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All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Improvements to Modeling Capabilities of ATF Concepts in the BISON Fuel Performance Code

Research into accident tolerant materials for the fuel and cladding in Light Water Reactors has been at the forefront of the nuclear fuel research community since the events that oc- curred at the Fukushima Daiichi nuclear power plant in March 2011. Accident tolerant materials are defined as those that provide significantly increased response time in the event of an accident while providing similar or improved performance as the conventional UO2/zirconium-based cladding fuel rods dur- ing normal operation [1]. In particular, qualitative attributes for materials with enhanced accident tolerance include im- proved reaction (e.g., oxidation) kinetics with steam, resulting in slower hydrogen (or other combustible gases) generation rate, while maintaining acceptable thermo-mechanical prop- erties, fuel-clad interactions, and fission-product behavior [1]. Through its Office of Nuclear Energy the United States De- partment of Energy (U.S. DOE) has accelerated research in this area through the Fuel Cycle Research and Development (FCRD) Advanced Fuels Campaign (AFC). The goal of the AFC Accident Tolerant Fuel (ATF) program is to guide se- lection of promising concepts for insertion into a commercial reactor as part of a lead test rod or assembly in 2022. Given the aggressive development schedule, it is impossi- ble to perform a comprehensive set of experiments to provide material characterization data. Therefore, the AFC is utilizing computational analysis tools in an effort to understand the proposed accident tolerant materials. The two materials of interest in this work are iron-chromium-aluminum (FeCrAl) cladding and U3Si2. From a fuel performance standpoint, the correlations available to describe the behavior of these two materials is limited. Therefore, as additional experimental data becomes available and correlations are updated, the fuel performance models must be updated to represent the current state of the art understanding of these materials. In this paper we demonstrate the importance of utilizing the latest state-of-the-art models for fuel performance simula- tions by comparing old and new thermal conductivity models for U3Si2 fuel and old and new oxidation models for FeCrAl cladding alloys using the BISON [2, 3] fuel performance code under normal operating conditions. The results indicate that the latest thermal conductivity model for U3Si2 results in fuel centerline temperatures that are on average approximately 3% higher than the previous model. For the oxidation behavior of FeCrAl alloys the new model predicts observable but small ox- ide thickness (~6 µm) compared to the previous model which predicted zero oxide scale formation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

OECD/NEA Ongoing activities related to the nuclear fuel cycle

As part of its role in encouraging international collaboration, the OECD Nuclear Energy Agency is coordinating a series of projects related to the Nuclear Fuel Cycle. The Nuclear Science Committee (NSC) Working Party on Scientific Issues of the Nuclear Fuel Cycle (WPFC) comprises five different expert groups covering all aspects of the fuel cycle from front to back-end. Activities related to fuels, materials, physics, separation chemistry, and fuel cycles scenarios are being undertaken. By publishing state-of-the-art reports and organizing workshops, the groups are able to disseminate recent research advancements to the international community. Current activities mainly focus on advanced nuclear systems, and experts are working on analyzing results and establishing challenges associated to the adoption of new materials and fuels. By comparing different codes, the Expert Group on Advanced Fuel Cycle Scenarios is aiming at gaining further understanding of the scientific issues and specific national needs associated with the implementation of advanced fuel cycles. At the back end of the fuel cycle, separation technologies (aqueous and pyrochemical processing) are being assessed. Current and future activities comprise studies on minor actinides separation and post Fukushima studies. Regular workshops are also organized to discuss recent developments on Partitioning and Transmutation. In addition, the Nuclear Development Committee (NDC) focuses on the analysis of the economics of nuclear power across the fuel cycle in the context of changes of electricity markets, social acceptance and technological advances and assesses the availability of the nuclear fuel and infrastructure required for the deployment of existing and future nuclear power. The Expert Group on the Economics of the Back End of the Nuclear Fuel Cycle (EBENFC), in particular, is looking at assessing economic and financial issues related to the long term management of spent nuclear fuel. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

JASMINE: a fuel rod thermal-mechanical performance's code

JASMINE, which is developed by China General Nuclear Power Corporation (CGNPC), is a code for calculating thermal-mechanical response of PWR fuel rods. The code models many physical phenomena, including heat conduction through the fuel and cladding to the coolant, cladding elastic and plastic deformation, fuel elastic deformation, fuel swelling and densification,fuel-cladding mechanical interaction, fission gas release from the fuel, rod internal pressure, cladding oxidation and hydriding. Just as most fuel rod codes, JASMINE, which is a quasi-two dimensional code, includes a thermal module, a mechanical module, a fission gas release (FGR) module, and an internal pressure module. For thermal module, the time dependent thermal conduction equation of axisymmetric cylindrical geometry, Halden's fuel thermal conductivity, thermal conductivity integration method and multi-dimension Newton-Raphson procedure are used; for the mechanical module, generalized plane strain hypothesis, cladding-fuel axial lockup model, cladding thermal stress and transfer matrix method are applied; for fission gas release module, the time dependent diffusion equation for a spherical grain, Speight-Turnbull grain surface boundary condition, and Forsberg-Massih's method are used; for the internal pressure module, the ideal gas state equation is used. The code, which is on validation stage, will be used for fuel rod design of nuclear power plants in China in a near future. So far, the preliminary validation process for pellet centerline temperature and fission gas release, which is based on fuel rod test data in FUMEX-III project, has finished. According to the validation results, JASMINE has the ability to reasonably predicts fuel behavior and performance in-pile. JASMINE has good prediction in fuel temperature, and good prediction on FGR as a whole. However, for FGR in the range 1% to 15%, JASMINE over-predicts FGR; for other range, JASMINE underestimates FGR. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Transition Benefits of using Low Enriched Uranium Fuel in Fast Reactors

An Evaluation and Screening (E and S) study of nuclear fuel cycle options was recently conducted for the U.S. Department of Energy to identify a relatively small number of promising fuel cycle options with the potential for achieving substantial improvements compared to the current nuclear fuel cycle in the U.S. This study considered the entire fuel cycle, i.e., the complete nuclear energy system from mining to disposal including both once-through and recycle fuel cycles, and identified four options that were most promising, offering the highest benefits compared to the current cycle. The E and S study considered performance at steady-state when evaluating the potential benefits and challenges to achieving that eventual end state. Based on the steady-state findings from the E and S, a methodology was developed for extending the evaluation of the fuel cycle options over the period of transition from the current state of the U.S. fuel cycle to a completely new system. Such methods are being applied to a range of potential transition scenarios involving the aforementioned most promising options, with the goal of identifying issues and challenges associated with such transitions. For the first detailed analysis of transition, a single example scenario of transition was developed in order to implement the methodology. The timescales, assumptions, and specifications of this example scenario were chosen to be representative of a reasonable transition from the current state of the U.S. fuel cycle to a fuel cycle that will continuously recycle U/Pu in fast critical reactors (referred to as 'EG23'). The results represent just one transition pathway, but not necessarily the best or optimized solution for that specific scenario. These transition scenarios were modeled using nuclear fuel cycle systems codes in order to provide the time-dependent mass flows and inventories, reactor/facility capacities and throughputs, and system behavior that were used for performance analyses. These analyses of the example scenario identified a number of potential system issues that can be applied generally, but they did not consider the much broader transition space (scenarios involving various FR startup fuels, different cooling times, growth rates, recycling technologies, etc.). Therefore, additional studies were performed to inform over a broad range of these potential transition pathways. The main focus of this paper is on the results of these additional analyses for transition pathways that involve the use of low enriched uranium fuel as the initial startup fuel for fast reactors during transition. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Improvements to Modeling Capabilities of ATF Concepts in the BISON Fuel Performance Code

Research into accident tolerant materials for the fuel and cladding in Light Water Reactors has been at the forefront of the nuclear fuel research community since the events that occurred at the Fukushima Daiichi nuclear power plant in March 2011. Accident tolerant materials are defined as those that provide significantly increased response time in the event of an accident while providing similar or improved performance as the conventional UO{sub 2}/zirconium-based cladding fuel rods during normal operation. In particular, qualitative attributes for materials with enhanced accident tolerance include improved reaction (e.g., oxidation) kinetics with steam, resulting in lower hydrogen (or other combustible gases) generation rate, while maintaining acceptable thermo-mechanical properties, fuel-clad interactions, and fission-product behavior. Through it's Office of Nuclear Energy, the United States Department of Energy (U.S. DOE) has accelerated research in this area through the Fuel Cycle Research and Development (FCRD) Advanced Fuels Campaign (AFC). The goal of the AFC Accident Tolerant Fuel (ATF) program is to guide selection of promising concepts for insertion into a commercial reactor as part of a lead test rod or assembly in 2022. Given the aggressive development schedule, it is impossible to perform a comprehensive set of experiments to provide material characterization data. Therefore, the AFC is utilizing computational analysis tools in an effort to understand the proposed accident tolerant materials. The two materials of interest in this work are iron-chromium-aluminum (FeCrAl) cladding and U{sub 3}Si{sub 2}. From a fuel performance standpoint, the correlations available to describe the behavior of these two materials is limited. Therefore, as additional experimental data becomes available and correlations are updated, the fuel performance models must be updated as well to assure that the material models reflect the latest experimental findings. In this paper we demonstrate the importance of utilizing the latest state-of-the-art models for fuel performance simulations by comparing the change in the updated thermal conductivity model for U{sub 3}Si{sub 2} fuel and oxidation model for FeCrAl cladding alloys using the BISON fuel performance code under normal operating conditions. The results indicate that the latest thermal conductivity model for U{sub 3}Si{sub 2} results in fuel centerline temperatures that are on average approximately 3% higher than the previous model. For the oxidation behavior of FeCrAl alloys the new model predicts observable but small oxide thickness (6 μm) compared to the previous model which predicted essentially zero oxide scale formation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Grid pressure drop prediction in a fuel assembly

In fuel assembly, spacer grids have strong effects on pressure drop and other thermal-hydraulic behaviors. Considering the design and safety operation of a reactor, it is important to predict pressure drop accurately in the fuel assembly. For a mixed core, a reactor with mixed fuel designs in the reactor core, undesired cross flow were often caused by differences in pressure drop among neighboring bundles. The pressure drop is often estimated for designs of new reactor core fuel assemblies. In the past, due to complex flow conditions in fuel assembly, the pressure drop of a fuel assembly relied greatly on costly and time-consuming full length thermal hydraulic tests. Some empirical pressure drop correlations and CFD methodology were applied, however, only limited to a single gird span. Without considering pressure drop in the entire fuel assembly it is quite difficult to optimize the fuel assembly design. Most experimental fuel assemblies consist of mixing vane grids (MVG) and simple support grids (SSG). The MVG's were the main tested spacer grids in the reactor and SSG's were used only in experimental study to support the fuel assembly. In fuel reactor core, the fuel assembly heats the coolant, which could turn the single-phase water system into a two-phase flow system and eventually lead to critical heat flux (CHF). Because of the complexity of phase change, it is very difficult to predict pressure drop in rod bundles with two-phase flow. In this paper, a new method to predict the pressure drop in the fuel assembly is proposed and verified by experimental data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Regulatory perspective of boiling water reactor peak reactivity credit in spent fuel storage and transportation - 14592

The U.S. Nuclear Regulatory Commission (NRC) performs reviews of applications for spent nuclear fuel transportation packages and storage casks to ensure pertinent safety regulations are met. Among other acceptance criteria, these regulations require that the package be subcritical under a variety of normal, off-normal and accident conditions. Currently, all spent nuclear fuel transportation packages and storage casks assume fresh fuel (i.e., the fuel is unirradiated) in their criticality safety analyses for boiling water reactor (BWR) fuels. Reviews using this conservative assumption are less complex. The fresh fuel assumption for BWR fuel does not allow the presence of gadolinium (often called the 'fresh fuel no-Gad' assumption), an integral burnable absorber present in nearly all BWR fuel assemblies. More recently, applicants began requesting credit for the reactivity reduction due to depletion. This credit is commonly referred to as 'burnup credit' (BUC). As of today, NRC recommends that only analyses for Pressurized Water Reactor (PWR) spent fuel implement BUC. This is due to the fact there is limited directly applicable data available to benchmark codes for depletion and reactivity calculations for BWR BUC analyses, and determining the most reactive irradiation conditions is much less straightforward than for PWR BUC analyses. Similar to what was done for PWR BUC, the NRC staff and its contractors have begun identifying and prioritizing significant technical issues so that a technical basis for the allowance of BWR BUC can be developed. BWR fuel exhibits a peak in reactivity where initial gadolinium is depleted. Crediting burnup at this point is generally referred to as using a 'peak reactivity method'. This is a conservative approach and a method routinely used in BWR spent fuel pool criticality analyses. NRC is implementing a two-phased approach in investigating BWR BUC. Phase 1 investigates peak reactivity credit and Phase 2 evaluates BUC at a typical discharge exposure. This paper discusses peak reactivity credit and its history in regulatory analyses, challenges the NRC expects in reviewing an application requesting peak BWR reactivity credit for a spent fuel transportation package or storage cask, the work that is being performed by NRC contractors to address these challenges, and future work on peak reactivity credit and full BWR BUC. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Temperature feedback of TRIGA MARK-II fuel

We study the amount of temperature feedback on reactivity for the three types of TRIGA fuel i.. ST8, ST12 and LEU fuel, are used in the TRIGA MARK II reactor in Malaysia Nuclear Agency. We employ WIMSD-5B for the calculation of kin f for a single TRIGA fuel surrounded by water. Typical calculations of TRIGA fuel reactivity are usually limited to ST8 fuel, but in this paper our investigation extends to ST12 and LEU fuel. We look at the kin f of our model at various fuel temperatures and calculate the amount reactivity removed. In one instance, the water temperature is kept at room temperature of 300K to simulate sudden reactivity increase from startup. In another instance, we simulate the sudden temperature increase during normal operation where the water temperature is approximately 320K while observing the kin f at various fuel temperatures. For accidents, two cases are simulated. The first case is for water temperature at 370K and the other is without any water. We observe that the higher Uranium content fuel such as the ST12 and LEU have much smaller contribution to the reactivity in comparison to the often studied ST8 fuel. In fact the negative reactivity coefficient for LEU fuel at high temperature in water is only slightly larger to the negative reactivity coefficient for ST8 fuel in void. The performance of ST8 fuel in terms of negative reactivity coefficient is cut almost by half when it is in void. These results are essential in the safety evaluation of the reactor and should be carefully considered when choices of fuel for core reconfiguration are made.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Research, Development and Demonstration of Advanced Vehicle Technologies in Clean Motor Fuels (CRADA Final Report)

NREL/DOE has been funding research, development, and demonstration (RD&D) projects to facilitate the deployment of alternative fuels into the marketplace in order to achieve three objectives: 1) enhance the reduction of mobile source emissions in California and the U.S.; 2) increase U.S. competitiveness and economic prosperity; and 3) preserve the environment through the reduction of emissions and toxins from the motor vehicle population. The Lewis-Presley Air Quality Management Act requires the South Coast Air Quality Management District to establish a program to encourage participation in projects to increase the utilization of clean-burning fuels. The parties seek to collaborate on a joint RD&D project to perform a field test on a small vehicle fleet operating on Fischer-Tropsch synthetic diesel fuel. Recently the 106th U.S. Congress designated "gas-to-liquid" (GTL) transportation fuels that are produced from domestic products as alternative fuels under the Energy Policy Act of 1992 (EPACT). Niche markets could develop quickly for these fuel products, perhaps especially for the use of Fischer-Tropsch synthetic fuels in centrally fueled vehicle fleets in California. NREL and its project partners from the U.S. Department of Energy and West Virginia University have recently conducted what we believe to be the first-ever controlled tests of Fischer-Tropsch synthetic fuels in heavy vehicles. These tests have shown that Fischer-Tropsch fuels can be substituted in unmodified trucks and buses without any detectable loss in drivability and performance. Compared to a California diesel fuel baseline, neat Shell Fischer-Tropsch fuel emitted about 12% lower NOx and 24% lower particulate matter over a five-mile driving route while maintaining the same fuel economy on an energy equivalent basis. Whereas these exhaust emissions reductions from these previous studies have been impressive, far greater exhaust emissions reductions can be achieved if the vehicles are retrofitted with emissions control technologies that are enabled by Fischer-Tropsch fuels. For this program, a test fleet would be selected and retrofitted with continuously regenerating traps (CRT’s) or diesel particulate filters (DPF's). The University of West Virginia, under a separate subcontract to SCAQMD will have the responsibility to test and measure the emissions from the test fleet of vehicles.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Effect of Fuel Properties on Spray and Combustion Characteristics under Compression Ignition Engine Conditions

In this paper, a review of experimental findings from multiple laboratories using different fuels was performed based on the Engine Combustion Network’s (ECN) Spray A. The main objective was to achieve a better understanding of fuel properties’ effects on spray and combustion characteristics at compression ignition (CI) engine conditions. The experimental summary includes results from a total of 26 fuels and they were classified into four categories: Primary Reference Fuels (PRF), jet fuels, gasoline fuels, and diesel fuels. The spray and combustion behaviors of those fuels, including liquid and vapor penetrations, lift-off length, and ignition delay, were analyzed and correlated with basic fuel properties. The results showed that higher density, boiling temperature and viscosity generally lead to longer liquid length. At reacting conditions, a higher cetane number results in a shorter ignition delay and lift-off length. Furthermore, a strong negative correlation between ignition delay/lift-off-length and cetane number was observed for a wide range of fuels. In the second part of this paper, 3-D computational fluid dynamics (CFD) modeling using the Reynolds-Averaged Navier-Stokes (RANS) formulation was performed on PRF fuels to obtain detailed insight into how the fuel physical and chemical properties affect the spray and combustion processes. The results showed that lower ignitability occurred as the iso-octane content in fuel increased and this led to a leaner fuel environment and lower emissions at a higher PRF.

fuel properties, spray and combustion characterist↗
DOE OSTI2017

Integrated Solutions for Interim Used Fuel Management: From Pool Unloading to Safe Delivery to Recycling or Repository Facilities - 17235

Safe management of used nuclear fuel (UNF) is key to the survival of the nuclear industry. That is why it is more important than ever to have a consent-based, practical, credible, and sustainable roadmap for managing the back-end of the nuclear cycle. Worldwide UNF Light Water Reactors (LWR) inventories are currently around 200,000 tons and are estimated to grow to more than 350,000 tons by 2030, and operating nuclear reactors in the U.S. continue to discharge UNF every 18 to 24 months. International experience has demonstrated that the development of a permanent geological repository can be a multi-decade process, especially in the face of public acceptance challenges. Meanwhile, the solution for permanent disposal of UNF in the U.S. is moving at a glacial pace. As a result, industrial stakeholders have been forced to find practical interim UNF storage solutions in order to continue safely operating their reactors. Among those interim solutions are the cask- or canister-based dry storage systems that have dramatically increased in the last 10 years as they provide flexibility for expansion with a low up-front investment. With interim dry storage in place for more than 30 years, our industry is entering a new phase as we are forced to prepare for a few more decades before geological repositories begin operating. Consequently, interim dry storage has to be extended for 80 years or more. Thus, new considerations have to be taken into account to ensure the safety of this stored used fuel: - Interim storage systems are aging; - High burn-up fuel behavior overtime is uncertain; - Used fuel is losing its self-protection; - The number of shutdown sites without a fuel transfer facility, such as a pool, is increasing; - Some owners of Independent Spent Fuel Storage installation (ISFSI) at shutdown sites are not nuclear operators anymore. With increasing uncertainties, AREVA TN -- based on its long expertise with used fuel transportation and interim storage systems -- is adapting its portfolio to develop integrated and flexible solutions that will remove the burden of interim used fuel management from nuclear operators. AREVA TN is developing comprehensive solutions to reduce risks including the continued supply of proven safe high-performance dry storage systems; on-site services to safely transfer used fuel from pool to pad; the optimization of fuel heat load in the storage pool and pad; innovative aging management services including inspection, monitoring and repair; a realistic solution for consolidated interim storage with a priority to remove Used Nuclear Fuel stored in dry storage systems from shutdown sites; world-class transport and logistics services to safely move the used fuel from nuclear reactor sites to consolidated storage and repository or recycling as applicable, and turnkey management of shutdown ISFSIs. Due to the lack of an available path for transporting used fuel away from reactors, nuclear operators are faced with many challenges and growing uncertainties. Our presentation will describe the practical solutions developed and being developed in order to manage used fuel on behalf of nuclear operators and allows them to continue focusing on the important job of producing carbon-free clean energy. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Evaluation of waste arising from future nuclear fuel cycle - 15197

A comprehensive study was recently completed at the request of the US Department of Energy Office of Nuclear Energy (DOE-NE) to evaluate and screen nuclear fuel cycles. The final report was issued in October 2014. Uranium- and thorium-based fuel cycles were evaluated using both fast and thermal spectrum reactors. Once-through, limited-recycle, and continuous-recycle cases were considered. This study used nine evaluation criteria to identify promising fuel cycles. Nuclear waste management was one of the nine evaluation criteria. The waste generation criterion from this study is discussed herein. The fundamental characteristics of nuclear fuel cycles were used to create a comprehensive set of fuel cycle options. These options were categorized into 40 Evaluation Groups based on similarities in their physics-based performance. These Evaluation Groups, listed below, comprehensively represent all fuel cycle options: - 8 once-through Evaluation Groups: 5 uranium-based fuel cycles and 3 thorium-based fuel cycles - 10 limited-recycle Evaluation Groups: 6 uranium-based fuel cycles and 4 thorium-based fuel cycles, and - 22 continuous-recycle Evaluation Groups: 14 uranium-based fuel cycles and 8 thorium-based fuel cycles. The study focused on the quantity and characteristics of radioactive wastes generated by the different fuel cycles, examining 5 metrics characterizing waste generation: - mass of spent nuclear fuel (SNF) plus high level waste (HLW) disposed per energy generated, - activity of SNF + HLW (at 100 years) per energy generated, - activity of SNF + HLW (at 100,000 years) per energy generated, - mass of depleted uranium (DU) + recovered uranium (RU) + recovered thorium (RTh) disposed per energy generated, and - volume of low level radioactive waste (LLW) per energy generated. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Computational Investigation of Fuel Dispersal Phenomena during Large-Break Loss of Coolant Accident in Light-Water Reactors

In the event of cladding rupture, which could occur in light water reactor fuel assemblies during a loss-of-coolant accident (LOCA), fuel particles, along with fission gases, can be expelled into the reactor core from the fractured fuel rod. This expulsion of fragmented fuel particles, referred as fuel dispersal, is the subject of investigation to evaluate the safety implications of increasing fuel burnup in light water reactors, with a specific focus on fuel fragmentation, relocation, and dispersal. Particle trajectories and the resulting mass distribution of the settled particles within the reactor pressure vessel can pose a long-term cooling challenge for the reactor core. The fuel dispersal phenomenon is significantly influenced by the ejection characteristics of the fuel fragments, as well as the size and shape of the cladding rupture and fuel rod depressurization history during LOCA transients. In this study, the transport of fuel particles within a scaled 5 × 5 lattice of a pressurized water reactor rod bundle geometry is modeled through a two-fluid Eulerian framework that treats the gas and solid phases as interpenetrating continua. The required boundary conditions are evaluated from the fuel performance code BISON in a postulated large-break LOCA scenario. The modeling framework considers solid fuel particles as granular matter, interacting with the gaseous dry steam phase and fission gases through the governing interfacial momentum and energy exchange between the gas and solid phases. The simulation results provide the volume fraction of the solids settled on the bottom surface of the fuel bundle, quantifying the deposition within the bundle geometry.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

A Hybrid Catalytic Route to Fuels from Biomass Syngas

LanzaTech partnered with the Pacific Northwest National Laboratory (PNNL), Imperium Aviation Fuels, InEnTec, Orochem Technologies, the University of Delaware, Michigan Technological University, the National Renewable Energy Laboratory, and The Boeing Company, to develop a cost-effective hybrid conversion technology for catalytic upgrading of biomass-derived syngas to sustainable alternative jet fuel (SAJF) meeting the price, quality and environmental requirements of the aviation industry. Alternative “synthetic paraffinic kerosene” (SPK) blendstock produced from syngas via “Fischer-Tropsch” (F-T) or from lipids via “hydroprocessing of esters and fatty acids” (HEFA) are currently being used in commercial jet fuel blends containing at least 50% petroleum-based fuel. This project developed an alternative route to SAJF from ethanol, a type of “alcohol to jet” (ATJ) SPK. The project objective was to demonstrate a pathway that combines syngas fermentation to ethanol with catalytic upgrading of ethanol to sustainable alternative jet fuel and shows attractive overall system economics to drive down the price of biomass-derived jet fuel. The hybrid pathway was to be demonstrated on three biomass feedstocks: corn stover, woody biomass, and third biomass feedstock, cellulosic residues. The objective also included the co-production of chemicals, exemplified by 2,3-Butanediol (2,3-BDO), which can be converted to key chemical intermediates. The team successfully demonstrated that biomass syngas fermentation followed by catalytic conversion is a viable alternative to the Fischer-Tropsch process and produces a fuel with properties comparable to F-T and HEFA SPKs. Plasma gasification and gas fermentation were successfully integrated and demonstrated in continuous fermentations on waste wood, corn stover, and cellulosic bagasse. Gas fermentation was demonstrated to produce ethanol suitable for catalytic upgrading, isolating the upgrading from variations in biomass feed, syngas composition, and impurities. Ethanol feedstocks from all three types of biomass were demonstrated to be comparable to grain derived ethanol and suitable for the LT-PNNL ATJ process. The LT-PNNL ATJ catalytic upgrading process was demonstrated at lab scale for over 2000 hours of continuous operation on a single catalyst load. LanzaTech scaled up the ATJ process, producing 4000 gallons of jet and 600 gallons of diesel for testing and a future proving flight. The LT-PNNL ATJ process, at lab and pilot scale, using commercial grain-based ethanol and steel mill waste gas-based ethanol (“Lanzanol”), produces high-quality fuel-range distillates containing primarily normal paraffins and isoparaffins. The LT-PNNL ATJ fuel has equivalent properties to previously-approved SPKs such as F-T, HEFA, and ATJ from isobutanol, and conforms with critical properties needed to blend with conventional jet fuel. The project showed that the 2,3-BDO fermentation co-product can be separated economically utilizing Simulated Moving Bed (SMB) technology. 2,3-BDO can be catalytically converted to 1,3-butadiene (BD) in a two-step process with at least 70% yield, producing a chemical intermediate suitable for downstream applications. Technoeconomic and life cycle analyses of the biomass to jet process with and without 2,3-BDO production showed that capital costs are sensitive to the proportion of the 2,3-BDO co-product and biomass feedstock. The co-product 2,3-BDO, converted through to BD, significantly reduces the cash cost of production of the hydrocarbon fuels. Life cycle GHG emissions of ATJ SPK produced from biomass using a steam gasification system are projected to be significantly lower than those of conventional jet fuel. The project demonstrated that a high quality ATJ SPK, can be produced from biomass via a hybrid gas fermentation/catalytic route. Validation of the LT-PNNL ATJ process using a variety of ethanol feedstocks demonstrated the viability of a future model of distributed ATJ production, in which ethanol may be produced at multiple facilities from local feedstocks and shipped to a central facility for conversion. The project demonstrated that co-production of chemicals has the potential to reduce jet cost of production, thereby accelerating commercial production of SAJF from biomass.

09 BIOMASS FUELS↗
DOE OSTI2016

Characterization of Fresh Nuclear Fuel using Time-Of-Flight Neutrons

Neutrons offer excellent characterization capabilities for nuclear fuels and can provide non-destructive insight on micro structure, chemistry and crystallographic phase. Measurements are possible at reactors or pulsed sources, but the inherent energy resolution implicit at pulsed sources offers unique opportunities. Recent advances in 2D neutron detection enabled new capabilities of material characterization using neutron imaging and tomography for nuclear materials. Moreover, time-of-flight (TOF) neutron measurements can enable isotope specific tomography by deriving isotope densities from transmission spectra exhibiting neutron resonances, which are recorded for each pixel. Tomographic algorithms allow 3D reconstructions of the spatial distribution of isotopes, density and features in typical fuel pellet samples. The ability to select radiographs for different energies allows characterizing samples which are opaque for thermal neutrons, such as enriched fuels or fuels containing plutonium, by selecting epi-thermal neutron energies and by knowledge of the total neutron cross sections of the constituents, isotopic enrichment levels can be determined. Nuclear cross sections are typically not calculated directly and databases such as the Evaluated Nuclear Data File (ENDF) database provide this information with cross sections determined by standardized experimental measurements, such as neutron transmission measurements for individual isotopes. Utilizing the information in the ENDF database, the 'inverse' problem can be solved by assuming cross section parameters to be known parameters and areal densities can be determined. This work presents recent advances at the Los Alamos Neutron Science Center (LANSCE) facility at Los Alamos National Laboratory (LANL), which provides the infrastructure to handle radioactive samples, in the development of fuel characterization with TOF neutrons. Examples include recent work on prototype accident tolerant nuclear fuels (ATF). The potential application of these techniques for nondestructive examination of irradiated fuel is under consideration. Non-destructive access to materials features for specimens embedded in containers, particularly for hazardous samples, such as a radioactive nuclear fuel, is indispensable to characterize and ultimately license new fuel forms. Energy-resolve neutron imaging is a new tool for this research field. The results reported here present a new imaging technique, setting a milestone in the capabilities of measuring non-destructively absolute quantities of physical properties. The enabling physics behind this new technique are nuclear resonances. We have demonstrated how absolute areal densities can be extracted from radiographs utilizing pulsed neutron sources. This technique provides information that is otherwise difficult and costly to obtain. In the case of nuclear fuels, the results from energy-dispersive neutron imaging may guide destructive examination of irradiated fuel. This summery does not describe recent analysis, which is ongoing. Particularly, the implementation of calibration standards has improved the determination of enrichment levels without additional calibration. The analysis of the samples was performed with full tomographic reconstructions for isotope specific data and presents a first approach in absolute isotope specific 3D reconstruction. This work was predominantly funded by and received substantial support from the Fuel Cycle R and D program at Los Alamos National Laboratory. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Metal fuel relocation experiments with pressure injection

A pool-type sodium-cooled fast reactor (SFR) using metal fuels has a number of inherent safety features that can support benign consequences for design basis accidents (DBAs). Even in postulated severe accident conditions, the core is designed to remain under sub-critical condition in a passive coolable geometry. In case of the postulated severe accidents in SFRs, fuel relocation in the core region along the coolant channel is an important negative reactivity feedback factor that lowers the reactor power level and consequently eliminates the possibility of recriticality. Therefore, understanding the relocation behavior of fuels and the coolability of the relocated fuels in the postulated severe accident is one of the most important factors in the safety assessment of SFRs. In the present study, the relocation behavior of the metal fuel in a pin bundle geometry was investigated by injecting the metal fuels into the coolant channels with pressure. The first metal fuel relocation with pressure injection (RPI-1) experiment showed that many of the metal fuels levitated to upper plenum. In case of RPI-2 experiment, the Real Time X-ray Video System (RTXVS) was constructed and used to obtain a real time X-ray video of the experiment. This real time X-ray video clearly showed the relocation behavior of the pressure injected metallic uranium in the sodium coolant channel. Through this video, it was confirmed that part of the fuel was dispersed downward and part of the fuel was dispersed upward, and the relocation behavior of the injected fuel proceeded simultaneously in the downward and upward directions. So, it can be concluded that in case of pressure injection of the metallic fuel, there is a possibility that the metallic fuel can be quickly removed from the core region, resulting in a negative reactivity feedback effect.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Evaluation of flow-induced plate deflection for University of Missouri research reactor low-enriched uranium fuel element

The University of Missouri Research Reactor (MURR), located on the campus of the University of Missouri in Columbia, Missouri, is one of the six United States (U.S.) High Performance Research Reactors (USHPRR), including one critical facility, that are actively collaborating with the U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA) Office of Material Management and Minimization (M3) Reactor Conversion Program to convert from highly enriched uranium (HEU, ≥20 wt% U-235) fuel to low-enriched uranium (LEU, <20 wt% U-235) fuel. A new type of very high-density LEU fuel based on a monolithic alloy of uranium and 10 wt% molybdenum (U-10Mo) is expected to allow conversion of some USHPRR, including MURR. In the design of its fuel elements, MURR is using thin parallel curved fuel plates separated by coolant channels. In this work, fluid-structure interaction (FSI) analysis of the MURR LEU fuel element is performed at the element level (as compared to the plate level analysis), which models all components of the LEU fuel element, including fuel plates and the supporting structures. Therefore, the effect of supporting structures on the flow distribution within the element and the fuel plate deflection are evaluated. In addition to the element nominal flow rate and dimensions, the tolerances in the geometry of the coolant channel and plate thickness, the effect of a comb on plate deflection, and the uncertainty of the flow rate per element are evaluated. For the LEU fuel plates, which are thinner than the current HEU plates, the predicted plate deflection is found to be small compared to the fabrication and assembly tolerances. Thus, the FSI-induced deflections are not expected to noticeably reduce the coolant flow rate or predicted safety margins in the limiting channels for the MURR LEU fuel element. In addition to the simulation work, a hydraulic performance test of the MURR LEU fuel element is currently being planned to support conversion to the use of LEU fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Comparison of Irradiated TRISO Fuel Radioactivity from Multiple Advanced Reactor Designs

The SCALE code system was used to model, deplete, and compare several different TRISO-fueled reactor designs: a helium-cooled prismatic reactor, a helium-cooled pebble-bed reactor (PBR), and a Fluoride-Lithium-Beryllium (FLIBE) molten-salt-cooled PBR. The purpose of this comparison was to understand how differences in the reactor designs affect the radioactivity of the fuel after discharge and whether those differences are significant. First, the various reactor designs were build and depleted in the TRITON module for each design and fuel enrichment. Then, the TRITON outputs were used to create burn-up dependent reactor libraries. These libraries were then used by ORIGEN to determine the activities of discharged fuel for each reactor, which were compared to generic Westinghouse 17x17 fuel. Overall, the results showed that short term decays are dominated by reactors with higher operating powers, and the reactor type, initial fuel enrichment, and maximum burn-up are of only secondary importance. Although this analysis only focuses on activities in becquerels, these dependencies are consistent with the expected behavior of decay heat. However, analysis of long- term time periods post-irradiation shows that the reactor type and maximum burn-up have strong impacts on the activities; initial fuel enrichment has a secondary impact while operating power is inconsequential. These results would be useful for analyses, such as dose assessment and modeling in post- release scenarios; normal fuel handling operations; and spent fuel transport, storage and disposal. Of particular interest, the results in this report show that analyses that focus on spent nuclear fuel of advanced reactors need to consider each parameter carefully. Unsurprisingly, if the correct operating power is not used in short term analyses, the results will not be correct. Perhaps unexpectedly, however, if the correct reactor type is not used, then the long term results will also be incorrect, especially for areas such as permanent disposal. Even though this report focuses on the total activity of nuclear fuel, it provides initial results on the effects of various input parameters and also provides a framework to extend the work into other analyses of spent fuel from advanced reactors, especially those employing TRISO fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗