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DOE OSTI2014

AGR-2 Irradiation Test Final As-Run Report, Rev 2

This document presents the as-run analysis of the AGR-2 irradiation experiment. AGR-2 is the second of the planned irradiations for the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program. Funding for this program is provided by the U.S. Department of Energy as part of the Very High Temperature Reactor (VHTR) Technical Development Office (TDO) program. The objectives of the AGR-2 experiment are to: (a) Irradiate UCO (uranium oxycarbide) and UO 2 (uranium dioxide) fuel produced in a large coater. Fuel attributes are based on results obtained from the AGR-1 test and other project activities. (b) Provide irradiated fuel samples for post-irradiation experiment (PIE) and safety testing. (c) Support the development of an understanding of the relationship between fuel fabrication processes, fuel product properties, and irradiation performance. The primary objective of the test was to irradiate both UCO and UO 2 TRISO (tri-structural isotropic) fuel produced from prototypic scale equipment to obtain normal operation and accident condition fuel performance data. The UCO compacts were subjected to a range of burnups and temperatures typical of anticipated prismatic reactor service conditions in three capsules. The test train also includes compacts containing UO 2 particles produced independently by the United States, South Africa, and France in three separate capsules. The range of burnups and temperatures in these capsules were typical of anticipated pebble bed reactor service conditions. The results discussed in this report pertain only to U.S. produced fuel. In order to achieve the test objectives, the AGR-2 experiment was irradiated in the B-12 position of the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) for a total irradiation duration of 559.2 effective full power days (EFPD). Irradiation began on June 22, 2010, and ended on October 16, 2013, spanning 12 ATR power cycles and approximately three and a half calendar years. The test contained six independently controlled and monitored capsules. Each U.S. capsule contained 12 compacts of either UCO or UO2 AGR coated fuel. No fuel particles failed during the AGR-2 irradiation. Final burnup values on a per compact basis ranged from 7.26 to 13.15% FIMA (fissions per initial heavy-metal atom) for UCO fuel, and 9.01 to 10.69% FIMA for UO 2 fuel, while fast fluence values ranged from 1.94 to 3.47 x 10 25 n/m 2 (E >0.18 MeV) for UCO fuel, and from 3.05 to 3.53 x 10 25 n/m 2 (E >0.18 MeV) for UO 2 fuel. Time-average volume-average (TAVA) temperatures on a capsule basis at the end of irradiation ranged from 987°C in Capsule 6 to 1296°C in Capsule 2 for UCO, and from 996 to 1062°C in UO 2 -fueled Capsule 3. By the end of the irradiation, all of the installed thermocouples (TCs) had failed. Fission product release-to-birth (R/B) ratios were quite low. In the UCO capsules, R/B values during the first three cycles were below 10 -6 with the exception of the hotter Capsule 2, in which the R/Bs reached 2 x 10 -6 . In the UO 2 capsule (Capsule 3), the R/B values during the first three cycles were below 10 -7 . R/B values for all following cycles are not reliable due to gas flow and cross talk issues.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

BISON Capability, Validation and Demonstration for Reactivity-Initiated Accidents

Reactivity Initiated Accidents (RIA) are design basis accidents that could have adverse impacts on the core coolability. In the unlikely event that sufficient reactivity is inserted into the reactor core by the ejected/dropped control rod, prompt energy deposition into the fuel can occur, which when sufficiently high can lead to fuel rod failure or, at large energy deposition levels, expulsion of UO2 fragments or molten UO2 material from the fuel rod. This results in a release of fission product and fuel into the coolant and has the potential to compromise core coolability and threatening the pressure boundary of the primary coolant system. The design basis RIA is one of the industry challenging problems that the CASL aimed to address; the CASL RIA Challenge Problem Charter [1] states, ?The Pressurized Water Reactor (PWR) Rod Ejection Accident (REA) and Boiling Water Reactor (BWR) Control Rod Drop Accident (CRDA) are postulated accidents with consequences that are important to nuclear safety (fuel rod integrity and core coolability). Currently each reload core design must be analyzed to meet regulatory acceptance criteria. The goal of CASLs ModSim capability for RIA is to model the event at a higher fidelity, with validation to existing tests, to better model the transient neutronics and the progression of the fuel and cladding thermal-mechanical behavior. These improved analytical capabilities can be used to better inform reload core design, limits on fuel assembly discharge burnup, restrictions on placement of fuel in the reactor, control rod insertion limits, operating margin, and performance sensitivities.? In support of that charter, BISON, the fuel performance code has been used to demonstrate the simulation of thermal-mechanical behavior of LWR fuels during a reactivity-initiated accident. The combination of mechanical, thermal, and thermal-hydraulic phenomena all present during an RIA makes a multi-physics code such as BISON a valuable tool for modeling these scenarios. This paper will highlight many of the activities associated with BISON relevant to reactivity-initiated accident capability development and validation efforts. These efforts have been performed under both CASL and the Nuclear Energy Advanced Modeling and Simulation (NEAMS) programs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Analytical workflow dependence of experimental observables for uranium chemistries

In this work, we investigated how the sequencing of laboratory analytical methods used for chemical and morphological characterization influences analytical findings for particulate materials relevant to the nuclear fuel cycle, including UO2, U3O8, studtite (UO2O2·4H2O), and β-UO3, in the context of nuclear forensic analysis. Particles of each chemistry obtained from consistent production batches were exposed to Raman spectroscopy and scanning electron microscopy in varying orders to elucidate how the order in which the techniques are applied influences morphological and chemical observations as a function of particle size. The results indicate that particles from all four chemistries exposed to high-resolution electron imaging before Raman spectral analysis demonstrate optical vibrational spectral changes that reduce accurate interpretation of the underlying chemistry via Raman spectral analysis. We hypothesize that these changes are due to the thermal load of the electron beam imparted to the sample being unable to be dissipated by materials with poor thermal conduction properties. Results from this study will aid in determining best practices for forensic analysis procedures to reduce uncertainty in chemical determination of unknown particulate samples.

Manns, Rebecca [University of Nevada, Las Vegas]↗

DOE OSTI2024

UZrCN Synthesis via Arc Melting - A Novel Synthesis Study

The next generation of nuclear reactors for both power production and space nuclear propulsion require fuel that is more durable, thermally stable, and more thermally conductive to support rapid heat transfer. High temperature gas reactors (HTGR), advanced gas reactors (AGR), and space-based nuclear thermal propulsion (NTP) are advanced reactor concepts that require a fuel type that can withstand high temperatures (1000-2900K) and flow of corrosive gas coolants such as helium, hydrogen, and carbon dioxide. One fuel with the potential to meet these demanding requirements is uranium-zirconium-carbonitride (UZrCN). UZrCN has many favorable fuel qualities compared to other eligible fuel forms such as uranium dioxide (UO2) and uranium mononitride (UN) that could support the aforementioned reactor concepts. UZrCN has an exceptionally high operating temperature and thermal conductivity which are highly desirable to improve reactor economics and safety. It far exceeds the properties of UO2 which is the most common fuel form in the United States. UZrCN also surpasses UN in terms of thermal conductivity and operating temperature by eliminating the dissociation problem UN has at 1700K. UZrCN could improve gas reactor performance and enable NTP technologies; however, it is an under-researched fuel that lacks rigorous scientific study. In recent efforts by the Idaho National Laboratory, a variety of novel methods to produce this fuel composition have been explored. One such method is via arc melting of uranium, zirconium, and carbon under a nitrogen atmosphere. Alloy fabrication using arc melting has been utilized for close to 150 years now and is well-understood as a method for rapid alloy prototyping. This process will be used to perform in-situ nitriding to form UZrCN.

36 MATERIALS SCIENCE↗

DOE OSTI2024

UZrCN Formation via Arc Melting – A Novel Synthesis Study

36 MATERIALS SCIENCE↗

DOE OSTI2026

Assembly Bowing Reactivity Calculation Methodology Applied to Lead Fast Reactor

Ducted assemblies bow during operation due to power and temperature gradients which can be influenced by operating flow rates. For fast spectrum cores using ducted assemblies, the bowing behavior follows that of the duct and because there are gaps between the ducts, the bowing can result in compaction or expansion of the active core. This local displacement can have a positive or negative impact and knowing the net effect during transients is important for system reactivity control. Keeping the net bowing reactivity worth low is possible with attentive placement of load pads above the active core and selecting load pad gap thicknesses that result in a desired behavior at standard operating conditions. This paper considers a Lead Fast Reactor (LFR) concept fueled by HALEU UO2 developed by Westinghouse Electric Company (WEC) and applies a workflow of Argonne-developed codes to estimate the core bowing reactivity worth. Using orifice flow rates grouped by assembly type, the net reactivity impact due to core assembly bowing for the LFR was found to be small and in line with other liquid metal fast reactors: +29/+32/+35 pcm, or about +$0.049/+$0.055/+$0.059, for BOEC/MOEC/EOEC, respectively.

bowing reactivity↗

DOE OSTI2026

Identifying microstructures susceptible to pulverization in commercially irradiated high burnup UO2 under LOCA conditions

High burnup fuel fragmentation (HBFF) has been a concern in the nuclear industry for many years. When UO2 reaches and exceeds pellet average burnups around 55 GWd/tU, microstructural changes in the fuel pellet begin to occur that render the pellet susceptible to fine fragmentation under loss-of-coolant accident (LOCA) conditions. During a LOCA event, the cladding balloons and bursts, potentially releasing part of these fine fuel fragments into the reactor pressure vessel. This process is known as fuel fragmentation, relocation, and dispersal (FFRD). Presently, the US nuclear industry is developing a safety basis for FFRD with the goal of increasing burnups and pressurized water reactor cycle lengths. Increased cycle lengths would push the burnup limits of the fuel rods past the known threshold for HBFF susceptibility. In this work, the microstructural impact on HBFF was investigated by comparing the microstructures of as-irradiated rod segments to their post-LOCA tested counterparts. This investigation found that varied operational histories result in different microstructural evolutions across the pellet radius, which impacts the fragmentation behavior and radial location of the fragmentation. It is noted that regions with a high bubble density and a high density of grain boundaries fragment under LOCA-relevant conditions. In addition to the fragmentation that has been previously reported at the periphery of the fuel, fragmentation was also noted in the dark zone toward the fuel center. Analysis of the power histories of the fuel samples suggests that the dark zone forms in the central regions of the pellet between temperatures of approximately 740 and 960 °C.

McKinney, Casey [ORNL] (ORCID:0000000335383614)↗

DOE OSTI2022

Phase-field simulations to inform nuclear fuel performance modeling

Software tools to simulate nuclear fuel performance at the engineering scale, such as Idaho National Laboratory (INL)’s BISON code, are increasingly relied upon in regulatory and economic decision-making. However, accurate results from these tools depends on the availability of materials parameters that are used as input. In recent years, atomistic and mesoscale simulation methods have emerged as a cost-effective, expedient means to obtain such input parameters. Phase-field simulations using INL’s Marmot application have been used to obtain microstructure-level parameters and to improve material models for fuel performance modeling using BISON. In this talk, recent examples of this process are given, including applications in UO2, U3Si2, and UZr fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Advanced Pellet Cladding Interaction Modeling Using the US DOE CASL Fuel Performance Code: Peregrine

The US DOE’s Consortium for Advanced Simulation of LWRs (CASL) program has undertaken an effort to enhance and develop modeling and simulation tools for a virtual reactor application, including high fidelity neutronics, fluid flow/thermal hydraulics, and fuel and material behavior. The fuel performance analysis efforts aim to provide 3-dimensional capabilities for single and multiple rods to assess safety margins and the impact of plant operation and fuel rod design on the fuel thermomechanical- chemical behavior, including Pellet-Cladding Interaction (PCI) failures and CRUD-Induced Localized Corrosion (CILC) failures in PWRs. [1-3] The CASL fuel performance code, Peregrine, is an engineering scale code that is built upon the MOOSE/ELK/FOX computational FEM framework, which is also common to the fuel modeling framework, BISON [4,5]. Peregrine uses both 2-D and 3-D geometric fuel rod representations and contains a materials properties and fuel behavior model library for the UO2 and Zircaloy system common to PWR fuel derived from both open literature sources and the FALCON code [6]. The primary purpose of Peregrine is to accurately calculate the thermal, mechanical, and chemical processes active throughout a single fuel rod during operation in a reactor, for both steady state and off-normal conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Advanced Pellet-Cladding Interaction Modeling using the US DOE CASL Fuel Performance Code: Peregrine

The US DOE’s Consortium for Advanced Simulation of LWRs (CASL) program has undertaken an effort to enhance and develop modeling and simulation tools for a virtual reactor application, including high fidelity neutronics, fluid flow/thermal hydraulics, and fuel and material behavior. The fuel performance analysis efforts aim to provide 3-dimensional capabilities for single and multiple rods to assess safety margins and the impact of plant operation and fuel rod design on the fuel thermo-mechanical-chemical behavior, including Pellet-Cladding Interaction (PCI) failures and CRUD-Induced Localized Corrosion (CILC) failures in PWRs. [1-3] The CASL fuel performance code, Peregrine, is an engineering scale code that is built upon the MOOSE/ELK/FOX computational FEM framework, which is also common to the fuel modeling framework, BISON [4,5]. Peregrine uses both 2-D and 3-D geometric fuel rod representations and contains a materials properties and fuel behavior model library for the UO2 and Zircaloy system common to PWR fuel derived from both open literature sources and the FALCON code [6]. The primary purpose of Peregrine is to accurately calculate the thermal, mechanical, and chemical processes active throughout a single fuel rod during operation in a reactor, for both steady state and off-normal conditions.

CASL, Consortium for Advanced Simulation of LWRs, ↗

DOE OSTI2019

Separate Effects Testing in TREAT for ATF Fuels

This work performed examinations on high burnup UO2 from commercial power plant with the intention of better understanding fission gas and fragmentation behavior. Fuel fragmentation, relocation, and dispersal (FFRD) is a major factor in fuel lifetime limits imposed on UO2 by regulators, both domestic and foreign, and is a major area of interest by industry groups (e.g., Electric Power Research Institute, [EPRI]). The characterization of the fuel focused on the differences in porosity between the high burnup (rim) zone, the dark (intermediate) zone, and center zones of the fuel as well as the fission gas content of each region. Work involved thermal treatments to analyze fission gas and high resolution microscopy techniques to investigate pore structure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Mn-doped oxide nuclear fuel

A nuclear fuel includes uranium(IV) oxide (UO2) and manganese (Mn) as a dopant. The Mn dopant may be present in the fuel in an amount up to the solubility limit for Mn under a given set of conditions, for example, about 0.01 wt % to about 1 wt %. The nuclear fuel is substantially free of aluminum (Al). The nuclear fuel exhibits enhanced grain size development during sintering temperatures as low at 1400 K due to an increase in uranium sub-lattice vacancies induced by dissolution of the Mn dopant at interstitial defect sites. The Mn-doped nuclear fuel exhibits improved grain sizes at lower temperatures compared to Cr-, Al-, and undoped UO2, and therefore desirably exhibits lower fission gas release and higher plasticity, reducing the chances of fuel rod failure.

Cooper, Michael William Donald↗

DOE OSTI2021

Integral Experiment Request 523 Feasibility Study (Summary Report)

This report documents the feasibility phase of the Critical Experiment Design (CED) conducted as part of integral experiment request (IER) 523. The purpose of IER-523 is to explore the effects of using 35 weight percent enriched uranium dioxide-beryllium oxide (UO 2 -BeO) material on critical configurations using the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories (Sandia). Preliminary experiment design concepts, neutronic analysis results, and proposed paths for continuing the CED process are presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

In situ synthesis and characterization of uranium carbide using high temperature neutron diffraction

Advances in neutron flux, neutron instrumentation, and sample environments over the past years allowed the development of unique techniques to characterize material synthesis and processing. The available infrastructure at LANL allows to apply these techniques to radioactive materials or materials containing actinides. Here, we present capabilities and results to characterize materials in situ at temperatures above 2000 Celsius degrees such as in loss-of-coolant accidents. Temperatures in excess of 2000 C. degrees are not readily achieved and neutrons are one of a few probes to characterize materials under these conditions. Research in refractory materials, phase diagram studies or accident scenarios for nuclear materials are research areas where such extreme conditions are required. As an example, we present the formation of UC{sub x} from UO{sub 2+x} and graphite in situ using high temperature neutron diffraction with particular focus on resolving the conflicting reports on the crystal structure of non-quenchable cubic UC{sub 2}. The ability to follow the reaction UO{sub 2}+C → UC{sub x}+CO{sub y} in situ with neutron diffraction allows us to conclude that the reaction occurs within minutes over a temperature range of 60 Celsius degrees. The initiation of the reaction is far below the reaction temperature of 2000 C. degrees reported for this reaction in standard text books on actinide chemistry. This may be due to the unusually small ∼100 nm grain size of our UO{sub 2} initial powder. Furthermore, the holding time of several hours reported in the literature would be unnecessary. The neutron diffraction data collected for the cubic high temperature UC{sub 2} phase unambiguously confirmed the disordered C-C dumbbells and excluded structures previously determined by X-ray diffraction.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Thermodynamic modeling of the U 3 O 8-x solid solution phase

It is important to accurately characterize the equilibrium behavior of U 3 O 8 during UO 2 nuclear fuel fabrication as the determination of the oxygen to uranium ratio in UO 2 powders and pellets is dependent on U 3 O 8 stoichiometry. Prior thermodynamic modeling efforts have treated U 3 O 8 as stoichiometric; however, it is experimentally known that the phase exhibits hypostoichiometric behavior at temperatures >850 K. The goal of this work was to model U 3 O 8 as a solid solution using the compound energy formalism and optimize the model to experimental data according to the CALPHAD methodology. Results of the U 3 O 8-x model assessment were visualized by recalculating the previously assessed U–O binary phase diagram replacing a stoichiometric representation of U 3 O 8 with a U 3 O 8-x solid solution model. Moreover, a recommendation is made to revise the U 3 O 8 to U conversion factor used in the ASTM C 1453 standard based on the literature and updated thermodynamic representation for U 3 O 8-x presented in this work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Impact of uranium oxide (UO 2 ) fuel with molybdenum (Mo) inserts on pressurized water reactor performance and safety

This work investigates nuclear reactor performance and safety characteristics of UO 2 with high thermal conductivity Mo insert structures by using multiphysics modeling techniques. Additionally, the purpose of this study is to use scoping analyses to quantify the impact of using Mo inserts from neutronic and heat transfer standpoints. Attention is given to reactor performance parameters, such as cycle length, maximum fuel temperature, temperature gradients in the fuel, and stored energy in the fuel. The finite-element code BISON and the Monte Carlo particle transport code Serpent were used to perform sensitivity analyses on the Mo insert geometry to optimize the insert design and inform larger scale modeling that required the homogenization of the UO 2 and Mo. Although BISON is often used as a fuel performance analysis tool, it is used in this context for heat transfer analysis only. Fuel performance optimization is outside the scope of the current study, but would be important for future work focused on this concept. The results showed that the insert had little impact on neutronic performance and that homogenizing the UO 2 and Mo was acceptable for reactor physics calculations. Reactivity temperature coefficients calculated using homogeneous UO 2 -Mo were shown to be relatively similar to UO 2 , but higher Mo content and 235 U enrichment can reduce the worth of soluble boron and control rods. The effect of insert geometry on heat transfer was much greater, and an approximately 15–20% difference in maximum fuel temperature was predicted between the best and worst performing heat transfer geometries. Furthermore, thermal conductivity calibration based on the finite element analysis results was performed to improve the accuracy of temperature predictions in reactor analysis models that homogenized the UO 2 -Mo fuel. Compared with UO 2 in a pressurized water reactor (PWR), the optimized UO 2 -Mo design increased the margin to fuel melt by 13–32% across the fuel cycle, but it requires the 235U enrichment to exceed 5% to match the cycle length of conventional UO 2 .

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Neutronics and Transient Calculations for the Conversion of the Transient Reactor Rest Facility (TREAT)

The Transient Reactor Test Facility (TREAT) is a graphite-reflected, graphitemoderated, and air-cooled reactor fueled with 93.1% enriched UO2 particles dispersed in graphite, with a carbon-to-235U ratio of ~10000:1. TREAT was used to simulate accident conditions by subjecting fuel test samples placed at the center of the core to high energy transient pulses. The transient pulse production is based on the core’s selflimiting nature due to the negative reactivity feedback provided by the fuel graphite as the core temperature rises. The analysis of the conversion of TREAT to low enriched uranium (LEU) is currently underway. This paper presents the analytical methods used to calculate the transient performance of TREAT in terms of power pulse production and resulting peak core temperatures. The validation of the HEU neutronics TREAT model, the calculation of the temperature distribution and the temperature reactivity feedback as well as the number of fissions generated inside fuel test samples are discussed.

Kontogeorgakos, Dimitrios C.↗

DOE OSTI2024

Mesoscale Modeling of the Effects of Accelerated Burnup on UO2 Microstructural Evolution

Accelerating the nuclear fuel qualification process will rely on some combination of advanced modeling and simulation techniques with accelerated irradiation testing and separate effects experiments to enable the development of new fuel concepts in a shorter time frame. One of the key challenges to successfully leveraging accelerated irradiation tests will be understanding the artifacts that may be introduced with accelerated accumulation of dose and/or burnup. This work presents phase field (MARMOT) simulations of the evolution of representative 2D UO2 microstructures up to 40 MWd/kgU. Simulations were performed under both commercial light water reactor fuel conditions as well as those that would be expected for highly accelerated (~10x) burnup conditions similar to those used in the MiniFuel irradiations in Oak Ridge National Laboratory’s High Flux Isotope Reactor. The phase field model was coupled with a discrete nucleation algorithm to model re- structuring at high burnup. The effect of the different fission rates in both microstructures was investigated at two temperatures: 650?C and 800?C. The lower temperature simulations both showed an onset of restructuring at nearly 60 MWd/kgU. More extensive restructuring was obtained in the MiniFuel microstructure compared with that of the PWR fuel. At 800?C, no restructuring was obtained as a result of the thermally activated diffusion of Xe atoms and U vacancies to fission gas bubbles, which reduces the nucleation driving force. These results highlight the importance of using modeling and simulation tools to inform the environmental conditions during targeted accelerated irradiation tests to extract the most useful fuel performance data.

accelerated fuel qualification, Phase Field, Restr↗