effective modeling of gamma signatures for safeguards applications. This advancement is essential for the International Atomic Energy Agency (IAEA) in detecting anomalies and potential smuggling attempts in TRISO reactor fuel elements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Comparison of mechanical properties measured on multiple scales

FeCrAl alloys are being developed for accident tolerant fuels for current light water reactors. Specifically as fuel claddings with enhanced safety. These alloys are being developed to have excellent corrosion resistance in light water reactor coolant environments and structural integrity for longer durations in the case of a loss of coolant scenario where time is critical for safety. Tensile, shear punch, and Vickers hardness testing was performed on neutron irradiated FeCrAl alloys with three variations in composition. Testing was done at room temperature for comparison of the three techniques. FeCrAl alloys in this report were irradiated at Oak Ridge National Laboratory (ORNL) in the High Flux Isotope Reactor (HFIR) to 7 dpa and at 320 °C.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Hydrogen Diffusivity Measurements of YH 1.87 Moderator Material with Incoherent Quasielastic Neutron Scattering

Yttrium hydride is an optimal choice of moderator material for thermal neutron spectrum reactors requiring small core volumes. The Transformation Challenge Reactor (TCR) program at Oak Ridge National Laboratory (ORNL) aims to develop an additively manufactured microreactor core by leveraging recent advances in materials, manufacturing, data analytics, and high-fidelity modeling and simulation. Yttrium hydride was selected as the moderator material for TCR due to its high moderating power, which enables the spatially efficient reactor design and thermal stability that is superior when compared with zirconium hydride. Hydrogen desorption from yttrium hydride is expected at elevated temperatures, posing safety and performance concerns. As a lifetime component in advanced reactors, appropriate strategies to mitigate hydrogen release from yttrium hydride over long-term reactor operation are required. Understanding hydrogen mobility in yttrium hydride provides the scientific basis for developing a hydrogen barrier for hydride moderator and predicting the hydrogen redistribution within the material during various operational conditions. This study investigated the hydrogen motion in YH 1.87 as a function of temperature ranging from 200 to 1,173 K using incoherent quasielastic neutron scattering (IQNS) at the Spallation Neutron Source (SNS). The results are presented and discussed in terms of hydrogen self-diffusion coefficients, activation energy for translational hydrogen motion, and hydrogen jump distances. Based on the IQNS data, YH 1.87 is found to be stable at high temperatures with no translational H motion below 1,023 K within the IQNS detection limits. In the temperature range of 1,073–1,173 K, hydrogen diffusivity in YH 1.87 is $D = 4.57 X 10^{⁻3} [m^2/s] exp (⁻\frac{1.73[eV]}{RT}$). The hydrogen concentration’s dependence on hydrogen diffusivity is also discussed in this report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Theoretical and kinetic modeling study of H 2 S pyrolysis

Hydrogen sulfide pyrolysis was investigated theoretically and through chemical kinetic modeling. Reactions on the SHH potential energy surface, primarily S + H 2 (+Ar) ⇌ H 2 S (+ Ar) (R1) and S + H 2 ⇌ SH + H (R6b) were characterized by ab initio calculations. Results for k 1 were in good agreement with experiment, but deviated strongly below 2000 K from values previously used in modeling. Collider efficiencies for H 2 S, S 2 , and N 2 compared to Ar were calculated for R1. Hydrogen sulfide decomposition experiments reported in literature were re-examined in terms of an updated detailed chemical kinetic model. Concentration profiles for the atomic S at high temperature in shock tubes supported the present value of k 1 and served to constrain the rate constants for reaction of S with SH and H 2 S. To explain results from batch and flow reactors, conducted at high H 2 S concentrations in the 900–1400 K range, a very fast rate constant was required for HSS + H ⇌ SH + SH. Under dilute conditions, the gas-phase chemistry was too slow to compete and the decomposition of H 2 S was controlled by loss on the reactor surface.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Stochastic optimization of a uranium oxide reaction mechanism using plasma flow reactor measurements

Abstract In this work, a coupled Monte Carlo Genetic Algorithm (MCGA) approach is used to optimize a gas phase uranium oxide reaction mechanism based on plasma flow reactor (PFR) measurements. The PFR produces a steady Ar plasma containing U, O, H, and N species with high temperature regions (3000–5000 K) relevant to observing UO formation via optical emission spectroscopy. A global kinetic treatment is used to model the chemical evolution in the PFR and to produce synthetic emission signals for direct comparison with experiments. The parameter space of a uranium oxide reaction mechanism is then explored via Monte Carlo sampling using objective functions to quantify the model-experiment agreement. The Monte Carlo results are subsequently refined using a genetic algorithm to obtain an experimentally corroborated set of reaction pathways and rate coefficients. Out of 12 reaction channels targeted for optimization, four channels are found to be well constrained across all optimization runs while another three channels are constrained in select cases. The optimized channels highlight the importance of the OH radical in oxidizing uranium in the PFR. This study comprises a first step toward producing a comprehensive experimentally validated reaction mechanism for gas phase uranium molecular species formation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

The Future of Nuclear Energy: Electrochemical Reprocessing of Fuel Takes Center Stage

Nuclear power plants use energy-dense fuel and provide dependable baseload energy without generating greenhouse gas emissions. Despite these advantages, the long-term management of used nuclear fuel (UNF) remains a key challenge due to its lifetime (hundreds of thousands of years) and radiotoxicity. The components of UNF that contribute the most to this challenge are the actinide elements. A potential solution to this issue is to separate these radioisotopes from the bulk of the UNF and recycle them as fuel in advanced nuclear reactors. These separations can be achieved using electrochemical reprocessing, which employs electrochemical conversion and electrodeposition in a high-temperature molten salt electrolyte medium to separate the actinides from UNF. In this work, we review the current status, fundamental challenges, and future prospects of electrochemical reprocessing as they relate to UNF recycling.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗