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Nuclear Data Management and Analysis System Plan

The United States Department of Energy Advanced Reactor Technologies Program was formed in Fiscal Year 2015 and encompasses the Next Generation Nuclear Plant Project and Very High Temperature Reactor (VHTR) Program as they were known previously. The VHTR Program was created to support design and licensing of the first VHTR nuclear plant. Data created for and used by the program must be qualified for use, stored in a readily accessible electronic form, categorized to assure the correct data are used, and controlled to prevent data corruption or inadvertent changes. The Nuclear Data Management and Analysis System was designed to support the data needs of the VHTR Program, at the time and now the Advanced Reactor Technologies Program. Since its inception, use of the Nuclear Data Management and Analysis System has expanded to support additional projects and programs with similar requirements for control, analysis, and availability of large data sets.

99 GENERAL AND MISCELLANEOUS↗

Status of U.S. DOE Deliverables 0 July 2023

An annual status of the US TRISO fuel qualification program is provided, with a focus on activities linked to the Generation IV International Forum (GIF) Very High Temperature Reactor (VHTR) Fuel and Fuel Cycle (FFC) Project Management Board (PMB).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Validation Studies of RELAP5-3D for High-Temperature Gas-Cooled Reactor Analysis Using a Refined RELAP5-3D Model of the High Temperature Test Facility

RELAP5-3D has been used extensively for high-temperature gas-cooled reactor (HTGR) analysis, but such analysis lies outside the validation basis for the code. Oregon State University (OSU) and the United States Department of Energy’s (DOE) Advanced Reactor Technologies (ART) – Gas-cooled reactor campaign worked together to design and operate the High Temperature Test Facility (HTTF) at OSU to provide validation data for prismatic HTGR thermal hydraulics analysis. Work using a previous RELAP5-3D model of HTTF demonstrated the ability to reproduce trends in HTTF data but an inability to reproduce the values measured in multiple experiments within the uncertainty. It was hypothesized that a new model with a finer radial nodalization would perform better for HTTF analysis. In this paper, we present the development of that more refined model and analyze HTTF experiments PG-27 and PG-29, a pressurized (PCC) and depressurized conduction cooldown (DCC) transient. Comparing PG-27 results to experimental data shows a better prediction of steady state and transient temperatures; however, a deeper dive reveals that better transient temperature predictions are a result of better initial conditions. The transient temperature rise in the core is comparable between the two models, but the legacy model predicts temperatures in the reflectors better. The new model demonstrates the ability to predict unique temperatures in each sector of the core during PG-29, capturing the azimuthal asymmetry; however, the temperature predictions still differ from measured temperatures. One hypothesis is that differences between the assumed and actual power distribution leads to the underprediction of the individual block temperatures. These results suggest that gaps and uncertainties in the measured boundary conditions for the HTTF tests do not allow to fully validate RELAP5-3D for prismatic HTGR analyses. The authors suspect that some of the differences between predicted and measured temperatures may be a result of uncertainties associated with HTTF itself rather than RELAP5-3D. We demonstrated improved validation for steady-state analysis, but significantly improved transient performance has yet to be recognized.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Application of MELCOR for Simulating Molten Salt Reactor Accident Source Terms

Molten Salt Reactor (MSR) systems can be divided into two basic categories: liquid-fueled MSRs in which the fuel is dissolved in the salt, and solid-fueled systems such as the Fluoride-salt-cooled High-temperature Reactor (FHR). The molten salt provides an impediment to fission product release as actinides and many fission products are soluble in molten salt. Nonetheless, under accident conditions, some radionuclides may escape the salt by vaporization and aerosol formation, which may lead to release into the environment. Here, we present recent enhancements to MELCOR to represent the transport of radionuclides in the salt and releases from the salt. Some soluble but volatile radionuclides may vaporize and subsequently condense to aerosol. Insoluble fission products can deposit on structures. Thermochimica, an open-source Gibbs Energy Minimization (GEM) code, has been integrated into MELCOR. With the appropriate thermochemical database, Thermochimica provides the solubility and vapor pressure of species as a function of temperature, pressure, and composition, which are needed to characterize the vaporization rate and the state of the salt with fission products. Since thermochemical databases are still under active development for molten salt systems, thermodynamic data for fission product solubility and vapor pressure may be user specified. This enables preliminary assessments of fission product transport in molten salt systems. In this paper, we discuss modeling of soluble and insoluble fission product releases in a MSR with Thermochimica incorporated into MELCOR. Separate-effects experiments performed as part of the Molten Salt Reactor Experiment in which radioactive aerosol was released are discussed as needed for determining the source term.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

An Assessment of Nuclear Fuel Options for Microreactors

A design options trade-off study was conducted for various nuclear fuel system options. This study developed requirements for ideal fuel system characteristics and weighted ranking criteria specifically for microreactor designs. A semiquantitative method of consensus ranking on a numeric scale was used with input from several nuclear fuel experts. The purpose of this study was to assess options and provide recommendations for further nuclear fuel technology development to better support small reactor cores. Modern microreactor designs have only recently begun emerging and have little in common except their diminutive size. The purpose of this study was not to determine which reactor type is best (e.g., coolant type and/or neutron energy spectrum), but rather to assess fuel system options within five broad categories of reactor types inspired by: 1) Very High Temperature Reactors (VHTR), 2) Sodium Fast Reactors (SFR), 3) System for Nuclear Auxiliary Power (SNAP) reactors, 4) Gas Fast Reactor (GFR), and 5) Molten Salt Reactors (MSR). The order in which these reactor types were listed generally represents the amount of current interest and technological maturity in the microreactor development community (in descending order). As such, the conclusions drawn for each reactor type category have varying levels of certainty, but there is confidence in the general conclusion that known fuel technologies can support small reactors, but that microreactors will be able to maximize their performance potential if these fuel systems were further optimized. These optimization opportunities were found to revolve around increasing uranium loading and improving behaviors/understanding for long time-at-temperature conditions. Further details about these recommendations can be found in the concluding section of this report.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Gen IV International Forum Interactions

Gen IV International Forum Interactions and how this applies to working groups for Hi-temp Reactor Systems and specific technical areas for each GIF reactor system. This includes Very-High Temperature Reactor (VHTR) and Material (MAT) and how R&D is shared and managed.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Summary Report Of The FY25 Computational Fluid Dynamics Verification And Validation Exercises In The Advanced Reactor Technologies - Gas-cooled Reactor Program

Verification and Validation (V&V) of numerical tools is critical for ensuring reasonable predictions during design, safety analysis, and licensing. Recent work in the Advanced Reactor Technologies - Gas-cooled Reactor (ART-GCR) program has focused on V&V of common Computational Fluid Dynamics (CFD) tools that are used within the Untied States. This report presents an update on these CFD V&V activities. These Generation IV Forum (GIF) Very High Temperature Reactor (VHTR) Computational Methods, Validation, and Benchmarking (CMVB) is an international organization dedicated to the verification and validation of High Temperature Gas-Cooled Reactor (HTGR) simulation tools. Participation in the CMVB provides additional value to the V&V activities, as it allows for access to a wider range of data, and provides valuable benchmarking exercises. Three HTGR phenomena are targeted: Reactor Cavity Cooling System (RCCS) performance, core bypass flow, and lower plenum mixing. Simulations of the University of Wisconsin-Madison (UW-Madison) RCCS facilities are performed with Reynolds Averaged Navier-Stokes (RANS) in StarCCM+. Results are compared for both forced and natural convection conditions, with both exhibiting good agreement with experimental measurements. The Idaho National Laboratory (INL) matched index of refraction (MIR) and Korean Atomic Energy Research Institute (KAERI) bypass flow expeirments are used to validation CFD predictions of bypass flow. Simulations are performed with RANS in StarCCM+ and with Large Eddy Simulation (LES) in NekRS. Finally, preliminary simulations of the Institute of Nuclear and New Energy Technology (INET) lower plenum mixing facilities are presented. Initial work has developed models with LES, RANS, and porous media models. These preliminary models are presented and compared to each other to gauge differences in predictions with each of the three methods.

and Benchmarking (CMVB)↗

Assembly of MiniFuel Targets for Irradiation of TRISO Fuel Compacts in the High Flux Isotope Reactor

To support the development of Kairos Power’s fluoride-salt-cooled high-temperature reactor, irradiation testing of tristructural isotropic (TRISO) fuel compacts was performed at the Oak Ridge National Laboratory (ORNL) High Flux Isotope Reactor (HFIR) to collect experimental data on TRISO fuel during high particle-power operation and validate fuel performance models. Fuel compacts containing enriched uranium oxycarbide (UCO), natural UCO (NUCO), or uranium dioxide (UO 2 ) TRISO particles were fabricated at ORNL and inserted into MiniFuel targets for HFIR irradiation. Five MiniFuel targets were successfully assembled, welded, tested, and delivered to HFIR, along with their quality assurance documentation. The targets were inserted into HFIR’s inner vertical experiment facility within the permanent beryllium reflector. Each target contains six fuel compacts and will be irradiated in HFIR for four cycles, with target temperatures of 500, 700, and 900°C. This report summarizes the experiment design, test matrix, and fabrication. This work was performed under the Nuclear Science User Facility program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A neutron tomography study to visualize fluoride salt (FLiNaK) intrusion in nuclear-grade graphite

Manufactured graphite is a preferred material for in-core components of molten salt reactors and fluoride salt-cooled high-temperature reactors, which are in permanent contact with liquid salts. However, owing to the porous nature of nuclear graphite, under certain conditions, molten salts may intrude graphite's pores and affect graphite's properties and functionality. Therefore, a better understanding of molten salt intrusion (distribution across sample cross section and penetration depth) is needed to assess its effects. Here, in this work, we have demonstrated the use of neutron imaging (computed tomography) in the evaluation of salt penetration and distribution of a wide range of graphite grades with diverse microstructures that have been subjected to FLiNaK (LiF–NaF–KF) intrusion at 750 °C and 5 bar pressure for 12 h. Because of the great neutron attenuation contrast from scattering and adsorption between Li (from FLiNaK) and the graphite matrix, we have obtained direct visualization of FLiNaK salt distribution in the salt-impregnated graphites for the first time. Three-dimensional reconstructed images and cross-sectional concentration profiles demonstrate that salt penetration and density distribution are greatly dependent on the microstructural properties of the graphite grade.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Novel pyrolytic boron nitride coating to reduce graphite interactions in molten fluoride salt

Future salt reactors like the Fluoride-salt-cooled-High Temperature Reactor require varying material flavors. Graphite is required for neutron moderation and potential fuel forms, while structural metals are required for containment. Studies show graphite/metal interactions exist when both materials share a salt medium. These interactions may accelerate the corrosion of the metal and change the surface of graphite materials. A novel pyrolytic boron nitride coating on graphite is investigated for reducing graphite/metal interactions. Finally, this is the first known application of such a coating, and salt exposure tests reveal the pyrolytic boron nitride coating reduces the interactions between stainless steel and uncoated graphite.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

SAM User's Guide

The System Analysis Module (SAM) is a modern system analysis tool being developed at Argonne National Laboratory for advanced non-LWR safety analysis. It aims to provide fast-running, whole-plant transient analyses capability with improved-fidelity for Sodium-cooled Fast Reactors (SFR), Lead-cooled Fast Reactors (LFR), and Molten Salt Reactors (MSR) or Fluoride-cooled High-temperature Reactors (FHR). SAM takes advantage of advances in physical modeling, numerical methods, and software engineering to enhance its user experience and usability. It utilizes an object-oriented application framework (MOOSE), and its underlying meshing and finite-element library (libMesh) and linear and non-linear solvers (PETSc), to leverage the modern advanced software environments and numerical methods. This document provides a user’s guide, which will help users understand the input description and core capabilities of the SAM code. A brief overview of the code is presented, as well as how to obtain and run it. The input syntax for various parts of the code is provided. Additionally, a number of example problems, starting with simple unit component problems to problems with increasing complexity, are provided. Because the code is still under active development, this SAM User’s Guide will evolve with periodic updates.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Improvement and Verification of Online Cross Section Generation Capability of Griffin for TRISO-fueled Reactors

Griffin, a MOOSE-based reactor multiphysics code jointly developed by Idaho National Laboratory and Argonne National Laboratory under the DOE Office of Nuclear Energy’s NEAMS program, has pursued the development of an online multigroup cross section generation capability for a few years to enable high-fidelity, problem-dependent neutronics analyses of advanced thermal reactors. Recent advancements in Griffin’s online multigroup cross section generation capability have significantly improved the accuracy, robustness, and efficiency of self-shielding calculations for both prismatic and pebble-bed TRISO-fueled reactor applications. Key developments include a unified fuel self-shielding method applicable to both TRISO and annular compact/spherical shell fuel zone geometries; an advanced Dancoff Category-based Equivalence Theory using a bell function for non-fuel resonance treatment, achieving more than an order-of-magnitude speedup compared to the Tone method; an on-the-fly multigroup equivalence approach to mitigate group condensation errors; and a streaming correction method for pebble-bed homogenization. A proof-of-concept demonstration of on-the-fly group condensation with consistent P0 transport correction was also achieved. The method reproduced direct fine-group solutions with excellent accuracy (eigenvalue errors within 10 pcm and pin-power differences within 0.5%), but due to performance limitations of the current fixed-source solver, improvements to solver efficiency will be addressed in future work. Verification tests were performed on graphite-moderated TRISO-fueled two-dimensional core benchmark problems representing gas-cooled microreactors, heat pipe-cooled microreactors, gas-cooled pebble-bed reactors, and fluoride salt-cooled high-temperature reactors. Across all cases, Griffin showed excellent agreement with Serpent2 continuous energy Monte Carlo solutions: eigenvalue errors within 200 pcm, pin-power root-mean-square errors within 2%, and control rod and drum worth errors less than 2%. It should be noted that, for the benchmark problem, cross section generation contributed less than 3% of the total simulation times. These results demonstrate that Griffin’s online cross section generation capability delivers accurate and efficient reactor physics solutions across a wide spectrum of TRISO-fueled advanced reactor designs. With further improvements to the fine-group fixed-source solver and planned extensions to depletion, transients, and coupled neutron–gamma transport, Griffin will be well-positioned to become a powerful and comprehensive tool for advanced reactor analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Effects of Geometric Discontinuities on Creep Behavior of Alloy 617

Due to the excellent long-term high-temperature performance of Alloy 617, the Alloy has been identified as the primary structural material for the intermediate heat exchanger of the Very High Temperature Reactor (VHTR). Both the base and welded alloy has been qualified to be used up to 950 °C up to 100,000 hours by the American Society of Mechanical Engineer (ASME) Boiler and Pressure Vessel Code (BPVC). The qualification properties of the material were exclusively determined by uniaxial creep tests. The components may, however, experience multiaxial stress conditions in service due to the reactor geometry. This study used notched creep tests to investigate the effect of geometric discontinuities on creep behavior of both the base and welded Alloy 617. The V-notch tests reveal that the geometric discontinuities do not reduce the creep rupture live under high and intermediate stress conditions. The U-notch tests show that a larger radius notch behave in a similar way as a straight gauge section of a uniaxial test. The creep rupture live of the welded alloy was slightly longer than the base metal.

36 - MATERIALS SCIENCE↗

Process Heat for Chemical Industry

Process heating with nuclear energy can reduce greenhouse gas emissions by reducing combustion of fossil fuels in fired heaters as steam boilers. Light water reactors can replace the majority of steam duties used by industry; however, high temperature processes such as steam methane reforming require advanced high temperature reactors. Here, guidance on matching the scale of nuclear reactors with specific industries is provided. Principles of heat transport, temperature boosting, and substitution for hot combustion gases are also discussed in this section.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Assessment of BISON capabilities for component-level prediction of tritium transport in fusion and fission applications

Here we assessed the hydrogen migration and redistribution model implemented in the BISON fuel performance code for component-level tritium transport applications in fusion and fission example scenarios. We developed BISON models of an ITER heat exchanger, light water reactor fuel cladding, and a fluoride salt cooled high temperature reactor heat exchanger. Reasonable agreement between reported values in reference studies and BISON predictions demonstrated the ability of the BISON models to predict tritium transport behavior through steel materials. Next, sensitivity and uncertainty analysis was used to understand key parameter sensitivities within the BISON model for evaluation of tritium migration and redistribution. . The sensitivity analysis showed that the diffusivity activation energy was the most important parameter and that the heat of transport was the least important parameter for tritium migration in steels. Overall, the capabilities of the BISON code for component level modeling of tritium transport are promising.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Recent Improvements in Pronghorn for Advanced Reactor Modeling

Pronghorn is a thermal-hydraulics computational tool developed using the Idaho National Laboratory's Multiphysics Object-Oriented Simulation Environment (MOOSE). It is designed to support Computational Fluid Dynamics (CFD) modeling, ranging from subchannel and porous media analysis to Reynolds Averaged Navier-Stokes (RANS) turbulence modeling. As an integral part of the MOOSE-based suite of tools, Pronghorn seamlessly couples with other MOOSE-based applications to simulate a variety of physical phenomena. This article highlights recent significant enhancements to Pronghorn's CFD modeling capabilities and demonstrates their application to advanced nuclear reactor designs. The recent improvements in Pronghorn primarily focus on modifications to its turbulence modeling capabilities, near-wall corrections and numerical schemes. In terms of turbulence modeling, the two-equation $k-\epsilon$ and $k-\omega$ SST models have been implemented and validated with both equilibrium and non-equilibrium wall treatments. Additionally, corrections for wall roughness, and curvature, and wall-channeling in pebble beds have been introduced in the near-wall modeling. These developments enable more accurate simulations of advanced nuclear reactors. Two case studies are presented in this work: a pool-type Molten Chloride Reactor and a salt-cooled Pebble-Bed High Temperature Reactor. In both cases, the previous models in Pronghorn are compared with the new implementations, demonstrating the improved accuracy achieved with the updated models.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Irradiation-Induced Defect Evolution in Nuclear Graphite

Graphite has historically been used as a moderator material in nuclear reactor designs dating back to the first man-made nuclear reactor to achieve criticality (Chicago Pile 1) in 1942. Additionally, graphite is a candidate material for use in the future envisioned next-generation nuclear reactors (Gen IV); specifically, the molten-salt-cooled (MSR) and very-high-temperature reactor (VHTR) concepts. Gen IV reactor concepts will introduce material challenges as temperature regimes and reactor lifetimes are anticipated to far exceed those of earlier reactors. Irradiation-induced defect evolution is a fundamental response in nuclear graphite subjected to irradiation. These defects directly influence the many property changes of nuclear graphite subjected to displacing radiation; however, a comprehensive explanation for irradiation-induced dimensional change remains elusive. The objectives of this project were focused on the characterization of irradiation-induced defect evolution in nuclear graphite via transmission electron microscopy (TEM). With the use of novel TEM specimen preparation techniques, high-temperature electron-irradiation and characterization of high-temperature neutron-irradiated nuclear graphite, novel fullerene-like defects are shown to be a dominant defect type, especially at higher temperatures. These results contradict the historical models of defect evolution and provide valuable insight into the macroscopically observed property changes in irradiated nuclear graphite.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

On the thermal oxidation of nuclear graphite relevant to high-temperature gas cooled reactors

Thermal oxidation of nuclear graphite components is highly undesirable because it can cause structural and property degradation that negatively affect a reactor's intended operation. In this work, the body of knowledge of nuclear graphite oxidation is highlighted, including when O 2 , H 2 O, and/or CO 2 are the oxidant. Oxidation conditions relevant to high-temperature gas-cooled reactors (i.e., when oxidation could occur either as an acute or chronic phenomenon) are emphasized. Here, the objective is to summarize graphite oxidation data in a practical and accessible way to inform future research and regulatory requirements. Although each grade of nuclear graphite is different, the oxidation mechanism has underlying commonalities. Although oxidation behavior is grade dependent, the general temperature dependence is well described by a sequence of elementary steps which become rate limiting. Because the regime transition temperature depends on sample microstructure, size, and oxidant supply rate, extrapolating results beyond the experimental range should be done cautiously. Gravimetric oxidation rate measurements generally replicate well. However, caution must be exercised when rates are estimated by other methods or for samples that deviate significantly in size. Air oxidation data for IG-110, NBG-18, and PCEA graphite is critically reviewed to emphasize this point. Despite the amount of experimental data, gaps remain. Sample size and shape effects are not fully explained. Data on the oxidant penetration depth are insufficient. Analytical assessments demonstrate that lower temperature oxidation does not necessarily imply that oxidation is uniform throughout the bulk. Oxidation occurs faster at higher temperature but is more localized to the exposed surface. Paradoxically, at equal mass loss percentage, low temperature oxidation leads to greater property degradation than at high temperature. The isolated effect of oxidation is important; however, a gap remains in the systematic understanding of any potential effect of neutron irradiation on graphite structure and reactivity.

36 MATERIALS SCIENCE↗