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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Understanding the interplay between pilot fuel mixing and auto-ignition chemistry in hydrogen-enriched environment

The diesel-piloted dual-fuel compression ignition combustion strategy is well-suited to accelerate the decarbonization of transportation by adopting hydrogen as a renewable energy carrier into the existing internal combustion engine with minimal engine modifications. Despite the simplicity of engine modification, many questions remain unanswered regarding the optimal pilot injection strategy for reliable ignition with minimum pilot fuel consumption. The present study uses a single-cylinder heavy-duty optical engine to explore the phenomenology and underlying mechanisms governing the pilot fuel ignition and the subsequent combustion of a premixed hydrogen-air charge. The engine is operated in a dual-fuel mode with hydrogen premixed into the engine intake charge with a direct pilot injection of n-heptane as a diesel pilot fuel surrogate. Optical diagnostics used to visualize in-cylinder combustion phenomena include high-speed IR imaging of the pilot fuel spray evolution as well as high-speed HCHO* and OH* chemiluminescence as indicators of low-temperature and high-temperature heat release, respectively. Three pilot injection strategies are compared to explore the effects of pilot fuel mass, injection pressure, and injection duration on the probability and repeatability of successful ignition. The thermodynamic and imaging data analysis supported by zero-dimensional chemical kinetics simulations revealed a complex interplay between the physical and chemical processes governing the pilot fuel ignition process in a hydrogen containing charge. Hydrogen strongly inhibits the ignition of pilot fuel mixtures and therefore requires longer injection duration to create zones with sufficiently high pilot fuel concentration for successful ignition. Results show that ignition typically tends to rely on stochastic pockets with high pilot fuel concentration, which results in poor repeatability of combustion and frequent misfiring. In conclusion, this work has improved the understanding on how the unique chemical properties of hydrogen pose a challenge for maximization of hydrogen’s energy share in hydrogen dual-fuel engines and highlights a potential mitigation pathway.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Impact of Selected High-Performance Fuel Blends on Three-Way Catalyst Light Off under Synthetic Spark-Ignition Engine-Exhaust Conditions

The U.S. Department of Energy funded Co-Optimization of Fuels and Engines initiative aims to simultaneously develop advanced engines along with high-performance fuels to reduce petroleum consumption. The engine exhaust of spark-ignited light-duty vehicles contains pollutants such as nitrogen oxides, carbon monoxide (CO), and non-methane organic gases. When operated above their “light-off” temperature, three-way catalysts (TWCs) efficiently control the emissions of these pollutants from the vehicle exhaust. However, below the catalyst light-off temperature, during cold start, the TWCs are not effective. Thus, the stringent environmental regulations necessitate cold-start compliance of advanced engines operating on novel fuels for commercialization. Exhaust composition strongly impacts the effectiveness of TWCs. Hence, ensuring that the high-performance fuels under consideration do not have detrimental effects on current emissions control technology is necessary. To mitigate cold-start emissions, a low light-off temperature of the fuel on the TWC is desirable. As real-world fuels are multicomponent blends, we conducted investigations into the light-off behavior of representative fuel mixtures on a three-mode redox-aged commercial TWC under synthetic engine-exhaust conditions. The high-performance fuels in this study included 10–30% volumetric levels of ethanol, isobutanol, diisobutylene, and an aromatic mixture. Each of these high-performance fuel components was mixed into a gasoline surrogate blendstock for oxygenate blending (BOB). Our results showed that aromatics and alkenes in the surrogate BOB inhibit low-temperature reactivity of alkanes, alcohols, and CO on the TWC and dominate the blend light-off behavior. All the high-performance fuel blends had a very similar light-off behavior to the surrogate gasoline BOB, indicating that blending up to 30% (by vol.) of high-performance blendstocks in a gasoline base fuel can potentially reduce greenhouse gas emissions through improved engine efficiency and petroleum displacement without jeopardizing the ability to meet emissions regulations. While some high-performance blendstocks demonstrated lower light-off temperatures than a surrogate gasoline blend, taking advantage of the higher catalytic reactivity of these blendstocks to reduce cold-start emissions would require reducing the aromatic content in petroleum-based market fuels.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2014

Overview of Aviation Fuel Markets for Biofuels Stakeholders

This report is for biofuels stakeholders interested the U.S. aviation fuel market. Jet fuel production represents about 10% of U.S. petroleum refinery production. Exxon Mobil, Chevron, and BP top producers, and Texas, Louisiana, and California are top producing states. Distribution of fuel primarily involves transport from the Gulf Coast to other regions. Fuel is transported via pipeline (60%), barges on inland waterways (30%), tanker truck (5%), and rail (5%). Airport fuel supply chain organization and fuel sourcing may involve oil companies, airlines, airline consortia, airport owners and operators, and airport service companies. Most fuel is used for domestic, commercial, civilian flights. Energy efficiency has substantially improved due to aircraft fleet upgrades and advanced flight logistic improvements. Jet fuel prices generally track prices of crude oil and other refined petroleum products, whose prices are more volatile than crude oil price. The single largest expense for airlines is jet fuel, so its prices and persistent price volatility impact industry finances. Airlines use various strategies to manage aviation fuel price uncertainty. The aviation industry has established goals to mitigate its greenhouse gas emissions, and initial estimates of biojet life cycle greenhouse gas emissions exist. Biojet fuels from Fischer-Tropsch and hydroprocessed esters and fatty acids processes have ASTM standards. The commercial aviation industry and the U.S. Department of Defense have used aviation biofuels. Additional research is needed to assess the environmental, economic, and financial potential of biojet to reduce greenhouse gas emissions and mitigate long-term upward price trends, fuel price volatility, or both.

09 BIOMASS FUELS↗
DOE OSTI2025

Tantalum Experiments in Fully-Reflected Water-Moderated Triangular-Pitched U(6.90)O 2 Fuel Rod Lattices (1.02 cm Pitch)

The United States (US) Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories (SNL). The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5 % 235 U. The 7uPCX assembly is a water moderated and — reflected array of aluminum-clad U(6.90 %)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMP-THERM 096, LEU- COMP-THERM-097, LEU-COMP-THERM-101, LEU-COMP-THERM-102, and LEU-COMP-THERM-111. Applied interests in neutron-absorbing elements at epithermal and intermediate neutron energy ranges at DOE’s Hanford Site and Savannah River Site were identified through DOE Office of Environmental Management (EM) workshops and needs surveys performed in conjunction with the National Nuclear Security Administration/Nuclear Criticality Safety Program. In response, a team lead by Oak Ridge National Laboratory (ORNL) performed a study evaluating the use of 7uPCX for testing the epithermal cross sections of materials at SNL. This marked the inception of the set of experiments described here. The purpose of these experiments was to measure the effects of tantalum in nearly-critical systems. The tantalum was introduced into the fuel arrays as experiment rods within a central test region. The central test region was designed to target the epithermal neutron energy range by providing a dry cylindrical cavity constructed of aluminum and lined with 0.04 in (0.1016 cm) thick cadmium sheet. The central test region has an outer diameter of 3.75 in (9.525 cm) length of 31 in (78.74 cm) and can hold 85 tantalum rods nominally 0.25 in (0.635 cm) outside diameter and 31.25 in (79.375 cm) long. The critical experiments were done using a set of triangular-pitched grid plates fabricated for these experiments. The grid plate set accommodated a fuel array of a total of 2016 fuel rod positions on a pitch of 0.4 in (1.016 cm) in a series of 21 hexagonal rings positioned around the central test region. The fuel used in these experiments was fabricated using unirradiated 6.90 % enriched UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The eight cases in this experiment series were performed in 2024 in the Sandia Critical Experiments (SCX) at the Sandia Pulsed Reactor Facility by varying the number of fuel rods in the critical assembly. The personnel involved in conducting these experiments included David Ames, Elijah Lutz, Beth Hanson, Patrick Ward, Jason Soares, and Augie Chapa from SNL, as well as Mathieu Dupont and B.J. Marshall from ORNL. Case 1 had no tantalum experiment rods. Case 2 had seven tantalum rods in the center of the central test region. Case 3 had 18 tantalum rods in the third hexagonal ring of the central test region. Case 4 had 19 tantalum rods in the center of the central test region. Case 5 had 30 tantalum rods in the outer most positions of the central test region. Case 6 had 37 tantalum rods in the center of the central test region. Case 7 had 61 tantalum rods in the center of the central test region. Case 8 had 85 tantalum rods filling all positions in the central test region. All eight critical experiments are judged to be acceptable as benchmark experiments.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2016

Application of High Performance Computing for Simulating Cycle-to-Cycle Variation in Dual-Fuel Combustion Engines

Interest in operational cost reduction is driving engine manufacturers to consider lower-cost fuel substitution in heavy-duty diesel engines. These dual-fuel (DF) engines could be operated either in diesel-only mode or operated with premixed natural gas (NG) ignited by a pilot flame of compression-ignited direct-injected diesel fuel. One promising application is that of large-bore, medium-speed engines such as those used in locomotives. With realistic natural gas substitution levels in the fleet of locomotives currently in service, such fuel substitution could result in billions of dollars of savings annually in the US alone. However, under certain conditions, dual-fuel operation can result in increased cycle-to-cycle variability (CCV) during combustion, resulting in variations in cylinder pressure and work extraction. In certain situations, the CCV of dual-fuel operation can be notably higher than that of diesel-only combustion under similar operating conditions. Excessive CCV can limit the NG substitution rate and operating range of a dual-fuel engine by increasing emissions and reducing engine stability, reliability and fuel efficiency via incomplete natural-gas combustion. Running multiple engine cycles in series to simulate CCV can be quite time consuming. Hence innovative modelling techniques and large computing resources are needed to investigate the factors affecting CCV in dual-fuel engines. This paper discusses the use of the High Performance Computing resource Titan, at the Oak Ridge Leadership Computing Facility at Oak Ridge National Laboratory, to investigate cycle-to-cycle combustion variability of a dual-fuel engine. The CONVERGE CFD software was used to simulate multiple, parallel single cycles of dual-fuel combustion with perturbed operating parameters and boundary conditions. These perturbations are imposed according to a sparse grids sampling of the parameter space. The sampling scheme chosen is similar to a design of experiments method but uses functions designed to minimize the number of samples required to achieve a desired degree of accuracy. The perturbed input parameters were connected to engine performance output over a large parameter space. Additionally, the same methodology was used to perform a set of diesel-only simulations at similar operating conditions to assess the numerical capability of capturing relatively low combustion variation. Lastly, this technique is expected to be useful to understand and predict combustion stability limits (knock and misfire) which are important for designing dual-fuel engines with improved operability and reliability.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

In Situ Laser Induced Florescence Measurements of Fuel Dilution from Low Load to Stochastic Pre Ignition Prone Conditions

This work employs a novel laser induced fluorescence (LIF) diagnostic to measure fuel dilution in a running single cylinder research engine operated at stochastic pre ignition (SPI) and non-SPI prone conditions. Measurements of LIF based fuel dilution are quantified over a range of engine loads and fuel injection timings for two fuels. The in situ LIF measurements of fuel/lubricant interactions illustrate regions of increased fuel dilution from fuel-wall interactions and is believed to be a fundamental underpinning to generating top ring zone liquid conditions conducive to SPI. Furthermore, a novel level of dye doped in the fuel, between 50 to 500 ppm was used as the fluorescence source, at engine operating speed of 2000r/min from 5 to 18 bar of IMEPg injection timings was swept for two fuels of varying volatility. The direct real time LIF measurements highlight that there are non-linear trends in fuel dilution beyond simple dependencies of fuel volatility, injection duration or injection timing, suggesting that further understanding of spray interaction with engine surfaces and the turbulent field are needed to quantify fuel dilution effects that are conducive to SPI. Moreover, results show the potential of this diagnostic technique as an additional tool for quantifying spray and fuel mixing in fundamental studies deployable across a variety of engine loads from law to full load.

47 OTHER INSTRUMENTATION↗
DOE OSTI2014

Analysis of Double-encapsulated Fuel Rods

In an LWR fuel rod, the cladding encapsulates the fuel, contains fission products, and transfers heat directly to the water coolant. In some situations, it may be advantageous to separate the cladding from the coolant through use of a secondary cladding or capsule. This may be done to increase confidence that the fuel or fission products will not mix with the coolant, to provide a mechanism for controlling the rod temperature, or to place multiple experimental rodlets within a single housing. With an axisymmetric assumption, it is possible to derive closed-form expressions for the temperature profile in a fuel rod using radially-constant thermal conductivity in the fuel. This is true for both a traditional fuel-cladding rod and a double-encapsulated fuel (fuel, cladding, capsule) configuration. Likewise, it is possible to employ a fuel performance code to analyse both a traditional and a double-encapsulated fuel. In the case of the latter, two sets of gap heat transfer conditions must be imposed. In this work, we review the equations associated with radial heat transfer in a cylindrical system, present analytic and computational results for a postulated power and gas mixture history for IFA-744, and describe the analysis of the AFC-2A, 2B metallic fuel alloy experiments at the Advanced Test Reactor, including the effect of a release of fission products into the cladding-capsule gap. The computational results for these two cases were obtained using BISON, a fuel performance code under development at Idaho National Laboratory.

BISON↗
DOE OSTI2016

Modelling Accident Tolerant Fuel Concepts

The catastrophic events that occurred at the Fukushima-Daiichi nuclear power plant in 2011 have led to widespread interest in research of alternative fuels and claddings that are proposed to be accident tolerant. The United States Department of Energy (DOE) through its Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has funded an Accident Tolerant Fuel (ATF) High Impact Problem (HIP). The ATF HIP is a three-year project to perform research on two accident tolerant concepts. The final outcome of the ATF HIP will be an in-depth report to the DOE Advanced Fuels Campaign (AFC) giving a recommendation on whether either of the two concepts should be included in their lead test assembly scheduled for placement into a commercial reactor in 2022. The two ATF concepts under investigation in the HIP are uranium silicide fuel and iron-chromium-aluminum (FeCrAl) alloy cladding. Utilizing the expertise of three national laboratory participants (Idaho National Laboratory, Los Alamos National Laboratory, and Argonne National Laboratory), a comprehensive multiscale approach to modeling is being used that includes atomistic modeling, molecular dynamics, rate theory, phase-field, and fuel performance simulations. Model development and fuel performance analysis are critical since a full suite of experimental studies will not be complete before AFC must prioritize concepts for focused development. In this paper, we present simulations of the two proposed accident tolerance fuel systems: U3Si2 fuel with Zircaloy-4 cladding, and UO2 fuel with FeCrAl cladding. Sensitivity analyses are completed using Sandia National Laboratories’ Dakota software to determine which input parameters (e.g., fuel specific heat) have the greatest influence on the output metrics of interest (e.g., fuel centerline temperature). We also outline the multiscale modelling approach being employed. Considerable additional work is required prior to preparing the recommendation report for the Advanced Fuels Campaign.

Accident Tolerant Fuel↗
DOE OSTI2016

Fuel Performance Simulation of Iron-Chrome-Aluminum Cladding during Steady-State LWR Operation

During a severe accident scenario, such as a loss-of-coolant accident, a nuclear reactor may lose its capacity to cool its fuel. The fuel rod temperatures begin to increases, quickly reaching temperatures where the coolant begins to evaporate. This lowers the coolant level in the core and eventually uncovers the fuel. Without sufficient heat transfer from the fuel rods to the coolant, the temperature of the fuel and cladding will increase dramatically. In the case of traditional zirconium-based alloys, as the temperature of the cladding reaches ∼1200 deg. C the zirconium rapidly begins to oxidize with H{sub 2}O in the coolant and steam. This oxidation reaction causes both thinning of the Zr-alloy cladding as the metal reacts and releases large amounts of H{sub 2} gas into the reactor pressure vessel. In order to increase the safety margin of LWR fuel in severe accident scenarios, several alternative cladding materials have been proposed to replace the currently used zirconium-based alloys. Of these materials, there is a particular focus on select iron-chrome-aluminum (FeCrAl) alloys because of slower oxidation Kinetics in high temperature steam than zirconium-based alloys. This increased oxidation resistance may provide additional coping time to mitigate any further damage resulting from an accident. However, by changing the cladding material, the neutronic characteristics of the core will change. FeCrAl alloys exhibit thermal neutron absorption cross sections nearly ∼12-16 x greater than Zr-alloys. This decreases the reactivity of the core, subsequently decreasing the potential cycle length for operation. To counteract this, fissile material may be added in the form of increased enrichment or increased fuel mass or the cladding thickness might be decreased, effectively reducing the neutronic penalty from using the alloy. In this study, all three changes are considered. To assess the viability of FeCrAl as an alternative cladding to Zr-alloys, engineering-scale fuel performance analysis is used to monitor the cladding and integral fuel rod behavior through its operation. Ongoing work is being performed to identify key parameters essential to modeling FeCrAl alloys for LWR applications and properly model fuel compliance and stress relief mechanisms for UO{sub 2} fuel. To improve the predictive capability of fuel performance codes for FeCrAl cladding under normal operation, high-fidelity mechanistic/physics-based material models are needed. This information can be generated and improved by access to experimental data on targeted FeCrAl alloys. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2013

Lattice cell and full core physics of internally cooled annular fuel in heavy water moderated reactors

A program is underway at Atomic Energy of Canada Limited (AECL) to develop a new fuel bundle concept to enable greater burnups for PT-HWR (pressure tube heavy water reactor) cores. One option that AECL is investigating is an internally cooled annular fuel (ICAF) element concept. ICAF contains annular cylindrical pellets with cladding on the inner and outer diameters. Coolant flows along the outside of the element and through the centre. With such a concept, the maximum fuel temperature as a function of linear element rating is significantly reduced compared to conventional, solid-rod type fuel. The preliminary ICAF bundle concept considered in this study contains 24 half-metre long internally cooled annular fuel elements and one non-fuelled centre pin. The introduction of the non-fuelled centre pin reduces the coolant void reactivity (CVR), which is the increase in reactivity that occurs on voiding the coolant in accident scenarios. Lattice cell and full core physics calculations of the preliminary ICAF fuel bundle concept have been performed for medium burnups of approximately 18 GWd/tU using WIMS-AECL and reactor fuel simulation program (RFSP). The results will be used to assist in concept configuration optimization. The effects of radial and axial core power distributions, linear element power ratings, refuelling rates and operational power ramps have been analyzed. The results suggest that burnups of greater than 18 GWd/tU can be achieved in current reactor designs. At approximately 18 GWd/tU, expected maximum linear element ratings in a PT-HWR with online-refuelling are approximately 90 kW/m. These conditions would be prohibitive for solid-rod fuel, but may be possible in ICAF fuel given the reduced maximum fuel temperature as a function of linear element rating. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Full-core analysis for FeCrAl enhanced accident tolerant fuel in boiling water reactors

The impact of replacing Zircaloy with FeCrAl, a candidate enhanced accident-tolerant fuel cladding material, was evaluated for 10 × 10 boiling water reactor fuel bundles. Results from a series of full-core parametric studies estimated that replacing UO 2 /Zircaloy with UO 2 /FeCrAl would require an average enrichment increase of 0.6% 235 U throughout the fuel lattice with the cladding and channel box thicknesses halved and fuel pellet diameter increased. Full-core results indicated that UO 2 /FeCrAl models with these geometric/enrichment specifications matched the base UO 2 /Zircaloy cycle length of 527 effective full power days. Optimization studies of the full-core design established loading and control blade patterns for both Zircaloy and FeCrAl models. A side study was conducted modeling a hybrid fuel bundle consisting of FeCrAl cladding and a SiC/Ni/Cr channel box. By halving the cladding thickness, the enrichment level required was less than that of the Zircaloy base case design after performing loading pattern optimization of the hybrid bundle core. Lastly, the thermomechanical performance of a Zircaloy-cladded fuel rod was compared to that of a FeCrAl system. Results from this analysis show that, if starting from the same fuel-cladding gap thickness, a FeCrAl-clad fuel rod operates with a greater average fuel centerline temperature, comparable axial elongation and radial displacement, and longer time to gap closure compared to a Zircaloy-clad fuel rod. Furthermore, this fuel performance analysis was primarily based on the commercial Kanthal APMT FeCrAl alloy but also used available data for the C35M FeCrAl alloy developed at Oak Ridge National Laboratory.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Impacts of annealing treatment on the microstructure of U-Mo monolithic fuel plates

The objective of this paper is to analyze the effect of different heat treatments on the fuel microstructure and texture in laboratory scale monolithic U-Mo fuel plates. Such analyses are relevant as they could possibly inform future fabrication methods for the optimization of microstructure and of material properties to ultimately improve fuel performance during irradiation. For this reason, detail characterization including Energy x-ray dispersive spectroscopy (EDS) and electron backscattered diffraction (EBSD) techniques were applied on U-Mo plates fabricated with different heat treatments to understand the influence of fabrication on fuel microstructure. Here, U-Mo fresh fuel specimens with or without annealing treatments (homogenization and stress release annealing) after rolling were analyzed in this work. In this study for the first time EBSD was systematically used to analyze the heat treatments influence on texture present in fresh fuel monolithic U-Mo fuel plates. Such changes were connected to other known microstructural and chemical changes. In this work minimization of molybdenum concentration variation and gamma phase decomposition of the U-Mo fuel core after homogenization was observed. Also, an increase in the interaction layer of the U-Mo fuel core with the Zr interlayer diffusion barrier was observed with the UZr 2 growing up to 1 µm in thickness. Such microstructural changes were aligned to the changes in texture and grain structure. Indeed, common texture observed in body-centered cubic (BCC) metal after cold rolling (e.g., α, ξ, γ fibers) were minimized by the annealing/homogenization process. Moreover, grain structure was influenced by the fabrication route with elongated grains formed in the rolled sample and equiaxed grains found after annealing. Such features are relevant since the formation of microstructural features formed during fuel fabrication can impact fuel performance in reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Geography of Existing and Potential Alternative Fuel Markets in the United States

When deploying alternative fuels, it is paramount to match the right fuel with the right location, in accordance with local market conditions. We used six market indicators to evaluate the existing and potential regional market health for each of the five most commonly deployed alternative fuels: electricity (used by plug-in electric vehicles), biodiesel (blends of B20 and higher), E85 ethanol, compressed natural gas (CNG), and propane. Each market indicator was mapped, combined, and evaluated by industry experts. This process revealed the weight the market indicators should be given, with the proximity of fueling stations being the most important indicator, followed by alternative fuel vehicle density, gasoline prices, state incentives, nearby resources, and finally, environmental benefit. Though markets vary among states, no state received 'weak' potential for all five fuels, indicating that all states have an opportunity to use at least one alternative fuel. California, Illinois, Indiana, Pennsylvania, and Washington appear to have the best potential markets for alternative fuels in general, with each sporting strong markets for four of the fuels. Wyoming showed the least potential, with weak markets for all alternative fuels except for CNG, for which it has a patchy market. Of all the fuels, CNG is promising in the greatest number of states--largely because freight traffic provides potential demand for many far-reaching corridor markets and because the sources of CNG are so widespread geographically.

09 BIOMASS FUELS↗
DOE OSTI2015

Status Report on the Fabrication of Fuel Cladding Chemical Interaction Test Articles for ATR Irradiations

FeCrAl alloys are a promising new class of alloys for light water reactor (LWR) applications due to their superior oxidation and corrosion resistance in high temperature environments. The current R&D efforts have focused on the alloy composition and processing routes to generate nuclear grade FeCrAl alloys with optimized properties for enhanced accident tolerance while maintaining properties needed for normal operation conditions. Therefore, the composition and processing routes must be optimized to maintain the high temperature steam oxidation (typically achieved by increasing the Cr and Al content) while still exhibiting properties conducive to normal operation in a LWR (such as radiation tolerance where reducing Cr content is favorable). Within this balancing act is the addition of understanding the influence on composition and processing routes on the FeCrAl alloys for fuel-cladding chemical interactions (FCCI). Currently, limited knowledge exists on FCCI for the FeCrAl-UO 2 clad-fuel system. To overcome the knowledge gaps on the FCCI for the FeCrAl-UO2 clad-fuel system a series of fueled irradiation tests have been developed for irradiation in the Advanced Test Reactor (ATR) housed at the Idaho National Laboratory (INL). The first series of tests has already been reported. These tests used miniaturized 17x17 PWR fuel geometry rodlets of second-generation FeCrAl alloys fueled with industrial Westinghouse UO 2 fuel. These rodlets were encapsulated within a stainless steel housing.To provide high fidelity experiments and more robust testing, a new series of rodlets have been developed deemed the Accident Tolerant Fuel Experiment #1 Oak Ridge National Laboratory FCCI test (ATF-1 ORNL FCCI). The main driving factor, which is discussed in detail, was to provide a radiation environment where prototypical fuel-clad interface temperatures are met while still maintaining constant contact between industrial fuel and the candidate cladding alloys, hence promoting FCCI between the fuel-clad systems. The other factor was to develop a test bed where multiple candidate alloys could be evaluated within a single irradiation test train, thereby reducing overall costs and increasing efficiency in alloy screening efforts. A collaboration between ORNL and INL was developed to facilitate the completion of the test bed for FCCI testing. The report highlights the activities related to the development of the ATF-1 ORNL FCCI rodlets for irradiation in INL’s ATR as part of the on-going ATF-1 experiments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

HOT CELL SYSTEM FOR DETERMINING FISSION GAS RETENTION IN METALLIC FUELS

A system has been developed to perform measurements on irradiated, sodium bonded-metallic fuel elements to determine the amount of fission gas retained in the fuel material after release of the gas to the element plenum. During irradiation of metallic fuel elements, most of the fission gas developed is released from the fuel and captured in the gas plenums of the fuel elements. A significant amount of fission gas, however, remains captured in closed porosities which develop in the fuel during irradiation. Additionally, some gas is trapped in open porosity but sealed off from the plenum by frozen bond sodium after the element has cooled in the hot cell. The Retained fission Gas (RFG) system has been designed, tested and implemented to capture and measure the quantity of retained fission gas in characterized cut pieces of sodium bonded metallic fuel. Fuel pieces are loaded into the apparatus along with a prescribed amount of iron powder, which is used to create a relatively low melting, eutectic composition as the iron diffuses into the fuel. The apparatus is sealed, evacuated, and then heated to temperatures in excess of the eutectic melting point. Retained fission gas release is monitored by pressure transducers during the heating phase, thus monitoring for release of fission gas as first the bond sodium melts and then the fuel. A separate hot cell system is used to sample the gas in the apparatus and also characterize the volume of the apparatus thus permitting the calculation of the total fission gas release from the fuel element samples along with analysis of the gas composition.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Overview of the U.S. DOE Fast Reactor Fuel Development Program

Research and development activities on fast reactor fuels in the US are focused on their potential use for actinide transmutation in future sodium fast reactors. As part of this application, there is a desire to demonstrate a multifold increase in burnup potential. A number of fuel design innovations are under investigation with a view toward significantly increasing the burnup potential of fuels, since higher discharge burnups equate to lower potential actinide losses during recycle. Promising innovations under investigation include: 1) lowering the fuel smeared density in order to accommodate the additional swelling expected as burnups increase, 2) utilizing an annular fuel geometry for better geometrical stability at low smeared densities, as well as the potential to eliminate the need for a sodium bond, and 3) minor alloy additions to immobilize lanthanide fission products inside the metallic fuel matrix and prevent their transport to the cladding resulting in fuel-cladding chemical interaction. This paper presents results from these efforts to advance fuel and cladding technology in support of high burnup and actinide transmutation objectives. Highlights include examples of fabrication of low smeared density annular metallic fuels, experiments to identify alloy additions effective in immobilizing lanthanide fission products, and early postirradiation examinations of annular metallic fuels having low smeared densities and palladium additions for fission product immobilization. Advanced cladding development activities include the investigation of high dose tolerant steel alloys. An overview of the U.S. Department of Energy fast reactor fuel research and development activities will be provided.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

FAST - A Unique Experiment and Simplified Approach to Accelerated Integral Fuel Testing

Idaho National Laboratory has a long and internationally recognized history of performing irradiation testing of advanced fast reactor fuels in the Experimental Breeder Reactor II (EBR-II) and the Advanced Test Reactor (ATR). Since EBR-II’s decommissioning in the early 1990’s, irradiation testing has been exclusively performed in ATR. The testing of fast reactor fuels in ATR is challenging given its thermal neutron spectrum and coolant temperatures far below those prototypic of fast reactors. Adept researchers have overcome these obstacles through the use of Cadmium shrouds which attenuate all thermalized neutrons and an experiment design that fosters fuel and cladding temperatures prototypic of fast neutron reactors. Although this design has successfully demonstrated temperatures and temperature gradients that closely mimic those seen in fast reactors, irradiation performance is highly sensitive to fabrication tolerances and the time requirements necessary for high fuel burnup, where irradiation performance data of fast fuel is lacking, are significant. This work summarizes two novel experiment designs and their associated physics analyses for testing fast reactor fuels in ATR; an accelerated irradiation experiment and a fast spectrum experiment. The accelerated irradiation experiment does not utilize a Cadmium shroud, has been shown to triple the burnup rate, yet yields temperatures and radial power profiles prototypic of fast reactor fuels. The fast spectrum experiment utilizes a booster fuel element that that hardens the incident neutron spectrum and also yields temperatures and radial power profiles prototypic of fast reactor fuels. These experiment designs efficiently reduce irradiation time requirements, are more economical, and significantly increase ATR throughput. Fast reactor experiments that capitalize on these designs expedite irradiation performance data for fast reactor fuels and provide information invaluable to fuel performance modeling and simulation validation over a wide range of parameters.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Fuel hardware considerations for BWR PCI mitigation

Pellet-clad interaction (PCI) remains a potential cause of fuel failures and is a major consideration in the design of new BWR fuel assemblies. The design and material properties of both the pellet and the cladding have been investigated and optimized to mitigate the impact of PCI. The creep behavior of standard and ADOPT (Advanced Doped Pellet Technology) fuel pellets has been measured across a wide range of temperatures. Dopants have been found to increase the high temperature creep properties of the fuel and can explain the improved PCI resistance of ∼5 kW/m in ramp tests. Other effects, such as chemical trapping of fission products and modified crack patterns cannot be ruled out, but these are at an earlier stage of investigation. It is shown that the enhanced creep effect occurs at the high centerline fuel temperatures during a ramp test, but is not present during the much lower temperatures of commercial fuel operation. Thus low temperature PCI benefits in routine commercial operation are not expected. The development of cladding materials with liner provided a great improvement for PCI mitigation in BWRs. With the softer Westinghouse liner, stepwise ramp tests have shown a benefit of ca 15-20 kW/m. Differences between stepwise and single step ramp tests are discussed. Notably the benefit of the liner remains under all types of fuel operation and temperatures. It is also thought to provide significant benefit in the case of fuel relocation or pellet defects such as missing pellet chips. The results of post irradiation examination (PIE) of a commercial fuel rod that experienced fuel fragment relocation are presented in the paper. To provide the maximum PCI benefit in the next generation BWR fuel design, TRITON11, the proven benefits of both the liner and ADOPT pellets will be included. To reduce the hydrogen pickup, below that of Zircaloy-2, the outer cladding component will be made from HiFi. TRITON11, ADOPT and HiFi are registered trademarks of Westinghouse Electric Company LLC in the United States. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗