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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Thermal Modeling of Advanced Test Reactor Fuel in a Generalized Dry Storage System Under Hypothetical Accident Conditions

Work was performed to investigate the thermal behavior of a sealed aluminum-clad spent nuclear fuel (ASNF) dry storage configuration under hypothetical accident conditions during long-term storage. The considered system consists of a concrete dry storage overpack; a welded over canister, backfilled with argon; and nine Department of Energy (DOE) standardized canisters (DOESCs) loaded with ASNF, backfilled with helium gas. One technical concern associated with the long-term storage of ASNF includes radiolytic hydrogen generation. The yield of large quantities of hydrogen could lead to DOESC over pressurization or a flammable internal atmosphere. While flammability concerns can be resolved by preventing the ingress of oxygen, the canister pressure is partially controlled by the atmosphere temperature. This memorandum summarizes the results of modeling and simulation (M&S) work completed with Star CCM+ (a computational fluid dynamics [CFD] software) considering the thermal effects of a fully engulfing flame and another scenario with the vent ports of the concrete dry storage overpack completely blocked. The goal was to determine the bounding maximum temperature of the DOESC internal atmosphere to evaluate a worst-case pressure scenario, as well as the critical vent port blockage durations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Evaluation of China Experimental Fast Reactor Start-up Tests (Final Report, Revision 1)

This report documents the results and observations on the Coordinated Research Project (CRP) of the International Atomic Energy Agency (IAEA) on “Neutronics Benchmark of CEFR Start-Up Tests.” The China Experimental Fast Reactor (CEFR) is a 65MWt sodium-cooled fast reactor with highly enriched uranium oxide fuel. The reactor achieved first criticality in 2010, and a series of start-up tests were conducted to measure various reactor physics parameters. In 2018, the IAEA launched the CRP for validation and qualification of member states' computation capabilities in the field of fast reactor simulation by utilizing the measured data in the CEFR start-up test. Twenty-nine international organizations from eighteen member countries, including Argonne National Laboratory, have participated in the CRP. The CEFR start-up tests offer a rare opportunity to validate U.S. nuclear engineering software because it is a well-specified benchmark with corresponding measurements for a recently built fast reactor starting up with a known fuel composition (fresh fuel). Previous fast reactor validation benchmarks frequently involve reactors that have already been started up and contain irradiated fuel that is difficult to characterize with high certainty.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Methodological approach to the sensitivity analysis of failure effects in modern digital I and C systems - 136

Modern I and C systems of nuclear power plants increasingly use digital equipment, software-based applications for I and C functions and different types and topologies of communication networks as well. The structure, operation and communication of digital safety-related I and C systems are strongly influenced by the implemented automatic fault detection and fault treatment procedures as barriers against failure propagation. Thus, these I and C systems can change their operating states automatically during the operation time, e.g. due to the detection and correction of certain failure types. Reasonably because of these dynamic properties of digital I and C systems the use of classical fault tree and event tree methods solely for the reliability analysis of modern I and C systems is less suitable. These methods basically apply static models and do not consider the temporal changes of the operating state of the I and C system or equipment appropriately. In this paper, a recently developed approach for the sensitivity analysis of digital I and C systems will be introduced that allows to investigate the dynamic behavior of such systems in cases of internal faults and to quantify the effects on the system reliability. The development and testing of the analysis methodology is carried out using models of generic I and C systems with different typical architectures of stepwise increased complexity. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Fission product distribution in irradiated safety-tested and as-irradiated AGR-2 TRISO particles

In this work, two tristructural isotropic (TRISO)-coated nuclear fuel particles were examined by electron probe microanalysis (EPMA) as part of the Advanced Gas Reactor program. The compacts’ average irradiation temperatures ranged from approximately 1260 to 1290 °C. One particle was examined in the as-irradiated condition, while the other was subject to 1600 °C post-irradiation safety testing. This study was undertaken to test a newly-developed EPMA technique to determine fission product masses in TRISO particles on a layer-by-layer basis, and to compare fission product distributions between an as-irradiated and safety-tested particle. Fission product concentration profiles were collected along two radii in each particle, with measured concentrations used to compute the fission product mass in each TRISO particle layer. These measured masses were then compared to those predicted from ORIGEN modeling calculations. Data collected from these measurements show that for these two particles, masses determined via EPMA were within ± 20% of the calculated masses for the rare-earth elements, Mo, Zr, Cs, I, and Pd. Elements that tend to be less homogeneously distributed include Sr, Te, Eu, Ag, and possibly Ba. Measured Ag masses differed by more than 40% from the calculated mass. Lanthanides other than Eu remain primarily within the fuel kernel in the as-irradiated particle but in the safety-tested particle these element masses were divided approximately equally between the kernel and kernel periphery. In both particles, the majority of Sr and Eu accumulated in the carbon-rich kernel periphery, although in the safety-tested particle, Sr and Eu accumulated farther from the fuel kernel than occurred with irradiation alone. A greater mass fraction of mobile elements, such as Cs and I accumulated in the buffer and IPyC in the safety-tested particle as compared to the as-irradiated particle. When fully developed and tested, this mass balance approach to TRISO particle analysis has the potential to provide insight into fuel behavior.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Modeling of the Advanced Test Reactor Using OpenMC, Cubit and Griffin

In the pursuit of the ability to perform multiphysics simulations of the Advanced Test Reactor, it is crucial to have a fast and highly accurate deterministic model. To achieve this, a contemporary two-step method is employed. The first step involves generating homogenized cross sections using OpenMC, a cutting-edge Monte Carlo neutron transport code. OpenMC offers excellent modular capabilities, allowing for easy component integration and flexibility in incorporating new designs into the model. The second step involves deterministic transport calculations, which are performed using Griffin, a reactor multiphysics application based on the Multiphysics Object-Oriented Simulation Environment. To ensure the accurate spatial resolution and assignment of material cross sections, a Cubit-generated mesh for the Advanced Test Reactor is utilized as an intermediate step between the OpenMC and Griffin models; Griffin utilizes the mesh for its finite element solution, while OpenMC material IDs are written to the mesh file to be used in Griffin material assignments. Additionally, a Python-based script converts the cross sections generated by OpenMC into the ISOXML format required by Griffin. Preliminary comparisons indicate good agreement between the neutron multiplication factors obtained from the standalone OpenMC model and the Griffin model, with differences of less than 50 pcm in the two-dimensional geometry configuration. However, in three-dimensional calculations, an unacceptably large error is found in the Griffin solution. Future work is planned to resolve this discrepancy.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Application of Laser Powder Bed Fusion for Transformational Challenge Reactor Core

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

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2017

Non-Intrusive Velocity Measurements with MTV During DCC Event in the HTTF

Velocity profiles are measured using molecular tagging velocimetry (MTV) in the high temperature test facility (HTTF) at Oregon State University during a depressurized conduction cooldown (DCC) event. The HTTF is a quarter scale electrically heated nuclear reactor simulator designed to replicate various accident scenarios. During a DCC, a double ended guillotine break results in the reactor pressure vessel (RPV) depressurizing into the reactor cavity and ultimately leading to air ingress in the reactor core (lock-exchange and gas diffusion). It is critical to understand the resulting buoyancy-driven flow to characterize the reactor self-cooling capacity through natural circulation. During tests conducted at ambient pressure and temperature, the RPV containing helium is opened (via the hot and cold legs) to a large vessel filled with nitrogen to simulate the atmosphere. The velocity profile on the hot leg pipe centerline is recorded at 10 Hz with MTV based on NO tracers. The precision of the velocimetry was measured to be 0.02 m/s in quiescent flow prior to the tests. A helium flow from the RPV is initially observed in the top quarter of the pipe. During the first 20 seconds of the event, helium flows out of the RPV with a maximum velocity below 2 m/s. The velocity profile transitions from parabolic to linear in character and decays slowly over the rest of the recording; peak velocities of 0.2 m/s are observed after 30 min. A counter-flow of nitrogen is also observed intermittently, which occurs at lower velocities (>0.1 m/s).

Andre, M. A.↗
DOE OSTI2016

VERA 3.5 Installation Guide

This guide describes the structure and setup of the standard VERA development environment (VERA Dev Env) and standard VERA Third Party Libraries (TPLs) that need to be in place before installing many of the VERA simulation components. It describes everything from the initial setup on a new machine to the final build, testing, and installation of VERA components. The goal of this document is to describe how to create the directories and contents outlined in Standard VERA Dev Env Directory Structure and then obtain the remaining VERA source and build, test, and install any of the necessary VERA components on a given system. This document describes the process both for a development version of VERA and for a released tarball of the VERA sources.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Full Length Assembly Testing in PELICAN (Final Report)

In support of the development of the U.S. Department of Energy (DOE) Versatile Test Reactor (VTR), a thermal hydraulics test facility was constructed to generate experimental measurement of the pressure drop across a single full-scale assembly containing prototypic axial reflectors, fuel, and plena components. Constructed and operated at Argonne National Laboratory, the Pressure drop Experimental Loop for Investigations of Core Assemblies in Nuclear reactors (PELICAN) facility was designed to achieve hydraulic conditions identical to those anticipated for a full-scale fuel assembly located in the VTR core in the region with the highest flow rate. Using water as surrogate for liquid sodium, the flow loop was operated at elevated temperatures and pressures to match the thermophysical properties of liquid sodium and ensure matching Reynolds and Euler numbers. The measurement objectives for data generated from this test facility was driven primarily by the validation needs for code calculations and simulations of the reference VTR core. These objectives focused on the need to validate pressure drop results across the various segments of the fuel assembly as they relate directly to the pumping power and safety of the reactor. Presented in this report are experimental results and analytical comparisons based on testing of a full-length assembly in PELICAN. Housed within a hexagonal test section extending 3.4 m in length, the tested assembly features a prototypic lower reflector, grid plates, wire-wrapped rod bundle, upper reflector, and exit region. The rod bundle extends over 1.5 m in length and contains 217 individual wire-wrapped rods with dimensions that best reflect the reference VTR design. The as-tested bundle assembly was fabricated using 316 stainless steel 0.25-inch (6.35-mm) diameter rods wrapped with 0.04-inch (1.016-mm) diameter wire at a helical pitch of 10.51 inch (26.6 cm). Details of the method for in-house wire-wrapping, assembly, and installation are provided later in this report. Experimental measurements of pressure drop at 19 positions along the test assembly were recorded for a range of flow conditions, with special attention paid to key locations within the assembly, including component inlet and outlet, transition, and wire-wrapped rod bundle regions. Testing conditions were based on 110°C water with flow rates ranging from 50 to 450 GPM (3 to 27 kg/s) at the inlet of the test assembly generating Reynolds numbers and velocities up to ~8.0×10 4 and ~7.8 m/s, respectively, within the rod bundle region. Non-dimensional values for the friction factor were then calculated based on these experimental measurements and compared against those predicted by various analytical correlations available from open literature. Predictions by the upgraded Cheng and Todreas, Rehme, and Novendstern correlations fell within 4% to those values measured experimentally.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Comparison of fission product release predictions using PARFUME with results from the AGR-1 safety tests

Safety tests were conducted on fuel compacts from AGR-1, the first irradiation experiment of the Advanced Gas Reactor (AGR) Fuel Development and Qualification program, at temperatures ranging from 1600 to 1800 °C to determine fission product release at temperatures that bound reactor accident conditions. The PARFUME (PARticle FUel ModEl) code was used to predict the release of fission products silver, cesium, strontium, and krypton from fuel compacts containing tristructural isotropic (TRISO) coated particles during 15 of these safety tests. Comparisons between PARFUME predictions and post-irradiation examination results of the safety tests were conducted on two types of AGR-1 compacts: compacts containing only intact particles and compacts containing one or more particles whose SiC layers failed during safety testing. In both cases, PARFUME globally over-predicted the experimental release fractions by several orders of magnitude: more than three (intact) and two (failed SiC) orders of magnitude for silver, more than three and up to two orders of magnitude for strontium, and up to two and more than one orders of magnitude for krypton. The release of cesium from intact particles was also largely over-predicted (by up to five orders of magnitude) but its release from particles with failed SiC was only over-predicted by a factor of about 3. These over-predictions can be largely attributed to an over-estimation of the diffusivities used in the modeling of fission product transport in TRISO-coated particles. The integral release nature of the data makes it difficult to estimate the individual over-estimations in the kernel or each coating layer. Nevertheless, a tentative assessment of correction factors to these diffusivities was performed to enable a better match between the modeling predictions and the safety testing results. The method could only be successfully applied to silver and cesium. In the case of strontium, correction factors could not be assessed because potential release during the safety tests could not be distinguished from matrix content released during irradiation. Furthermore, in the case of krypton, all the coating layers are partly retentive and the available data did not allow the level of retention in individual layers to be determined, hence preventing derivation of any correction factors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Development of Accelerated High Temperature Mechanical Testing Techniques

The Advanced Materials and Manufacturing Technologies (AMMT) Program focuses on advancing materials and manufacturing techniques for nuclear energy applications, particularly in the qualification of materials for high-temperature structural use. This report presents work on refining the creep testing of small specimen geometries. Efforts include the development of a new specimen geometry for sub-sized specimens, which were subjected to uniaxial creep tests. The results contribute to the understanding of material behavior under stress at elevated temperatures and offer potential improvements in creep data collection methods. These findings support ongoing advancements in material qualification processes essential for nuclear reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Validation of the Fast and Thermal Neutron Flux Profiles in the Advanced Test Reactor for the AGR-3/4 Experiment

The AGR-3/4 experiment was designed to irradiate TRISO particle fuel in the Advanced Test Reactor (ATR) at the Idaho National Laboratory. Temperature control of the test capsules containing the TRISO particles was important since the goal was to measure diffusion rates of fission product elements through graphite as a function of temperature. During the experiment, differences were observed between temperatures measured by the thermocouples and temperatures calculated with the thermal analysis model. To rule out the possibility that the used ATR driver fuel elements were the root cause of these temperature differences, an experiment was devised to measure the axial fast and thermal neutron flux profiles in the northeast flux trap containing the AGR-3/4 experiment. An important input parameter to the thermal analysis model was the calculated compact heat rates from the MCNP physics model. To verify these calculated heat rates were consistent with the ATR driver fuel element loading and operating lobe power, axial flux wires were inserted into ATR northeast flux trap. The measured fast and thermal neutron axial flux profiles derived from the flux wire activation showed excellent agreement with the calculated flux profiles. This agreement dispelled any concerns that the used ATR fuel elements in the northeast lobe might have introduced unusual axial flux variation. In addition, the agreement provided a validation basis for the physics calculation, specifically, (1) MCNP physics model, (2) Monte Carlo depletion methodology, (3) method used to load the ATR driver fuel, and (4) ATR measured lobe power data used in the calculation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Advanced Construction Technology Initiative Program: ACTI Phase 1 ACTI Phase 2

Demonstrate technologies to significantly reduce the cost and schedule for construction of advanced reactors. Demonstrate the technology by 2026/2027 to improve the economics of deploying advanced reactors. Selected technologies will not require major R&D efforts. With prototyping and testing, the technologies will be ready for deployment at scale.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

A methodology for domain overlapping coupling of thermal-hydraulic systems

Multi-scale coupling has increasingly drawn attention as a promising approach for modeling thermal systems. Traditional system codes provide fast and robust predictions at the plant scale, while high-fidelity computational fluid dynamics (CFD)-based tools resolve localized flow and heat transfer phenomena with greater accuracy. By combining these complementary strengths, co-simulations enable multi-scale analysis that would otherwise be computationally prohibitive for a standalone CFD code. Here, this work introduces a robust and problem-agnostic domain overlapping (DO) coupling between the system thermal-hydraulic (STH) code System Analysis Module (SAM) and the coarse-mesh CFD code Pronghorn. Both applications belong to the Comprehensive Reactor Analysis Bundle (BlueCRAB) code suite, a code suite in active development at the Idaho National Laboratory (INL), tailored for multi-physics analysis of advanced reactors. Unlike previous approaches, BlueCRAB supports an agnostic interface between codes based on different fidelity, while its coupling formulation can address arbitrary flow geometries with multiple inlets and outlets in coupled components. The implemented method leads to consistent pressure drops, enthalpies, and scalar concentrations between coupled SAM and Pronghorn simulations. The methodology is demonstrated through two verification tests, which ensure the numerical consistency and conservation across the codes, and through one validation test against experimental data. The proposed problems explore different physical aspects inherent to thermal systems, with particular attention given to nuclear reactor analysis. These include buoyancy-driven flows, complex flow patterns, and setups with multiple inlets and outlets, representing challenges in advanced reactor applications.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Tensile behavior of diffusion bonded AA6061 - AA6061 with variation in cooling method

Hot isostatically pressed AA6061 cladding is an important structural component of the high performance, Zr-laminated U-10Mo monolithic fuel system for the application in research and test reactors. In this study, the mechanical behavior of two diffusion bonded aluminum alloy, AA6061, was examined using tensile testing. Solid-to-solid diffusion bonding between two pieces of AA6061 was performed by isothermal annealing at 560 °C for 1.5 h, and diffusion couples were subsequently cooled via three different cooling methods: furnace cooling, air cooling, and water quenching. Dog-bone shaped tensile specimens, with 10 mm in gauge length (with diffusion bonded interface in the middle), and 1.5 × 1.5 mm 2 gauge cross-sections, were fabricated from the diffusion bonded AA6061 by electro-discharge machining. Yield strength (% EL at failure) of furnace cooled, air cooled and water quenched tensile specimens determined was 82 ~ 89 MPa (10 ~ 30%), 112 ~ 116 MPa (10 ~ 14%), and 149 ~ 164 MPa (10 ~ 17%), respectively. This variation in mechanical behavior was examined with cooling-rate dependent, concentrated precipitation of Mg 2 Si at the diffusion bonded interface, with due respect for mechanical properties of the AA6061 alloy that inherently vary as a function of cooling rate from 560 °C. Finite element analysis using ABAQUS was employed to augment experimental findings with the appropriate microstructural constituents and alloy properties. Results suggest that the strength is dominated by matrix/bulk properties of AA6061, while ductility is strongly influenced by the cooling method dependent presence of Mg 2 Si precipitates at the interface.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

UN TRISO Compaction in SiC for FCM Fuel Irradiations

The U.S. Department of Energy Office of Nuclear Energy (DOE-NE) Advanced Fuels Campaign (AFC) is conducting research and development to elevate the technology readiness level of Fully Ceramic Microencapsulated (FCM) fuels, a candidate nuclear fuel with potentially enhanced accident tolerance due to very high fission product retention. One of the early activities in FY17 was to demonstrate production of FCM pellets with uranium nitride TRISO particles. This was carried out in preparation of the larger pellet production campaign in support of the upcoming irradiation testing of this fuel form at INL’s Advanced Test Reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Simulation of 15% and 50% Thermal Power Dispatch to an Industrial Facility Using a Flexible Generic Full-Scope Pressurized Water Reactor Plant Simulator

Nuclear power plants in the United States are increasingly challenged to compete in wholesale electricity markets due to the low electricity costs and increasingly dynamic grid conditions from competing generation sources. An alternative market for nuclear power is industrial facilities that can use the thermal and/or electrical power generated by a nuclear power plant to offset the economic losses incurred by electricity market challenges. A generic pressurized water reactor (PWR) simulator was used to show the results of a basic design for a generic thermal power extraction system and tests were run using a set of procedures to show what happens when a nuclear power plant transitions from full electrical power dispatch to 15% and 50% thermal power dispatch. This type of operation leads to losses in turbine performance efficiency due to the deviation from the design operating point, but because the thermal power is also used by the industry load without conversion losses, the combined thermal efficiency of the PWR increases. For the 15% case, the thermal efficiency increased from 32% to 41.9%, while for the 50% case, the efficiency increased up to 60.1%. In addition, for 50% thermal power dispatch, the power dissipated by the condenser decreased from approximately 2000 to approximately 1300 MW (thermal), indicating a substantially diminished impact on the environment in terms of releasing heat into the cooling water reservoir.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Corrosion Resistance and Mechanical Stability of Nickel Alloys in Molten-Salt Nuclear Reactors

Choosing structural materials for molten-salt nuclear reactors is a high-priority problem. The results making it possible to choose the basic structural material for a molten-salt nuclear reactor are colligated in the present article. Forced and natural circulation setups operating under reactor and laboratory conditions with molten metal-fluoride salts with different compositions have been developed at the National Research Center Kurchatov Institute: LiF–NaF–BeF{sub 2}–PuF{sub 3}, LiF–BeF{sub 2}–UF{sub 4}, and LiF–BeF{sub 2}–ThF{sub 4}–UF{sub 4}. Corrosion tests were conducted with domestically produced corrosion-resistant steel (12Kh18N10T, EP-164) and specially developed nickel-based alloys (KhN80M-VI, KhN80MTYu, KhN80MTV, et al.) as well as the alloy Hastelloy (USA), MONICR (Czechoslovakia) and EM-721 (France) in the working temperature range 600–800°C and mechanical loads up to 80 MPa on the samples.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗