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At least 145 records · Page 8

Accelerated thermal property mapping of TRISO advanced nuclear fuel

TRistructural ISOtropic (TRISO) fuel is a leading-edge nuclear fuel form representing a departure from the more traditional nuclear fuel forms utilized in the reactor fleet of today. Rather than a monolithic fuel pellet of uranium dioxide, integral fuel forms containing TRISO fuel are composed of thousands of microencapsulated uranium-bearing fuel kernels and individually coated with multiple layers of pyrolytic carbon and silicon carbide. These multilayered ceramic coatings serve as an environmental barrier to ensure radioactive and chemically reactive fission products are contained within the reactor fuel elements, but also participate in the transfer of heat generated in the nuclear fuel to the coolant – the primary purpose of a nuclear reactor. Since traditional thermal property measurement techniques, such as laser flash analysis, would be unable to resolve the thermal properties of the individual TRISO coating layers, a simplified frequency-domain thermoreflectance technique has been developed to rapidly map the thermal properties of TRISO particles. Using this technique, the thermal properties of TRISO particles have been mapped from room temperature up to 1000 °C to examine the spatial variation and temperature-dependency of the thermal properties within each layer. Additionally, spatial-domain thermoreflectance was used to examine the anisotropy of the thermal properties for each layer at different locations within a single TRISO particle, and across multiple TRISO particles to assess the intra- and inter-particle uniformity of thermal properties, respectively. To elucidate the underlying causes for the measured variations in thermal properties, scanning electron microscopy and Raman spectroscopy were used to examine variations in microstructure and chemical bonding within the different coating layers. Results from this work are then compared with previous examinations of TRISO fuel particles and microstructurally driven mechanisms for the variations in the measured thermal properties of the different carbonaceous layers are discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Irradiation Performance: High-Temperature Gas Reactor Fuels

The response of TRISO fuel under irradiation is complex and dictated by the integrated nature of all components which define the TRISO fuel architecture. Potential failure mechanisms have been well understood and iterative improvements to the TRISO fuel architecture have been made to ensure optimized performance for different reactor designs. Ultimately, modern TRISO fuel for HTGR applications has exceeded performance targets.

Gerczak, Tyler↗

Microstructural heterogeneity of the buffer layer of TRISO nuclear fuel particles

Tristructural isotropic (TRISO) nuclear fuel particles contain a layered spherical shell designed to retain fission products; however, failure occurs in rare cases—commonly initiated in the porous pyrocarbon buffer layer. Achieving a comprehensive understanding of the buffer-initiated failure mechanisms requires detailed characterization of the buffer porosity and its heterogeneous distribution across multiple length scales. Here we performed FIB-SEM tomography across the buffer layer thickness (~100 µm) to produce 3D reconstructions of the buffer microstructure with 50 nm spatial resolution. We found an average overall porosity of ~14%, which does not solely account for the low density of the buffer (50% of the theoretical density). Additionally, the local porosity and its fluctuation increase from the kernel interface towards the inner pyrocarbon (IPyC) layer, which we attribute to the chemical vapor deposition process conditions during the TRISO particle fabrication. Detailed characterization of the porous microstructure—including analysis of the pore size, distribution, shape, and orientation—provides insight into the process-structure-property-performance relations of TRISO nuclear fuel particles and will inform multiscale models designed to predict the failure of TRISO particles under irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

High volume packing fraction TRISO-based fuel in light water reactors

We report that for a decade, fully ceramic microencapsulated (FCM) fuel, containing tri-structural isotropic (TRISO) fuel particles in a silicon carbide (SiC) matrix, has been investigated as an accident-tolerant fuel for light water reactors (LWRs). Other examples exist of TRISO-based concepts for LWR fuels with different matrix materials. Previous studies assumed TRISO particle volume packing of approximately 0.44 in SiC (or another) matrix, the highest realistic packing fractions possible with conventional manufacturing. Recent advances in advanced manufacturing have yielded the development and demonstration of a fuel form that consists of conventionally manufactured TRISO particles in a 3D-printed SiC matrix with significantly higher possible TRISO packing fractions (0.5–0.7). This increased uranium loading enhances the viability of using TRISO-based particle fuel forms in LWRs. The viability of high-packing-fraction TRISO-based particle fuel forms in LWRs is assessed from the perspective of fuel cycle length, achievable fuel burnup, reactivity coefficients, and fuel cycle performance. Higher-packing-fraction TRISO-based fuel enables either longer cycle lengths (by ~25% at a packing fraction of 0.55 relative to 0.44) at a constant enrichment or decreased enrichments (by ~25% at a packing fraction of 0.55 relative to 0.44) at a constant cycle length. Studies of different fuel kernel types (uranium nitride, uranium oxycarbide, and uranium carbide) yield similar results, although the cycle length of uranium oxycarbide is shorter than for uranium nitride or uranium carbide (due to the lower density of uranium oxide). This work also characterized the production of 14 C resulting from neutron absorption in 14 N during operation for uranium mononitride fuel kernels; the ratio of 14 C/N was 1–2 at. % at discharge. For the fuel cycle evaluation, the activity of spent nuclear fuel and high-level waste at 100 and 100,000 years was lower for high-packing-fraction fuels than for conventional LWR fuel. Environmental impact metrics were similar overall, but higher on the front end of the fuel cycle and lower on the back end of the fuel cycle. Reactivity coefficients of higher-packing-fraction TRISO-based fuel were reasonable compared with those of conventional fuels.

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Fuel performance analysis of fully-resolved TRISO compact

The TRi-structural ISOtropic (TRISO) fuel multilayered coating structure offers multiple barriers to fission product release, enhancing safety and performance. The heterogeneous nature of TRISO fuel compacts, comprising thousands of randomly distributed coated fuel particles embedded in a graphite matrix, creates intricate stress fields and thermal gradients that cannot be accurately modeled using simplified one-dimensional or homogenized approaches. Consequently, three-dimensional modeling enables the prediction of fuel compact dimensional changes, internal pressure buildup, and fission product transport pathways under diverse irradiation and thermal conditions. This capability facilitates detailed analysis of particle-to-particle interactions, matrix cracking mechanisms, and the statistical distribution of coating failures, which directly impact fuel performance and safety margins. This capability is particularly critical for advanced reactors, such as high-temperature gas-cooled reactors and other Generation IV reactor designs where TRISO fuel operates at elevated temperatures and burn-up levels. This work introduces a novel method to generate an optimized packing of TRISO compacts and a complete 3D mesh with random distribution of TRISO particles, which are discretized into each coating component layer.

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Survey of Uranium Nitride and Mixed Oxide Fuels for Microreactor Applications

Different fuel systems are being proposed for use in microreactors including TRISO fuel and metallic U-Zr based fuel. TRISO fuel is considered the main fuel option for most of the industry teams. Given the need for compact size core and potential for long fuel life of a microreactor, high density fuels such as metallic and nitride fuels are potential options. Of interest here is the uranium nitride (UN) option, which can allow for higher fissile material content and higher thermal conductivity compared to conventional uranium oxide fuel, and also has higher melting temperature compared to metallic fuel. Meanwhile, the current availability is limited for high assay low enriched uranium (HALEU) that is needed for high density fuels, which motivates the consideration of using Pu as a potential replacement for HALEU until adequate production capacity is in place. Current Pu availability is mainly attributed to the inventory of excess weapons Pu rather than through reprocessing of spent nuclear fuel. This inventory of excess Pu can be used in both metallic and oxide fuel systems to replace HALEU. Of interest here, the oxide form, that is the mixed oxide form of PuO 2 and UO 2 (MOX). In this report, the options of using UN or MOX, in both pellet and TRISO fuel forms, in microreactors are evaluated in relation to their properties, fuel performance and irradiation data, as well as fabrication. Gaps related to those areas are identified for both fuel systems, to guide future activities by DOE programs such as the advanced fuels campaign (AFC), to enable their use in microreactors.

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The Use of High-Density UN Fuel in Heat-Pipe Microreactors

Heat-pipe microreactors (HPMRs) are very small-scale nuclear reactors that employ heat pipes (HPs) for heat removal. HPMRs can be easily integrated with other forms of renewable energies, can be used for emergency responses to disaster relief zones, can be deployed in remote locations not connected to the grid, and can be removed from sites and replaced by new ones. HPMRs can also be used for space missions as HPs do not rely on gravity for heat transfer. Conventional fuel materials, such as uranium oxide (UO 2 ) and uranium oxycarbide (UCO), are currently considered in most existing HPMR designs, but ceramic uranium nitride (UN) fuel that has high uranium density, high thermal conductivity, and high melting point may become a better fuel candidate. Through neutronics calculations, this paper assesses the impact of using UN fuel in HPMRs with two different neutron spectra (fast and thermal) and two different fuel forms [traditional solid fuel pellets and TRi-structural-ISOtropic (TRISO) fuel compacts]. It was concluded that retrofitting HPMRs with UN fuel has the potential to reduce the initial 235 U enrichment requirement by ~3 wt% (to keep the same cycle length) or increase the cycle length (by keeping the same initial 235 U enrichment), which enables more compact and transportable HPMR core designs. However, using UN fuel decreases the control element worth [by up to 20% for the Special Purpose Reactor (SPR) and 5% for HP-MR] and is up to 80% more costly. Increasing 15 N enrichment can further decrease the initial 235 U enrichment requirement and increase the control element worth but is more costly. In conclusion, compared to fast-spectrum HPMRs fueled with solid pellet fuels, retrofitting UN fuel is more suitable for thermal-spectrum HPMRs fueled with TRISO fuel compacts, where the neutron spectrum hardening caused by using UN is less significant.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Development of a BISON validation case for the TRISO transient irradiations in NSRR using effective heat capacity methods

The current tristructural isotropic (TRISO) fuel assessment and validation database in BISON primarily covers steady- state irradiation and high-temperature furnace testing. Transient assessment cases are potentially needed to support U.S. industry efforts in designing and deploying commercial reactors using TRISO fuels. Historical transient tests in- volving TRISO fuels used highly conservative conditions compared to the typical high-temperature gas-cooled reactor accident scenarios. Despite this, modeling historical transient tests is fundamental for evaluating BISON’s predictive capabilities, adapting material properties for high-temperature and high-particle-power regimes, and developing a sys- tematic validation approach for TRISO transient applications. This work developed a 1D model of transient experiments carried out at the Nuclear Safety Research Reactor using BISON. BISON’s predictions of energy deposition, UO 2 melting onset, and molten volume fractions are compared against experimental measurements. Melting was modeled using an effective specific heat capacity model for UO 2 . We found that BISON’s predictions are in reasonable agreement with experimental data for low-energy-deposition cases, and that BISON overpredicts melting at higher energy depositions. We also discuss the potential causes of discrepancies between the simulated and measured results and propose ways to further develop the model. Although these simulations used conservative conditions compared to those expected for actual TRISO-fueled reactors, they extended the range of conditions reflected in the data in the existing BISON database for TRISO fuels.

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Seeing through nuclear fuel: Three-dimensional, nondestructive X-ray microscopy and volumetric analyses of neutron-irradiated TRISO-coated fuel kernels

The three-dimensional (3D) characterization of nuclear fuel with X-ray microscopy has historically proven difficult, due to uranium’s high attenuation of easily accessible X-rays, both in a laboratory setting and at a synchrotron user facility. However, this imaging modality provides nondestructive information that can be used to investigate morphological changes arising from external stimuli (e.g., neutron irradiation, high-temperature testing). Using an appropriate X-ray energy spectrum and an adequate X-ray filter, suitable transmissions through properly sized nuclear fuel specimens can be achieved. Here, in this study, we present the methods and results of using a commercially available, laboratory-based X-ray microscope (XRM) to examine the extent of 3D morphological changes of tristructural isotropic (TRISO)-coated fuel particles, specifically uranium oxide/uranium carbide fuel kernels, after high-temperature neutron irradiation.

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UN-SiC TRISO Post Irradiation Examination Developmental Work

As part of efforts to strengthen INL?s post irradiation analysis capabilities with non-Advanced Gas Reactor (AGR) tristructural isotropic (TRISO) fuels, two developmental activities were conducted. The first activity was to determine how best to analyze uranium nitride TRISO fuel kernels using electron probe microanalysis, while the second activity focused on developing a method to deconsolidate TRISO fuel particles that have been encased in a silicon carbide matrix. Because these two activities were unrelated, they have been presented separately in this report. Initial EPMA analyses showed nitrogen contents that far exceeded the concentration expected for UN--a line compound. Further examination showed that current literature values for the mass absorption coefficient (MAC) for the N ka X-ray absorbed by U ranged from approximately 1600 to 9500, with most values tending toward 9500. Measuring UN with five different progressively increasing accelerating voltages followed by using the modeling program xMAC suggests the actual MAC is approximately 2115. Additional MAC modifications were required to produce reasonable analytical results. Because of the inaccuracies of necessary MAC coefficients, UN analysis via scanning electron microscopy (SEM) is likely to produce inaccurate results. This is because SEM software does not typically allow the user to alter MACs. Tests have been performed to examine the feasibility of an electrochemical technique to liberate irradiated TRISO fuel from a SiC matrix without damaging the outer pyrolytic carbon layer of the fuel particle. The method is performed by electrochemically exposing the SiC to magnesium metal forming Mg2Si and C. Following exposure, the small SiC samples showed slight mass increases with no evidence of conversion to Mg2Si and C nor obvious degradation of the SiC samples.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

An Assessment of Applying Pyroprocessing Technology to Advanced Pebble-Type Fuels

With an expected increased demand for high-assay low enriched uranium (HALEU) to supply advanced reactors, the possibility of recovering actinides from various used nuclear fuels (UNF) is being reassessed. Pebble-type fuels such as tristructural isotropic (TRISO) fuel are intended to be directly disposed after use, but the HALEU remaining in each pebble is a resource with increasing value. An economically feasible recovery strategy would maximize the amount of HALEU recovered for reuse in new fuel without increasing the waste volume relative to the direct disposal of used TRISO fuel. We are evaluating the technical feasibility of recycling TRISO or pebble fuels to recover actinides for reuse as new fuel for advanced reactors by using pyrochemical methods.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

An Assessment of Applying Pyroprocessing Technology to Advanced Pebble-Type Fuels

With an expected increased demand for high-assay low enriched uranium (HALEU) to supply advanced reactors, the possibility of recovering actinides from various used nuclear fuels (UNF) is being re-assessed. Pebble-type fuels such as tristructural isotropic (TRISO) fuel are intended to be directly disposed after use, but the HALEU remaining in each pebble is a resource with increasing value. An economically feasible recovery strategy would maximize the amount of HALEU recovered for reuse in new fuel without increasing the waste volume relative to the direct disposal of used TRISO fuel. We are evaluating the technical feasibility of recycling TRISO or pebble fuels to recover actinides for reuse as new fuel for advanced reactors by using pyrochemical methods.

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Concept of Operations for Advanced Reactor Spent Nuclear Fuel Management

This presentation presents a preliminary description of a concept of operations to incorporate advanced-reactor spent nuclear fuel (SNF) into an integrated waste-management system (IWMS). The evaluation includes SNF from four advanced-reactor concepts with the following fuel types: (1) small modular reactors using oxide fuels, (2) tristructural-isotropic (TRISO) fuels, (3) metallic fuels, and (4) fuel salts. To provide context for the proposed concept of operations for advanced reactors, a comparison is made with traditional light-water reactors (LWRs) to identify potential gaps in the IWMS. The technical differences between advanced reactors and LWRs are assessed to determine the feasibility of managing advanced-reactor waste streams using existing operations and technology. This presentation emphasizes fuel types from Advanced Reactor Demonstration Program reactors: Xe 100, which uses TRISO fuel and Natrium, with its metallic fuels while also analyzing management options for molten-salt reactors and advanced light-water reactors (ALWRs). Understanding the storage, transportation, and disposal requirements of SNF is dependent on both the quantity and characteristics of the SNF generated by nuclear reactors. This presentation provides a high level overview, comparing the anticipated concept of operations for different SNFs from advanced reactors. The IWMS includes at-reactor storage, transportation, potential off-site storage, potential treatment, and disposition. To assess the potential effect of advanced-reactor concept of operations on the IWMS, estimates were made for fuel characteristics that contribute to storage, transportation, disposal, and possible treatment of advanced-reactor SNF. These include canister heat load, dose rates, and criticality-control limits, which are important for determining the condition and configuration of the advanced reactor SNF. At-reactor storage of LWR SNF traditionally involves a spent-fuel pool (SFP) before transfer to an independent spent-fuel storage installation. However, some advanced-reactor concepts, particularly those using TRISO and salt fuels, do not anticipate the use of an SFP. This difference in at-reactor storage could impact the IWMS. Additionally, transportation of advanced-reactor SNF may include additional processes tied to potential off gassing, and transportation of microreactor SNF may occur within the reactor vessel. Some advanced-reactor SNF could also undergo treatment to meet requirements of an acceptable waste form for disposition, and the treatment location will be a major contributor to efficiently performing IWMS responsibilities. Moreover, the quantity of SNF generated is an important consideration for IWMS because it could affect the size of the transportation fleet and potential off-site storage requirements. Additionally, volume and heat load are the primary drivers for SNF disposition. This presentation compares potential packaging options for advanced reactor SNF with traditional LWR packaging to provide a high-level comparison for the needs of the IWMS for advanced-reactor SNF.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Understanding Model Inadequacy in TRISO Nuclear Fuel Fission Products Release Models: Empirical and Mechanistic Approaches

The increasing use of tristructural isotropic (TRISO) particle fuel in both advanced and existing reactors necessitates a thorough evaluation of uncertainties and shortcomings in TRISO fission product release models. These inadequacies arise from the simplifications made in computational models compared to experimental data. Utilizing the BISON fuel performance code and experimental data from the Advanced Gas Reactor (AGR) program provides a unique chance to rigorously assess these inadequacies within a Bayesian uncertainty quantification (UQ) framework. This study contrasts the standard Bayesian framework with the Kennedy-O'Hagan (KOH) framework, which explicitly accounts for modeling inadequacies, in the context of UQ for TRISO silver release models. It examines both the traditional Arrhenius equation and a more advanced lower-length-scale (LLS)-informed model that incorporates microstructure information. The inverse UQ process applied to AGR-2 and AGR-3/4 datasets identified modeling inadequacy as the primary source of uncertainty, with experimental noise also being significant, while model parameter uncertainty was minimal. Both the Arrhenius and LLS-informed models showed similar levels of modeling inadequacy. For forward predictive UQ using the AGR-1 dataset, the KOH framework enhanced the accuracy and quality of quantified uncertainties by approximately 30% and 40%, respectively, compared to the standard Bayesian framework. This improvement was observed for both the Arrhenius and LLS-informed models. At the engineering scale, both models performed similarly, but the LLS-informed model outperformed the Arrhenius equation at the mesoscale. These findings underscore the importance of explicitly considering modeling inadequacy in the UQ process and highlight the need for ongoing refinement of physics-based models to address these shortcomings.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Development of a TRISO assessment case for BISON based on transient experiments in the NSRR

The tristructural isotropic (TRISO) fuel assessment and validation database currently available in BISON is based mainly on steady-state irradiation and high-temperature furnace testing. Transient assessment cases are needed to support ongoing U.S. industry efforts to design and deploy commercial reactors that utilize TRISO fuels. Most available historical transient tests involving TRISO fuels were characterized by power densities, temperatures, and energy depositions that were highly conservative with respect to typical high-temperature gas-cooled reactor (HTGR) accident conditions. Nonetheless, assessment of BISON's predictive capabilities, adaptation of material properties toward high-temperature and high-particle-power regimes, and development of a systematic approach to validating BISON for TRISO transient applications now motivate the modeling of historical transient tests. This work describes the development of 1-D thermal models of transient experiments conducted at the Nuclear Safety Research Reactor (NSRR) in Japan, with BISON predictions of energy deposition, UO2 melting onset, and molten volume fractions being compared against experimental measurements. Melting is accounted for by defining an effective specific heat capacity for UO2—one that leverages the material's heat of melting. BISON's predictions of energy deposition and molten volume fraction are in good agreement with the experimental data from the low-energy-deposition tests; however, BISON tends to overpredict melting at higher energy depositions. Though overly conservative compared to the operating conditions expected for near-term TRISO-fueled reactor applications, these simulations effectively exercise BISON TRISO models over a wider range of conditions than those encompassed by the existing assessment database. Potential contributors to the observed discrepancies are noted and additional future developments proposed.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Assessment of buffer-IPyC thermomechanical debonding behavior using new experimental strength data in BISON

TRIstructural ISOtropic (TRISO) fuel is a nuclear fuel commonly used in High Temperature Gas-cooled Reactors (HTGRs). A single sub-millimeter-diameter TRISO fuel particle consists of a spherical fuel kernel surrounded by four coating layers: a low-density pyrocarbon buffer layer, an inner pyrolytic carbon (IPyC) layer, a silicon carbide (SiC) layer, and an outer pyrolytic carbon (OPyC) layer. The kernel is commonly made of UO2 or a mixture of uranium carbide and uranium oxide (UCO). During reactor operation, the TRISO coating layers are subjected to irradiation-induced dimensional changes and the associated thermomechanical behavior of each layer. One of the observed behaviors is gap formation between the buffer and IPyC layer due to the porous buffer’s irradiation-induced shrinkage exceeding that of the IPyC layer. Not all irradiated particles will experience buffer-IPyC gap formation. The debonding may be partial, or it may be nearly total. However, from post-irradiation examination of UCO TRISO fuels irradiated as part of the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program, it was concluded that partial buffer-IPyC debonding was the most common type of buffer-IPyC interaction. To predict TRISO thermomechanical performance, multi-physics models have been built that are being continually updated and refined. The BISON code is a finite element-based nuclear fuel performance code that may be used for 1D, 2D, and 3D TRISO particle simulations. This code is used to calculate fuel temperature, kernel swelling, buffer densification, thermal and irradiation creep, fracture, and fission gas production and release. One of the recent additions to the BISON code is the ability to model the process of layer debonding. This paper will focus on the simulation results of the improved BISON debonding model that will utilize updated strengths measured from irradiated AGR TRISO fuel particles. The new experimental strength data from micromechanical tests of irradiated TRISO fuel samples were exercised in the BISON simulations and compared to baseline strength data to assess their applicability in the models. This also includes updated buffer-IPyC bond strengths to simulate layer delamination. Based on current experimental observations it is noted that the buffer-IPyC separation occurs not exactly at the junction of these two layers, but more on the side of the buffer layer. That observation is also implemented in the TRISO interface debonding model. This improved modeling approach using experimental strength data to characterize buffer-IPyC debonding and its potential subsequent cracking will be presented in the paper along with comparisons to available experimental observations.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Methods and Usability Enhancements in Shift for Non-LWR Applications

Several development and analysis tasks were undertaken in FY21 under the Nuclear Energy Advanced Modeling and Simulation program to enhance modeling of non light–water reactors (LWRs) with Shift. Specifically, these efforts targeted enhancements for tristructural isotropic (TRISO) fuel modeling. A new Shift user interface was developed that allows for much better usability and ease of modeling for non-LWR problems and TRISO fuel. Performance studies were conducted using an HTR-10 fuel pebble model by comparing different geometry packages in Shift, KENO-VI, and Serpent. These studies showed that the new geometry package in Shift performs well compared to Serpent for TRISO fuel modeling with consistent tracking options between both packages. The studies also identified the most critical areas of improvement for more efficiently performing Monte Carlo transport on TRISO fuel models with Shift. Tally calculations in Shift were optimized for non-LWR cross section generation and depletion calculations, and areas for further optimization and accuracy improvements were identified. Finally, initial collaboration efforts were formed between Idaho National Laboratory, Argonne National Laboratory, and the Nuclear Regulatory Commission to use Shift for Comprehensive Reactor Analysis Bundle support.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗