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DOE OSTI2024

MARVEL Reactor Fuel Performance Report (Rev.2)

The Microreactor Applications Research Validation and EvaLuation (MARVEL) project is producing a high temperature liquid metal-cooled nuclear test bed at Idaho National Laboratory (INL) to ultimately improve the integration of microreactors to end-user applications. This ambitious effort seeks to design, authorize, construct, test, and operate the reactor within five years. In order to construct and operate the MARVEL reactor in a timely manner, the system will utilize materials and component designs which have already been used, qualified, or licensed from previous reactors. The MARVEL reactor will be located at the INL Transient Reactor Test (TREAT) facility in the north high-bay equipment pit and will use the existing 304 stainless steel-clad U-ZrH1.6 pin-type fuel system developed by General Atomics and purchased from TRIGA International. This fuel has been previously qualified under the United States Department of Energy’s (US DOE) Reduced Enrichment for Research and Test Reactors (RERTR) Program. Even though the regulator of the MARVEL reactor is the US DOE, the standards and overall approach recommended by the Nuclear Regulatory Commission is well-defined and utilized here. Following NUREG-1537 regulatory guidance, this report documents the authorization case for the MARVEL fuel system’s application to MARVEL and establishes stable and predictable fuel performance during the most thermophysically unfavorable conditions achievable in the MARVEL reactor. To that end, this report provides a comprehensive survey of the known thermophysical properties, performance, and quantitative relationships associated with the MARVEL reactor fuel element and uses this information to determine its mechanical integrity and risk of reaching unacceptable conditions during the most extreme accident scenarios predicted for the reactor using the most conservative assumptions available. The information contained herein is compiled from a combination of historical reports and peer reviewed scientific publication manuscripts. Known mechanisms under which the fuel is susceptible to failure are highlighted and compared to conditions that could exist in the MARVEL reactor during an unanticipated transient or accident scenario. The two scenarios considered for analysis in this report are (1) an unprotected loss of flow accident and (2) a hypothetical unprotected loss of coolant accident during the loss of flow accident. Preliminary 2D steady-state analyses herein indicate that both fuel-cladding chemical interactions and fuel-cladding mechanical interactions are negligible throughout the fuel’s operational cycle under both normal and high temperature accident scenario conditions. Although higher fidelity 3D time-dependent modeling and simulations are planned, the following may be concluded presently. The MARVEL fuel element maintains its geometric stability and structural integrity during the most extreme accident scenarios predicted for the MARVEL reactor. The hoop stress during the unprotected loss of flow accident reaches about -1.27 MPa; this negative stress indicates that it is compressive rather than tensile. The compressive stress is a result of the NaK pressure on the outside of the fuel element, caused by the restricted thermal expansion of the NaK coolant, exceeding the internal pressures generated inside of the fuel element. The hoop stress generated in the cladding during the unprotected loss of coolant accident reaches a maximum of about approximately 10 MPa, which is nearly an order of magnitude less than the predicted yield strength of the cladding under high-temperature accident scenario conditions. Calculations were compared with results from high performance computational simulations using BISON and are in very close agreement. A conservative MARVEL fuel meat peak temperature limit of 900 °C is recommended presently, which is about 180 °C higher than the peak fuel temperature predicted to occur during the most extreme accident. Based on the known properties and behavior of the MARVEL fuel element, the fuel successfully meets its design and safety requirements under normal and most extreme accident conditions with a large safety margin.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Analysis of Synergistic Fuel Cycle Options with Thorium and Heavy Water Reactors

Fuel cycle options (FCOs) with thorium-based fuels have characteristics that may have benefits for meeting certain objectives, such as transuranic actinide inventory management and overall natural resource utilization. Neutron irradiation of thorium and uranium-233 results in negligible production of transuranic actinides. This advantage is compromised, to a degree, when thorium fuels are used in conjunction with uranium-238; however, strategic reprocessing and fuel use (e.g., recycle of plutonium and/or minor actinides) can be used to manage this problem. Furthermore, thorium FCOs with reprocessing can extend the availability of natural nuclear resources by breeding new fissile material, recovering and recycling unused material, and achieving high burnups. In instances where natural thorium is more readily available than uranium, FCOs which use thorium may be preferable from sustainability and energy security perspectives. However, many hybrid uranium-thorium FCOs struggle to perform well in this regard, since large amounts of external fissile material (and therefore natural uranium) are required to breed the required uranium-233. DOE's evaluation and screening effort reports that for every metric ton (MT) of U-233 bred in a light water reactor for reuse, about 1000 MT of natural uranium are required to support such breeding, much of which is used inefficiently due to enrichment. The combination of HWRs and thorium-based fuels has the potential to reduce this consumption of natural uranium resources. Because heavy water moderates neutrons without significant absorption, fissile material requirements are lower compared to those of LWRs. This has enabled conventional 'once-through' HWRs to operate with only slightly-enriched or even natural uranium. Also, HWRs can be combined with LWRs in multistage FCOs where used LWR fuel can be processed and the remaining fissile content is sufficient to support use as fuel in HWRs in spite of the presence of neutron poisons (e.g., uranium-236); this concept has been demonstrated at a research scale in Korea. Thus, additional energy is extracted from the same initial natural uranium feed and uranium enrichment effort. Another consideration with using thorium-based fuels in HWRs is the current limited operational experience of the reactors and associated fuel cycle facilities using these fuels. However, work continues internationally towards gaining further experience. For example, at equilibrium the third stage of India's planned Three-Stage Nuclear Power Program uses thorium/uranium-233 or thorium/plutonium fuels with a fissile supply from second-stage fast reactors. Further, China plans to experiment with low-enriched uranium (LEU)-Th CANFLEX fuel bundles in a once-through configuration in its HWRs and a long-term objective is to transition to thorium use in a closed HWR FCO. Vanderbilt University (VU) and Oak Ridge National Laboratory (ORNL) are characterizing multi-stage, thermal-reactor FCOs that incorporate thorium and examining their potential performance. This paper presents insights from the examination of FCOs which consider the synergy of HWRs and thorium. Two multi-stage FCOs which incorporate thorium-based fuels in HWRs have been examined for their potential, one which uses recycled PWR uranium oxide fuel in conjunction with thorium in an HWR, and another that uses recycled HWR fuel in an MSR which also includes thorium. Both of the systems studied offer resource utilization improvements as compared to a once-through LWR fueled with low-enrichment uranium and highlight the potential synergy of thorium and HWRs. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

MARVEL Reactor Fuel Performance Report

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2013

Comparison of REMIX vs. MOX fuel characteristics in multiple recycling in VVER reactor

Multiple recycling of regenerated uranium-plutonium fuel in thermal reactors of VVER-1000 type with high enriched uranium feeding (REMIX-fuel) gives a possibility to terminate the accumulation of spent nuclear fuels (SNF) and Pu and decrease the accumulation of irradiated uranium by an order of magnitude. Results of comparison of VVER-1000 nuclear fuel cycle characteristics vs different fuel types such as UOX, MOX and REMIX-fuel have been presented. REMIX fuel (Regenerated Mixture of U-, Pu oxides) is the mixture of plutonium and uranium extracted from SNF and refined from other actinides and fission products with the addition of enriched uranium to provide the power potential necessary. The savings in terms of uranium quantities and separation works in the nuclear energy system (NES) with reactors using REMIX-fuel compared to the NES with uranium-fuelled reactors are shown to be of about 30% and 8%, respectively. For the NES with thermal reactors partially loaded with MOX-fuel, the uranium and separation works saving of about 14% would be obtained. Production of neptunium and americium in reactors with REMIX-fuel in steady state increases by a factor 3, and production of curium - by 10 compared to the reactors with UOX-fuel. This increase of minor actinide buildup is owed to the multiple recycling of plutonium. It should be noted that in this case all fuel assemblies contain high-background plutonium, and their manufacturing involves an expensive technology. Besides, management of REMIX-fuel will require special protection measures even during the fresh fuel manufacturing phase. The above-said gives ground to state that the use of REMIX fuel would be questionable in economic aspect.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Computed Tomography of Dry Cask Storage for Used Fuel

The demand for dry cask storage for used nuclear fuel is on the rise due to the continuous operation of currently existing nuclear plants which are reaching or have reached the capacity of their used fuel pools. Dry cask storage allows used fuel that has already been cooled in the used fuel pool for at least five years to be surrounded by an inert gas inside a specially designed and licensed cask. Currently, 75 of the 78 U.S.A reactor sites either have or are pursuing an independent spent fuel storage installation (ISFSI) for dry cask fuel storage with over 2,000 casks already loaded. Cask loading will only continue to increase until a final repository solution is operational or the U.S. begins to recycle fuel. The challenge of monitoring the condition of the used fuel inside the cask without exposing the used fuel has been apparent since the 1980's. The objective of the University of Florida (UF) project is ultimately to investigate the feasibility of imaging the used fuel assemblies' location and evaluating the inner structural condition using emission source computed tomography (CT). A combination of radiation transport models will be used to simulate gamma-rays and neutrons traversing through the used fuel, structure, and cask body materials. In the simulations, multiple linear detector arrays will record the radiation outside the cask wall and will be placed at various angles in order to model rotating a linear detector array around the entire cask. The combination of data from all the detectors will give the planar radiation projection onto the detectors, more commonly called the Radon transform, of the structure of used fuel assemblies. This project can be processed with filtered back projection or other more advanced reconstructive imaging algorithms to recreate the fuel structures. A majority of the historical work done for used fuel has been on verification, diversion detection, and burnup credit validation in order to meet regulatory guidelines. One of the more commonly used systems for single assembly verification is the Fork Detector developed at Los Alamos National Laboratory in 1988. A group at the Idaho National Laboratory developed a Compton Dry-Cask Imaging Scanner that has the ability to detect empty vs full storage positions but it suffered a setback when transported to the Doel Nuclear Power Plant near Antwerp, Belgium; the system was unable to detect full energy peaks because of the additional scattering caused by a thick ballistic steel shield. As detectors, computational power, and modeling improves, a few groups have leveraged these advancements and started to investigate CT hoping, that despite the difficulties, the technique can give information on fuel condition. So far the groups have mostly limited the tomographic work to a per assembly basis , rather than the full dry cask as the University of Florida plans to investigate. The downsides of CT versus simpler verification and validation are the amount of data required and the time it takes to acquire that data. Given that dry casks are intended to sit undistributed for up to 60 years, a scanning time of several weeks to several months is not unreasonable if such systems do not require human operators beyond the initial setup. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Steps in the Development of Nuclear Thermal Propulsion Fuels

Due to the recent increased interest in Mars and deep-space missions it has been determined to be feasible to revisit the ability for the United States to build a Nuclear Thermal Propulsion (NTP) system. The need to make and qualify a NTP fuel that meets mission performance requirements is an essential first step. Graphite fuels and cermet fuels are of particular interest since these fuels have shown significant advantages over other fuel types. This paper will address the history of NTP fuel fabrication technology as related to the NERVA, GE 710, and Argonne National Laboratory’s Nuclear Fuel Programs as well as recent efforts in recapturing heritage fuels and develop new NTP fuels. Substantial experimental databases and supporting documentation exists for the composite fuel. Some irradiation and high temperature test data is available for cermet fuels, but cermet fuels were never tested at prototypic NTP conditions. A first step in the development effort will be a fuel fabrication recapture effort to provide samples to show that the technology works and performance of the fuel is acceptable. Advances in fuel fabrication, materials processing, and coating technology are expected to improve and/or enhance future fuel development, maturation and certification efforts. The current plan is to perform, non-nuclear separate-effects and integrated tests to provide additional test data and insight into the capabilities of each fuel and to use that data to evaluate potential performance within a NTP engine stage.

Qualls, A↗

DOE OSTI2014

Techno-Economic Analysis of Scalable Coal-Based Fuel Cells

Researchers at The University of Akron (UA) have demonstrated the technical feasibility of a laboratory coal fuel cell that can economically convert high sulfur coal into electricity with near zero negative environmental impact. Scaling up this coal fuel cell technology to the megawatt scale for the nation’s electric power supply requires two key elements: (i) developing the manufacturing technology for the components of the coal-based fuel cell, and (ii) long term testing of a kW scale fuel cell pilot plant. This project was expected to develop a scalable coal fuel cell manufacturing process through testing, demonstrating the feasibility of building a large-scale coal fuel cell power plant. We have developed a reproducible tape casting technique for the mass production of the planner fuel cells. Low cost interconnect and cathode current collector material was identified and current collection was improved. In addition, this study has demonstrated that electrochemical oxidation of carbon can take place on the Ni anode surface and the CO and CO 2 product produced can further react with carbon to initiate the secondary reactions. One important secondary reaction is the reaction of carbon with CO 2 to produce CO. We found CO and carbon can be electrochemically oxidized simultaneously inside of the anode porous structure and on the surface of anode for producing electricity. Since CH 4 produced from coal during high temperature injection of coal into the anode chamber can cause severe deactivation of Ni-anode, we have studied how CH 4 can interact with CO 2 to produce in the anode chamber. CO produced was found able to inhibit coking and allow the rate of anode deactivation to be decreased. An injection system was developed to inject the solid carbon and coal fuels without bringing air into the anode chamber. Five planner fuel cells connected in a series configuration and tested. Extensive studies on the planner fuels and stack revealed that the planner fuel cell stack is not suitable for operation with carbon and coal fuels due to lack of mechanical strength and difficulty in sealing. We have developed scalable processes for manufacturing of process for planner and tubular cells. Our studies suggested that tubular cell stack could be the only option for scaling up the coal-based fuel cell. Although the direct feeding of coal into fuel cell can significantly simplify the fuel cell system, the durability of the fuel cell needs to be further improved before scaling up. We are developing a tubular fuel cell stack with a coal injection and a CO 2 recycling unit.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2016

Wabash Valley Integrated Gasification Combined Cycle, Coal to Fischer Tropsch Jet Fuel Conversion Study

This reports examines the feasibility of converting the existing Wabash Integrated Gasification Combined Cycle (IGCC) plant into a liquid fuel facility, with the goal of maximizing jet fuel production. The fuels produced are required to be in compliance with Section 526 of the Energy Independence and Security Act of 2007 (EISA 2007 §526) lifecycle greenhouse gas (GHG) emissions requirements, so lifecycle GHG emissions from the fuel must be equal to or better than conventional fuels. Retrofitting an existing gasification facility reduces the technical risk and capital costs associated with a coal to liquids project, leading to a higher probability of implementation and more competitive liquid fuel prices. The existing combustion turbine will continue to operate on low cost natural gas and low carbon fuel gas from the gasification facility. The gasification technology utilized at Wabash is the E-Gas™ Technology and has been in commercial operation since 1995. In order to minimize capital costs, the study maximizes reuse of existing equipment with minimal modifications. Plant data and process models were used to develop process data for downstream units. Process modeling was utilized for the syngas conditioning, acid gas removal, CO 2 compression and utility units. Syngas conversion to Fischer Tropsch (FT) liquids and upgrading of the liquids was modeled and designed by Johnson Matthey Davy Technologies (JM Davy). In order to maintain the GHG emission profile below that of conventional fuels, the CO 2 from the process must be captured and exported for sequestration or enhanced oil recovery. In addition the power utilized for the plant’s auxiliary loads had to be supplied by a low carbon fuel source. Since the process produces a fuel gas with sufficient energy content to power the plant’s loads, this fuel gas was converted to hydrogen and exported to the existing gas turbine for low carbon power production. Utilizing low carbon fuel gas and process steam in the existing combined cycle power plant provides sufficient power for all plant loads. The lifecycle GHG profile of the produced jet fuel is 95% of conventional jet fuel. Without converting the fuel gas to a low carbon fuel gas, the emissions would be 108% of conventional jet fuel and without any GHG mitigation, the profile would be 206%. Oil prices greater than $120 per barrel are required to reach a targeted internal rate of return on equity (IRROE) of 12%. Although capital expenditure is much less than if a greenfield facility was built, the relatively small size of the plant, assumed coal price, and the CTL risk profile used in the economic assumptions lead to a high cost of production. Assuming more favorable factors, the economic oil price could be reduced to $78 per barrel with GHG mitigation and $55 per barrel with no GHG mitigation.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Evaluation of BISON metallic fuel performance modeling against experimental measurements within FIPD and IMIS databases

Simulations were conducted using the BISON fuel performance code on an automated process to read initial and operating conditions from two databases—the Fuels Irradiation and Physics Database (FIPD) and Integral Fast Reactor Materials Information System (IMIS) database. These databases contain metallic fuel data from the Experimental Breeder Reactor-II (EBR-II) and the Fast Flux Test Facility (FFTF). The work demonstrates use of an integrated framework to access EBR-II fuel pin data for evaluating fuel performance models contained within BISON to predict fuel performance of next-generation metallic fuel systems. Between IMIS and FIPD, there is enough information to conduct 1,977 unique EBR-II metallic fuel pin histories from 29 different experiments, and 338 pins from FFTF MFF-3 and MFF-5 with varying levels of details between the two databases. Each of these fuel performance histories includes a high-resolution power history, flux history, coolant channel flow rates, and coolant channel temperatures, and new model developments in BISON since the initial demonstration of this integrated framework. Fission gas release (FGR), cumulative damage fraction, fuel axial swelling, FCCI wastage thickness, cladding profilometry, and burnup were all simulated in BISON and compared to post-irradiation examination (PIE) results to evaluate BISON fuel performance modeling. Implementation of new fuel performance models into a generic BISON input file coupled with IMIS and FIPD yielded results with a better representation of physics than the initial evaluation of the integrated framework. Cladding profilometry, FGR, and fuel axial swelling were found to be in good agreement with PIE measurements for most of the pins simulated. The chosen mechanical contact solver was found to significantly impact the axial fuel swelling and cladding strain predictions when used in conjunction with the U-Pu-Zr hot-pressing model since it bound the fuel to prevent further swelling and increased hydrostatic stresses. This work suggests that fuel performance modeling in BISON under steady-state conditions represents the PIE data well and should be reassessed when new PIE data become available in IMIS and FIPD databases and when improved physical models to better capture fuel performance are added to BISON.

Paaren, Kyle M.↗

NASA NTRS1997

Fuel Cell Power Plant Initiative: Preliminary Design of a Fixed-Base LFP/SOFC Power System - Volume 2

This report documents the preliminary design for a military fixed-base power system of 3 MWe nominal capacity using Westinghouse's tubular Solid Oxide Fuel Cell [SOFC] and Haldor Topsoe's logistic fuels processor [LFP]. The LFP provides to the fuel cell a methane rich sulfur free fuel stream derived from either DF-2 diesel fuel, or JP-8 turbine fuel. Fuel cells are electrochemical devices that directly convert the chemical energy contained in fuels such as hydrogen, natural gas, or coal gas into electricity at high efficiency with no intermediate heat engine or dynamo. The SOFC is distinguished from other fuel cell types by its solid state ceramic structure and its high operating temperature, nominally 1000'C. The SOFC pioneered by Westinghouse has a tubular geometry closed at one end. A power generation stack is formed by aggregating many cells in an ordered array. The Westinghouse stack design is distinguished from other fuel cell stacks by the complete absence of high integrity seals between cell elements, cells, and between stack and manifolds. Further, the reformer for natural gas [predominantly methane] and the stack are thermally and hydraulically integrated with no requirement for process water. The technical viability of combining the tubular SOFC and a logistic fuels processor was demonstrated at 27 kWe scale in a test program sponsored by the Advanced Research Projects Agency [ARPA) and carried out at the Southern California Edison's [SCE] Highgrove generating station near San Bernardino, California in 1994/95. The LFP was a breadboard design supplied by Haldor Topsoe, Inc. under subcontract to Westinghouse. The test program was completely successful. The LFP fueled the SOFC for 766 hours on JP-8 and 1555 hours of DF-2. In addition, the fuel cell operated for 3261 hours on pipeline natural gas. Over the 5582 hours of operation, the SOFC generated 118 MVVH of electricity with no perceptible degradation in performance. The LFP processed military specification JP-8 and DF-2 removing the sulfur and reforming these liquid fuels to a methane rich gaseous fuel. Results of this program are documented in a companion report titled 'Final Report-Solid Oxide Fuel Cell/ Logistic Fuels Processor 27 kWe Power System'.

Veyo, S.E.↗

DOE OSTI2021

VFA Biorefinery Design for Informed Production of Ground and Aviation Fuels

The rising demand for low-carbon intensity fuel options requires evaluation of a system which can support their production economically and sustainably. Volatile fatty acids (VFAs) ranging from C2 to C8 can be derived in high yield from arrested anaerobic digestion of biomass. This talk provides an overview of our work in which we upgrade wet waste-derived VFAs using ketonization to elongate their carbon backbone to reach a range relevant to jet or diesel fuels. Kinetic models were used to predict ketone profiles from varying VFA profiles, thereby informing potential carbon flow to either (a) mixed paraffins for use in diesel or aviation fuel, or (b) ethers for use in diesel fuel. To do this, the anticipated products were screened for critical fuel characteristics using predictive tools. The criteria for neat and blended bioblendstocks were chosen based on conventional petrofuel requirements, and they were applied to inform fuel targets, identify limiting characteristics, and guide conversion development. While paraffins can serve as either diesel or aviation fuels, the latter has stringent criteria which include a precise distillation curve range tied to carbon distribution. Fuels which fall outside this range typically fail to meet other property metrics, and as such flashpoint and viscosity were identified as potentially limiting properties of this VFA aviation fuel. However, paraffin fractions which fall outside aviation criteria may meet diesel fuel requirements, which are looser except for the flashpoint minimum. Flashpoint was also a concern for smaller VFA diesel ethers, which posed an additional oxygenate risk of high water solubility. This fuel-informed conversion design process was demonstrated through production of paraffins with reduced sooting as compared to petrodiesel (~34%), and increased renewable aviation fuel blend levels (>70%). VFA-derived ethers improved petrodiesel by increasing fuel autoignition quality by 56% and reducing sooting by 86%. These VFA aviation and diesel fuels could enable greenhouse gas (GHG) reductions of over 165% and 50%, respectively, relative to their purely fossil-derived counterparts. Collectively, this work provides (i) an overview of how we leveraged the flexibility of VFAs for fuel production; and (ii) insight into the potential of a VFA biorefinery to accommodate varied feed and fuel applications, while also considering the merit of tailored fuel production pathways and GHG reduction potential.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2015

Effects of High Octane Ethanol Blends on Four Legacy Flex-Fuel Vehicles, and a Turbocharged GDI Vehicle

The U.S. Department of Energy (DOE) is supporting engine and vehicle research to investigate the potential of high-octane fuels to improve fuel economy. Ethanol has very high research octane number (RON) and heat of vaporization (HoV), properties that make it an excellent spark ignition engine fuel. The prospects of increasing both the ethanol content and the octane number of the gasoline pool has the potential to enable improved fuel economy in future vehicles with downsized, downsped engines. This report describes a small study to explore the potential performance benefits of high octane ethanol blends in the legacy fleet. There are over 17 million flex-fuel vehicles (FFVs) on the road today in the United States, vehicles capable of using any fuel from E0 to E85. If a future high-octane blend for dedicated vehicles is on the horizon, the nation is faced with the classic chicken-and-egg dilemma. If today’s FFVs can see a performance advantage with a high octane ethanol blend such as E25 or E30, then perhaps consumer demand for this fuel can serve as a bridge to future dedicated vehicles. Experiments were performed with four FFVs using a 10% ethanol fuel (E10) with 88 pump octane, and a market gasoline blended with ethanol to make a 30% by volume ethanol fuel (E30) with 94 pump octane. The research octane numbers were 92.4 for the E10 fuel and 100.7 for the E30 fuel. Two vehicles had gasoline direct injected (GDI) engines, and two featured port fuel injection (PFI). Significant wide open throttle (WOT) performance improvements were measured for three of the four FFVs, with one vehicle showing no change. Additionally, a conventional (non-FFV) vehicle with a small turbocharged direct-injected engine was tested with a regular grade of gasoline with no ethanol (E0) and a splash blend of this same fuel with 15% ethanol by volume (E15). RON was increased from 90.7 for the E0 to 97.8 for the E15 blend. Significant wide open throttle and thermal efficiency performance improvement was measured for this vehicle, which achieved near volumetric fuel economy parity on the aggressive US06 drive cycle, demonstrating the potential for improved fuel economy in forthcoming downsized, downsped engines with high-octane fuels.

09 BIOMASS FUELS↗

DOE OSTI2019

Report on Assessment of Advanced Reactor Fuel Performance

Three activities have been performed in FY 2019 to support the Advanced Fuel Cycle Campaign, which include assessment of annular fuel performance in an ultra-high burnup sodium-cooled reactor (SFR), modeling of annular fuel behavior during a transient scenario, and feasibility of a sustainable closed fuel cycle utilizing melt-refining process. Annular fuel performance parameters, including temperature profile, swelling strain, and cumulative damage fraction (CDF), in a 3000 MWt Sustainable Sodium-cooled Fast Reactor (SSFR) were assessed using the BISON fuel performance code. The SSFR is once-through ultra-long-life core based on a 34-batch fuel management scheme with 1.5-year cycle length. The fuel residence time in the SSFR is 51 years and the average discharged burnup is about 30%. Annular fuel has potential to irradiate for ultra-high burnup without major fuel-cladding mechanical interaction. This feature is achieved by using a low smeared density (~55%). In the SSFR design, however, 75% smeared density and a thick fuel pin were preferred to maintain criticality for 51 years. Due to the high smeared density and thick fuel pin configuration, the annular fuel was predicted to suffer premature cladding failure before reaching the discharge burnup of the SSFR. The current fuel creep model predicts a prominent creep strain due to gravity over the half-century irradiation, which may significantly affect the evolution of CDF. Thus, in order to use the annular fuel in an ultra-high burnup core such as the SSFR, a low smeared density and thin annular fuel is strongly recommended.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Impact of a Diesel High Pressure Common Rail Fuel System and Onboard Vehicle Storage on B20 Biodiesel Blend Stability

Adoption of high-pressure common-rail (HPCR) fuel systems, which subject diesel fuels to higher temperatures and pressures, has brought into question the efficacy of ASTM International specifications for biodiesel and biodiesel blend oxidation stability, as well as the lack of any stability parameter for diesel fuel. A controlled experiment was developed to investigate the impact of a light-duty diesel HPCR fuel system on the stability of 20% biodiesel (B20) blends under conditions of intermittent use and long-term storage in a relatively hot and dry climate. B20 samples with Rancimat induction periods (IPs) near the current 6.0-hour minimum specification (6.5 hr) and roughly double the ASTM specification (13.5 hr) were prepared from a conventional diesel and a highly unsaturated biodiesel. Four 2011 model year Volkswagen Passats equipped with HPCR fuel injection systems were utilized: one on B0, two on B20-6.5 hr, and one on B20-13.5 hr. Each vehicle was operated over a one-hour drive cycle in a hot running loss test cell to initially stress the fuel. The cars were then kept at Volkswagen's Arizona Proving Ground for two (35 degrees C average daily maximum) to six months (26 degrees C average daily maximum). The fuel was then stressed again by running a portion of the one-hour dynamometer drive cycle (limited by the amount of fuel in the tank). Fuel rail and fuel tank samples were analyzed for IP, acid number, peroxide content, polymer content, and ester profile. The HPCR fuel pumps were removed, dismantled, and inspected for deposits or abnormal wear. Analysis of fuels collected during initial dynamometer tests showed no impact of exposure to HPCR conditions. Long-term storage with intermittent use showed that IP remained above 3 hours, acid number below 0.3 mg KOH/g, peroxides low, no change in ester profile, and no production of polymers. Final dynamometer tests produced only small changes in fuel properties. Inspection of the HPCR fuel pumps revealed no deposits or abnormal wear for any fuel. The results provide some confidence that the ASTM D7467 stability requirement of 6 hr. minimum IP for B6 to B20 blends provides adequate protection for modern engine fuel systems.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2019

Characteristics of TRU Fueled SFR Core during the Transition with Partially Loaded LEU Assemblies

The fast reactor (FR) fuels typically require higher fissile content than the thermal reactor fuels because the cross sections of the fissile isotopes are smaller relative to the fertile isotopes and higher neutron leakage from the reactor core. The medium-sized high-burnup sodium-cooled fast reactors (SFRs) in the framework of uranium-plutonium/transuranic (U/Pu or U/TRU) fuel-cycle can be optimized to operate with less than 17 % of Pu/TRU content in the driver fuel while having higher TRU conversion ratios (CR~1.0) [1]. However, possible shortage or inaccessibility to TRU based fuel could be accommodated by the use of uranium-based fuels on demand such as low enriched uranium (LEU) having significantly higher 235U content than used in the commercial light water reactors (LWRs), which is defined as high-assay LEU. The reactor systems having low TRU conversion ratio are commonly categorized as burner reactors, which include LWRs and even can be achieved by FRs with designed to utilize higher TRU fractions (e.g., increased neutron leakage and lower fuel volume fractions). Such reactor systems need to be initially loaded with high excess reactivity, which decreases toward the end of cycle, in order to achieve target burnup conditions. Therefore, in order to offset the excess reactivity, neutron absorbing materials need to be inserted into the core to compensate (e.g., control rods). By reducing the neutron leakage (e.g., increasing the fuel volume fraction or thicker blankets), the TRU conversion ratio in the FR can be increased. If the TRU conversion ratio becomes 1.0 (technically slightly greater than 1.0 to account for process losses during recycle), the reactor is in the condition known as “breakeven”, in which fuel contains the same amount of fissile material after recycling that was used to fuel the reactor. In such a condition, combined with the fact that fission products do not have strong poisoning effects in FRs, the reactivity swing becomes smaller than that of burner type reactors. For breeders, the reactivity can increase toward the end of the cycle because more fissile material is produced than consumed. In this regard, the breakeven FR core is implicitly optimized in a sense by eliminating the large insertion of control elements to offset the reactivity during the normal operation. However, the breakeven condition here is assumed to be achieved only by the TRU based fuel. Possible lack of TRU based fuel needs to be compensated by available LEU resources containing equivalent amount of fissile (i.e., 235U). The use of LEU will have some impact on important safety parameters that need to be evaluated. U-235 has a higher effective delayed neutron fraction than Pu-239. Also, the number of neutrons produced by fissions per neutron absorption (i.e. ?) of 235U in the fast energy range (>1e4 eV) is lower than that of 239Pu, which may lead to the poor fissile conversion when LEU is used as a high-conversion FR fuel. The full-paper presents the study of the impact of partially loaded LEU fuels within TRU fueled breakeven SFR on the transition of nuclide evolutions and core characteristics particularly focusing on the burnup reactivity swing. The full paper analyzes how the large reactivity swing occurs during the LEU loading and addresses possible options to reduce it to the level equivalent to that of the TRU fueled SFR core.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Variants of Regenerated Fissile Materials Usage in Thermal Reactors as the First Stage of Fuel Cycle Closing

At present, 240 000 t of spent nuclear fuel (SF) has been accumulated in the world. Its long-term storage should meet safety conditions and requires noticeable finances, which grow every year. Obviously, this situation cannot exist for a long time; in the end, it will require a final decision. At present, several variants of solution of the problem of SF management are considered. Since most of the operating reactors and those under construction are thermal reactors, it is reasonable to assume that the structure of the nuclear power industry in the near and medium-term future will be unchanged, and it will be necessary to utilize plutonium in thermal reactors. In this study, different strategies of SF management are compared: open fuel cycle with long-term SF storage, closed fuel cycle with MOX fuel usage in thermal reactors and subsequent long-term storage of SF from MOX fuel, and closed fuel cycle in thermal reactors with heterogeneous fuel arrangement. The concept of heterogeneous fuel arrangement is considered in detail. While in the case of traditional fuel it is necessary to reprocess the whole amount of spent fuel, in the case of heterogeneous arrangement, it is possible to separate plutonium and {sup 238}U in different fuel rods. In this case, it is possible to achieve nearly complete burning of fissile isotopes of plutonium in fuel rods loaded with plutonium. These fuel rods with burned plutonium can be buried after cooling without reprocessing. They would contain just several percent of initially loaded plutonium, mainly even isotopes. Fuel rods with {sup 238}U alone should be reprocessed in the usual way.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Overview of the U.S. DOE advanced fuels campaign

Advanced Fuel Campaign (AFC) has responsibility to develop advanced nuclear fuel technologies for the Fuel Cycle Research and Development (FCRD) program. AFC focus areas include 4 topics: advanced LWR fuels, actinide transmutation, research infrastructure development for the study of new nuclear fuels and advanced modeling and simulation. This paper reviews the latest technical advances in the 4 topics. Fuel and cladding materials under investigation include the following general classes of technologies: iron-based cladding, ceramic cladding, coated Zirconium alloy cladding, molybdenum-based cladding, high-density fuel, fully ceramic matrix fuel, and metallic alloy-based nuclear fuel. Concerning actinide transmutation fuel alloy additions to immobilize the lanthanide fission products, sodium-free annular fuel concepts, and cladding coatings and liners for mitigation of fuel-cladding chemical interaction have been investigated. Direct casting of metallic fuel into a zirconium liner was demonstrated. A Talos Transmission Electron Microscope was acquired for the study of advanced nuclear fuels and materials. The conceptual and preliminary designs for a static capsule, a flowing water loop, and a flowing sodium loop to support future transient testing needs have been completed. AFC interfaces with the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program to develop multi-scale, multi-physics fuel performance codes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Westinghouse Quiver - A simple and safe system for the complete handling and storing of failed BWR and PWR fuel rods and fragments - 17049

Background: Extracted leaking fuel rods from fuel assemblies have been stored in the spent fuel pools at the Nuclear Power Plants for many years. Sending those fuel rods to an intermediate storage has been very difficult due to the uncertainty of the technical requirements. The Westinghouse Quiver is a container that can be used from the first moment when the leaking fuel rod is extracted from the Fuel Assembly. The leaking fuel rod can be placed in the Westinghouse Quiver. When the Quiver is filled, it can be sealed and dried and then treated as a regular fuel assembly during intermediate storage and final repository. Purpose of System: The purpose of the system is to store leaking fuel rods, broken rods and fuel rod fragments leak tight in the fuel pool and after vacuum drying and permanent sealing at an intermediate storage facility. The Quiver is designed to be fully compatible with a regular fuel assembly. That means all handling of the Quiver in a Nuclear Power Plant, during transportation or storage is also identical to that of a regular fuel assembly. Fulfilling these criteria together with functional testing, the Quiver is considered acceptable for long time storage of leaking fuel rods, both in dry or wet condition. The Quiver has been qualified in Switzerland for use in the spent fuel pool, intermediate storage, and for a final repository. The system will be implemented as well in Sweden during 2016-2019. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗