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Idaho National Laboratory's Materials and Fuels Complex is well equipped for research, development, and demonstration of nuclear fuel designs and reactor components. The capabilities for fuels RD&D at MFC are briefly presented and the observation of fuel behavior that merit RD&D at MFC are introduced, with emphasis on metal fast reactor fuel.
This report from Idaho National Laboratory (INL) summarizes the key modeling and simulation activities conducted under the Department of Energy (DOE) Molten Salt Reactor (MSR) Campaign during the Fiscal Year 2023 (FY23). The focus of the work was to leverage state-of-the-art modeling capabilities from the DOE Nuclear Energy Advanced Modeling and Simulation (NEAMS) codes to enable novel multiphysics and multiscale modeling and simulation of MSRs. Through collaboration with NEAMS code developers, advanced multiphysics analysis capabilities for MSR systems were demonstrated by coupling depletion, thermal-hydraulics, and thermochemistry into an innovative framework for chemical species transport in MSRs. As a result, the framework can track nuclides throughout their lifetimes in the core, from production (depletion) to advection throughout the salt volume (thermal-hydraulics) and off-gassing or precipitation outside of the salt (thermochemistry). This work supports the near-term deployment of MSRs by integrating the synergistic efforts between the DOE’s MSR Campaign and NEAMS program. The resulting framework will help better connect system design modelers with experimentalists to better understand and predict complex physical behaviors in MSRs. Researchers and MSR developers alike can now leverage these new modeling and simulation capabilities to perform novel analyses with applications including: • MSR dynamics during normal operational transients and accident scenarios • Off-gas system design and performance for fuel cycle and depletion analysis • Corrosion and active chemistry control for reactor component health and lifetime determination • Source term, decay heat and activity determination in accident scenarios • Special nuclear material accountancy and chemical forensic analysis for safeguards • Digital twin development of experiments and experimental reactor demonstrations • Measurement requirements for instrumentation and control design • Uncertainty and sensitivity analysis of missing data to inform future experimental data collection.
Gamma doses were measured in the Zero Power Plutonium Reactor (ZPPR) to provide data for validation of calculations of gamma heating in important reactor components. Stainless steel-encapsulated LiF thermoluminescent dosimeters (TLDs) were irradiated in two configurations in ZPPR-15B and one configuration in ZPPR-15D to provide gamma heating data for the Integral Fast Reactor design in the mid-1980s. The ZPPR-15 experimental records were used to develop detailed as-built Monte Carlo models for the gamma dose measurements in ZPPR-15B and ZPPR-15D. These Monte Carlo models can be converted to deterministic models for calculations with deterministic codes. The reported uncertainty in the published gamma dose measurements is just the statistical uncertainty in the TLD readout. In addition to this statistical uncertainty in the TLD readout, several corrections and other factors contribute to the total uncertainty for the gamma dose measurements. The total uncertainty for the gamma dose measurements can be significantly larger than the published statistical uncertainty for the TLD readout. All known contributions to the total uncertainty were analyzed, and a total uncertainty was derived for the ZPPR-15 gamma dose measurements.
During operation and maintenance of the High Flux Isotope Reactor (HFIR), metal waste from reactor components is generated. Due to space limitations in the pool fuel storage, it is necessary to remove the waste and send it to off-site disposal. Most of this waste was in the reactor and is radioactive through neutron activation. Prior to shipping and disposal at a waste disposal facility, the radiological activity of the waste must be determined. Therefore, a conservative methodology to characterize the radiological activity of the waste must be performed. The methodology used was based on being able to determine a conservative overall activity and radionuclide inventory based on radiological survey data and neutron activation products for the materials present.
The Fe-Cr alloys with ultrafine microstructures are primary candidate materials for advanced nuclear reactor components because of their excellent high temperature strength and high resistance to radiation-induced damage such as embrittlement and swelling. Mainly two types of Fe-Cr alloys have been developed for the high temperature reactor applications: the quenched and tempered ferritic-martensitic (FM) steels hardened primarily by ultrafine laths and carbonitrides and the powder metallurgy-based nanostructured ferritic alloys (NFAs) by nanograin structure and nanoclusters. This paper aims at elucidating the differences and similarities in the temperature and strength dependences of fracture toughness in the Fe-Cr alloys to provide a comparative assessment of their high-temperature structural performance. The K JQ versus yield stress plots confirmed that the fracture toughness was inversely proportional to yield strength. It was found, however, that the toughness data for some NFAs were outside the band of the integrated dataset at given strength level, which indicates either a significant improvement or deterioration in mechanical properties due to fundamental changes in deformation and fracture mechanisms. When compared to the behavior of NFAs, the FM steels have shown much less strength dependence and formed narrow fracture toughness data bands at a significantly lower strength region. It appeared that at high temperatures ≥600 °C the NFAs cannot retain the nanostructure advantage of high strength and high toughness either by high-temperature embrittlement or by excessive loss of strength. Finally, irradiation studies have revealed, however, that the NFAs have much stronger radiation resistance than tempered martensitic steels, such as lower radiation-induced swelling, finer helium bubble formation, lower irradiation creep rate and reduced low temperature embrittlement.
Advanced small modular reactors (AdvSMRs) can contribute to safe, sustainable, and carbon-neutral energy production. However, the economics of AdvSMRs suffer from the loss of economy-of-scale for both construction and operation. The controllable day-to-day costs of AdvSMRs are expected to be dominated by operations and maintenance (O&M) costs. These expenses could potentially be managed through optimized scheduling of O&M activities for components, reactor modules, power blocks, and the full plant. Accurate, real-time risk assessment with integrated health monitoring of key active components can support scheduling of both online and offline inspection and maintenance activities.
The DOE Nuclear Energy Advanced Reactor Technologies (ART) Program has supported the creation of several databases with information describing the safety performance of fast reactors, components, and fuels. This growing collection of legacy experimental data, operating data, and analysis is available online to registered users. Metallography data is one of the most important types of PIE data being collected, organized and stored in several ART Fast Reactor Databases (https://frdb.ne.anl.gov), including the Fuels Irradiation & Physics Database (FIPD), Out-of-Pile Transient Database (OPTD), and TREAT (the Transient Reactor Test Facility) Experimental Relational Database (TREXR). These databases contain three main sets of metallography data. The first set is the metallography data from Experimental Breeder Reactor-II (EBR-II) and Fast Flux Test Facility (FFTF) irradiated fuel pins measured in the Hot Fuel Examination Facility (HFEF); the second set is the metallography data from EBR-II irradiated fuel pins measured in the Alpha-Gamma Hot Cell Facility (AGHCF); the third set is the metallography data from transient tested fuel pins (the transients tests include the out-of-pile tests and TREAT tests) measured in AGHCF. Since both the second and third sets of data were measured in AGHCF, they are governed by the same specification. The metallography data in the databases are digital images scanned from either positive or negative photos. The quality of the images, including their resolution and contrast, relies on the preserved quality of the pictures and the scanning conditions. To analyze the microstructure of a fuel pin, a series of preparatory steps must be undertaken. These include sectioning, epoxy mounting, mechanical grinding and polishing, and often etching. The resulting samples were then transferred to a secondary hot cell, or glovebox (depending the strength of radiation field) for microscopy examination. The specifications provided herein focus on the metallography examinations. The sample grinding, polishing and etching processes are also discussed. The procedures involving sectioning and epoxy mounting are out of the scope of the current specification; details can be found in the corresponding operation manuals. If more data are collected and added to the ART Fast Reactor Databases, this specification will be updated to accommodate the additional data.
Shielding design is an important part of the Versatile Test Reactor (VTR) design. Various shielding implementations are required to protect workers and reactor components from damaging radiation sources. The major radiation source in VTR during operation is the prompt neutron and photon emitted from nuclear fuel fissions as well as the activated structure and coolant. Shields are needed to protect the structures located inside the reactor vessel, such as the lower grid, the barrel wall, etc., in order to limit the degradation of the materials properties as a result of neutron damage (“displacement per atom”). Another early key challenge of shielding design for a pool-typed Sodium-cooled Fast Reactor (SFR) such as VTR is the activation of the secondary sodium as to flows through the intermediate heat exchangers (IHX). For a pool-typed SFR, the IHXs are placed in the primary sodium pool inside the reactor vessel. During operation, neutrons produced in the core can reach the IHXs due to the small absorption cross section of sodium and the large mean free path of fast neutrons. The secondary sodium gets activated inside the IHX and carries some of that activity outside of the reactor vessel. This source of radioactivity contained in the secondary sodium needs to be mitigated to meet the radiation dose limit sets for personnel working at the plant. This summary focuses on describing the work performed for the in-vessel shielding design and analysis aiming at limiting the secondary sodium activation.
Provide material solutions to enabling design, construction, licensing and operation of advanced reactors Including Fast Reactors, Gas-cooled Reactors and Molten Salt Reactors (solid or liquid fuel) Could be of modular or micro designs, and from hundreds of MWe to kWe Provide technical bases needed for design and licensing of advanced reactor components Develop & validate improved high temperature design methodology Provide qualification data (to NQA-1 or equivalent) on structural materials Utilize consensus standards when appropriate (e.g., ASME, ASTM, etc.) Target resolution of issues needed for near to mid-term deployment of advanced reactors
Chromium ions can make their way into the primary coolant of nuclear power reactors from the corrosion of stainless-steel reactor components, decreasing the material's corrosion resistance and resulting in increased transport of further corrosion products. Despite these potential effects, the radiation-induced redox speciation of chromium ions in aqueous solution is not well understood, especially at the elevated temperatures experienced by reactor coolants. Here, in the present work, we report new experimental results demonstrating that in aerated aqueous solution, the radiolytic oxidation of Cr(III) to Cr(VI) occurs at pH 4, while the reduction of Cr(VI) to Cr(III) occurs at pH 2. The oxidation of Cr(III) is primarily attributed to the reaction of the hydroxyl radical (˙OH) with the Cr(OH) 2+ species, while the reduction of Cr(VI) is attributed to reactions involving the hydrated electron (e aq - ) and hydrogen atom (H˙). Additionally, the steady-state equilibrium yield of Cr(VI) from the gamma irradiation of pH 4 Cr(III) solutions decreased with increasing temperature (over a range of 37–195 °C). This observation indicates that the activation energy of the Cr(VI) reduction reactions is higher than that for the Cr(III) oxidation reactions, such that it becomes relatively more favorable at higher temperatures. Overall, these data are important for the development of complementary multiscale models for the prediction of metal ion speciation in high temperature radiation environments.
The National Reactor Innovation Center (NRIC) has conceptualized the design of the Laboratory for Operation and Testing in the United States (LOTUS) test bed to provide the United States Department of Energy (DOE) with the infrastructure necessary to make advanced reactor designs available for commercial developers. LOTUS will provide a test bed to developers with the capabilities of supporting a wide range of experiment design possibilities. Upon completion of the developers’ operations and experiments within the test bed, the irradiated fuel, reactor components, and other experiment materials must be removed. Idaho National Laboratory (INL) possesses significant capabilities for radioactive material handling such as casks, carts, and forklifts. However, given the unique environment presented by the NRIC-LOTUS test bed, located inside the Zero Power Physics Reactor (ZPPR) Perimeter Intrusion Detection and Assessment System (PIDAS) area at the Materials and Fuels Complex (MFC) and the complexity of novel removal activities of recently operated reactor experiments through the new proposed access tunnel. The efficacy was not apparent for existing equipment to provide all the needed capability. To bridge the potential gaps in cask designs, storage, and transportation, NRIC requested the development of trade studies for the transfer, handling, and storage requirements of irradiated fuel salts and other radioactive materials. NRIC directed Boston Government Services, LLC (BGS) to perform the trade studies and develop a report analyzing alternatives. In addition to the BGS reports, the Idaho National Lab’s (INL), provided by the first potential user’s Advanced Reactor Development (ARD) team, prepared a feasibility study for the storage of specific irradiated fuel within the existing ZPPR vault.This summary report is intended to present the trade studies, options, and alternatives that were investigated. The maturity level of LOTUS, the reactor, fuel salt containers, gloveboxes, and reactor testing campaign and concept of operations were not at a level sufficient to base critical decisions on. This report is not intended to present a final recommendation. The final recommendations for fuel storage location, transport, handling equipment, and operations will be made in FY 2024 and will be based on known materials, test campaign requirements, funding, and final analysis of the fuel and equipment to be used.
The DOE Nuclear Energy Advanced Reactor Technologies (ART) Fast Reactor Program (FRP) has supported the development of several databases containing information on the safety performance of fast reactors, components, and fuels. This growing collection of legacy experimental data, operating data, and analysis is available online to registered users. Metallography data represents one of the most critical types of post-irradiation examination (PIE) data being collected, organized, and archived in several ART Fast Reactor Databases (https://frdb.ne.anl.gov), including the Metallic Fuels Irradiation & Physics Database (FIPD), Out-of-Pile Transient Database (OPTD), and TREAT (the Transient Reactor Test Facility) Experimental Relational Database (TREXR). These databases contain three principal sets of metallography data. The first set comprises metallography data from Experimental Breeder Reactor-II (EBR-II) and Fast Flux Test Facility (FFTF) irradiated fuel pins examined in the Hot Fuel Examination Facility (HFEF). The second set consists of metallography data from EBR-II irradiated fuel pins examined in the Alpha-Gamma Hot Cell Facility (AGHCF). The third set includes metallography data from transient-tested fuel pins (including both out-of-pile furnace tests and TREAT tests) examined in AGHCF. Since both the second and third sets were generated in AGHCF, they are governed by identical specifications. The metallography data in the databases consist of digital images scanned from either positive or negative photographic films. To analyze the microstructure of a fuel pin, a series of preparatory steps are required, including sectioning, epoxy mounting, mechanical grinding and polishing, and etching. Following sample preparation, specimens are transferred for metallographic examination. The AGHCF and HFEF metallography data were generated using optical microscopes manufactured by Leitz and Bausch and Lomb (B&L). Images were recorded on Polaroid film at preset magnifications. Magnification verification for the Leitz and B&L metallographs was conducted every two months prior to 1989 and at least every six months from 1989 through the conclusion of the IFR program. Magnifications determined from imaging of microslide standards were compared to the instrument settings for magnifications ranging from 50× to 500×. If the magnifications determined from standards deviated from the instrument settings, adjustments were made to the bellows extension until agreement was achieved. The specifications for AGHCF and HFEF legacy metallography data have been established based on available hard-copy and digital records, most of which have been incorporated into the data repositories associated with FIPD, OPTD, and TREXR. Detailed specifications including hard-copy records, digitized records, cutting diagrams and sectioning schemes, high-magnification photographs, photomosaics (composites), information tags, scale bars, and magnification verification procedures can be found in a separate report.
Molten salt reactors (MSRs) are innovative advanced nuclear reactors that utilize nuclear fuel by dissolving it in a high-temperature liquid salt. This unique feature differentiates MSRs from other types of reactors and allows for enhanced safety and economic performance. The liquid fuel also entails several multiphysics effects that can complicate reactor design and operation. One primary effect termed here as depletion-driven thermochemistry is a driving force in altering the multiphysics behavior of the reactor. Essentially, depletion-driven thermochemistry is the effect that fuel depletion has on changing the chemical redox potential of the fuel salt over time. As the fuel is consumed, the redox potential shifts toward a more oxidizing state. Without active control, the changing chemistry due to depletion increases corrosion thereby limiting reactor component lifetimes. Additionally, the changing redox potential of the fuel salt alters the vapor pressures of chemical species dissolved in the fuel salt. Changing vapor pressures of species in the fuel salt is an important parameter to understand when off-gassing volatile species during normal reactor operation, and for source term characterization during accident scenario transients. The present work represents a fundamental step toward modeling and coupling the driving physics (i.e., neutronics and chemistry) involved in altering the redox potential in an MSR. Here, the neutronic code Griffin models the depletion of the fuel-salt system, while the chemical equilibrium code Thermochimica calculates the thermochemical state of the isotopic inventory, using the Molten Salt Thermodynamic Database - Thermochemical (MSTDB-TC). These two codes are tightly coupled to predict the impact of fuel depletion in altering the chemistry in MSR systems. Redox potential control methods are discussed and can be modeled using this multiphysics approach. The vapor pressures of chemical species that could be extracted to an off-gas system, as determined by the reactor’s thermochemical state, are examined. The neutronics-chemistry coupling developed in this work is expected to have potential application for analyzing corrosion, source term evolution, and material safeguards in MSR systems. Lastly, suggestions for areas of further improvements of the models to expand these capabilities by incorporating other coupled physics effects is provided.
Approximately 19% of the electricity produced in the United States comes from nuclear power plants. Traditionally, nuclear power plants, as well as larger coal-fired plants, operate in a baseload manner at or near steady-state for prolonged periods of time. Smaller, more maneuverable plants, such as gas-fired plants, are dispatched to match electricity supply and demand above the capacity of the baseload plants. However, air quality concerns and CO2 emission standards has made the burning of fossil fuels less desirable, despite the current low cost of natural gas. Wind and solar photovoltaic (PV) power generation are attractive options due to their lack of carbon footprint and falling capital costs. Yet, these renewable energy sources suffer from inherent intermittency. This inherent intermittency can strain electric grids, forcing carbon-based and nuclear sources of energy to operate in a load follow mode. For nuclear reactors, load follow operation can be undesirable due to the associated thermal and mechanical stresses placed on the fuel and other reactor components. Various methods of Thermal Energy Storage (TES) can be coupled to nuclear (or renewable) power sources to help absorb grid variability caused by daily load demand changes and renewable intermittency. Our previous research has shown that coupling a sensible heat TES system to a Small Modular Reactor (SMR) allows the reactor to run at effectively nominal full power during periods of variable electric demand by bypassing steam to the TES system during periods of excess capacity. In this study we demonstrate that this stored thermal energy can be recovered, allowing the TES system to act as a peaking unit during periods of high electric demand, or used to produce steam for ancillary applications such as desalination. For both applications the reactor is capable of operating continuously at approximately 100% power.
The increased penetration of intermittent renewable energy technologies such as wind and solar power can strain electric grids, forcing carbon-based and nuclear sources of energy to operate in a load follow mode. For nuclear reactors, load follow operation can be undesirable due to the associated thermal and mechanical stresses placed on the fuel and other reactor components. Various methods of Thermal Energy Storage (TES) can be coupled to nuclear (or renewable) power sources to help absorb grid variability caused by daily load demand changes and renewable intermittency. Two TES techniques are investigated as candidate thermal reservoirs to be used in conjunction with a Small Modular Reactor (SMR): a two-tank sensible heat storage system and a stratified chilled-water storage system. The goal when coupling the two systems to the SMR is to match turbine output and demand and bypass steam to the TES systems to maintain reactor power at approximately 100%. Simulations of IPWR dynamics are run in a high-fidelity FORTRAN model developed at NCSU. Both TES systems are developed as callable FORTRAN subroutines to model the time-varying behavior associated with different configurations of these systems when connected to the SMR simulator. Simulation results reveal the sensible heat storage system is capable of meeting turbine demand and maintaining reactor power constant, while providing enough steam to power four absorption chillers for chilled-water production and storage. Here,the stored chilled water is used to supplement cooling loads of an adjacent facility.
This report summarizes the current state of modeling and simulation methods for predicting the initial structure and properties of material in components assembled using advanced manufacturing technologies (AMTs). The report is the first volume in a two-volume series. This first volume focuses on predicting initial microstructures of AM material. The second volume discusses predicting material properties given the initial microstructure. The focus is on technologies of particular relevance to the design and manufacture of nuclear reactor components. The purpose of the report is to help develop the technical knowledge base to support regulatory decisions that will be needed to assess nuclear components manufactured with AMTs as these components are installed at nuclear power plants (NPPs). The report develops a list of AMTs of particular interest to the NRC and summarizes the key microstructural features and corresponding processing parameters relevant to each technology. Further sections describe available physically-based and data-driven prediction methods and survey widely available software tools. The report concludes with a summary of gaps that may be of particular interest to the NRC when evaluating modeling and simulation methods for AMTs.
Swelling, or volumetric expansion, is an inevitable consequence of the atomic displacement damage in crystalline silicon carbide (SiC) caused by energetic neutron irradiation. Because of its steep temperature and dose dependence, understanding swelling is essential for designing SiC-based components for nuclear applications. Here in this study, swelling behaviors of monolithic CVD SiC and nuclear grade SiC fiber – SiC matrix (SiC/SiC) composites were accurately determined, supported by the irradiation temperature determination for individual samples, following neutron irradiation within the lower transition swelling temperature regime. Slightly anisotropic swelling behaviors were found for the SiC/SiC samples and attributed primarily to the combined effects of the pre-existing microcracking, fiber architecture, and specimen dimension. A semi-empirical model of SiC swelling was calibrated and presented. Finally, implications of the refined model to selected swelling-related issues for SiC-based nuclar reactor components are discussed.
Recently, there has been renewed interest in the Molten Salt Reactor (MSR) concept. This interest is mainly due to its advantages over Light Water Reactors (LWRs). Among these advantages are the flexibility in the fuel choice and the possibility to burn actinides [1]. Currently, two molten research reactors are under development. A 2 MW molten salt experimental reactor has been constructed and is planned for operation in China. A 1 MW Molten Salt Research Reactor is under construction in the United States [2]. Thus, Research and Development (R&D) programs are needed for the MSR technology. Reactor dynamics studies are crucial safety evaluation studies. The development of reactor dynamics tools for MSRs started during the Molten Salt Reactor Program (MSRP) at ORNL, focusing on the Molten Salt Reactor Experiment (MSRE) [3]. Although various dynamic simulation tools are available, R&D efforts to develop specialized tools for MSRs are still ongoing [4]. The primary motivation for this interest is the goal of commercializing MSRs. Developing a dynamics tool for MSRs is crucial for analyzing their safety and supporting their demonstration efforts. A crucial safety issue in MSRs is ensuring that the fuel salt in the primary loop remains molten. This concern becomes particularly important when the reactor operates at lower power levels. Most chloride and fluoride salts used as fuel have a melting point of approximately 450 °C [5]. Therefore, maintaining fuel salt temperatures above this melting point is essential to prevent it from freezing. Freezing of the fuel salt can lead to volume expansion, potentially causing damage to reactor components [6]. Moreover, it can create local blockages within fuel salt channels, reducing cooling efficiency and resulting in hot spots [7]. Various methods can prevent fuel salt from freezing at low power levels. These include reducing the fuel mass flow rate in the primary loop, decreasing heat exchange between the primary and secondary loops in the reactor, and using electric fuel salt heaters. Reducing the mass flow rate of fuel salt in the primary loop can increase the fuel salt transit time in the core, enhancing heat production and increasing temperature. However, it can potentially lead to challenges. These include increasing the potential for fuel salt deposition on the reactor channel walls [8], affecting the overall heat transfer processes. Thus, alternative methods should be used [9]. This research investigates the effects of fuel salt heaters on the dynamics and stability during MSR operation. The investigation includes studying the reactor stability with the fuel salt heaters on and off. In addition, the reactor response to transients is compared with and without the operation of fuel salt heaters. These transients include reactivity insertion, primary and secondary pump failure, and heat sink temperature increase. The results of the reactivity insertion transient are presented in the summary.