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DOE OSTI2022

Updates to Nek5000: RANS wall functions, NRC support, and documentation

As a key part of the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation program (NEAMS), the next generation of tools for nuclear reactor design are being developed. A primary metric for success of this program is the adoption of those tools by industry stakeholders. To help meet this metric for Nek5000, development efforts this year have focused on the expansion of the available Reynolds-averaged Navier-Stokes (RANS) turbulence models to include wall function models, continued support of the U.S. Nuclear Regulatory Commission in simulating a hydrogen mitigation benchmark experiment, and expansion of the Nek5000 documentation to enhance the code’s usability. The implementation of wall functions is intended to significantly decrease time to-solution for a wide range of problems and it has been identified as an important feature by stakeholders across the nuclear community. The initial implementation of standard and pressure corrected wall functions has been tested in Nek5000 on the classical problems of channel flow and a backward facing step. It has also been tested on a 2D molten salt fast reactor core and a T-junction. The recommended formulation of choosing y + = 30 as a boundary value combined with a Neumann-Neumann formulation of the boundary condition for k and τ produces the most consistent results compared to a wall resolved approach. The collaboration with the NRC is a continuing exercise that has been ongoing for multiple years. This year we have concluded investigations into appropriate inlet conditions, showing that fully developed turbulent conditions are adequate for the full PANDA domain. We have also concluded simulations for an unobstructed jet and are now refocusing to the original obstructed jet case. The expansion of the code documentation has also been an ongoing effort over the past few years to address feedback from the various stakeholders. The documentation now more fully covers many of the available features and closes identified SQA gaps. Finally we report on three training sessions that were offered over the past year in an effort to expand the Nek5000 user base.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1971

Radiolysis of water in sealed aluminum capsules - Its prediction and inhibition.

This report presents the results of an investigation into methods of inhibiting the radiolysis of water in sealed aluminum capsules in the Plum Brook Reactor of NASA. Experimental design techniques are employed to identify the measured effects of eight variables and their interactions which control water decomposition and the resultant pressure buildup. Multiple regression analyses are used to develop predictive models for the pressure rise observed in an inpile capsule system. Predictive equations are derived for pressure rise due to the radiolysis of water with air as a cover gas or with helium cover gas containing air as an impurity or mixtures of hydrogen, oxygen, and nitrogen as impurities. Radiation induced reaction products of nitrogen and oxygen are identified as the key to radiolysis behavior. The prevention of radiolysis depends on the exclusion of air or mixtures of nitrogen and oxygen from the system. Pure inert gases, helium, neon, and argon prove to be satisfactory radiolysis inhibitors. This is demonstrated for helium by inpile tests lasting up to 14 days (one reactor cycle) in the Plum Brook Reactor.

Sheibley, D. W.↗

NASA NTRS1982

Evaluation of catalytic combustion of actual coal-derived gas

The combustion characteristics of a Pt-Pl catalytic reactor burning coal-derived, low-Btu gas were investigated. A large matrix of test conditions was explored involving variations in fuel/air inlet temperature and velocity, reactor pressure, and combustor exit temperature. Other data recorded included fuel gas composition, reactor temperatures, and exhaust emissions. Operating experience with the reactor was satisfactory. Combustion efficiencies were quite high (over 95 percent) over most of the operating range. Emissions of NOx were quite high (up to 500 ppm V and greater), owing to the high ammonia content of the fuel gas.

Blanton, J. C.↗

NASA NTRSDate not supplied

Design Study of a Nuclear-Electric Transport Vehicle for Ice Giant Missions

Nuclear-electric propulsion, in which a nuclear reactor is used to power high specific-impulse ion thrusters for propulsion, is a promising method for such applications as missions to the ice giants Uranus and Neptune, identified as targets of high science value in the most recent NASA Decadal Survey of Planetary Science. Until recently, however, this has required a lightweight space nuclear power system that has yet to be designed. NASA has recently been developing the “Kilopower” nuclear reactor as a power source for future exploration missions, with a 1-kW prototype recently tested under the KRUSTY program. We utilized a next-generation Kilopower reactor to design a transportation system for missions to the ice giant planets. The mission objectives were to carry a payload of 1164 kg, comprising a lander/hopper vehicle to be delivered to explore the moon or moons of the target ice giant, along with atmospheric probes to drop into the atmosphere, plus 188 kg of science instrumentation on the spacecraft itself.

nuclear electric propulsion↗

DOE OSTI2023

Optode performance data associated with: Metabolic Multireactor: practical considerations for using simple oxygen sensing optodes for high-throughput batch reactor metabolism experiments

This data package is associated with the publication “Metabolic Multireactor: practical considerations for using simple oxygen sensing optodes for high-throughput batch reactor metabolism experiments”, submitted to PlosONE (Kaufman et al. 2023; 10.1101/2023.03.28.534656).We carried out many testing and calibration experiments on a system of small oxygen consumption batch reactors designed for use with water and sediment samples for environmental questions. The oxygen sensing system is based very directly on the work of Larsen, et al. [2011], and similar oxygen sensing technology is widely used in the literature. Our primary focus was on practical considerations, such as temperature effects, lighting angle effects, sterilization, and other similar situations that a user may find useful. Most of the tests required comparing “base” calibration curves to “treatment” calibration curves to determine the extent to which the treatment impacted the reported measurements. This data package contains the performance and calibration data collected for that purpose.This dataset is comprised of one data folder containing (1) file-level metadata; (2) data dictionary; (3) readme; (4) diffusion test result files; (5) limit of detection test result files; (6) temperature impact files; (7) a main data file that contains test results for all other tests; and (8) an R script that uses Kolmogorov-Smirnov tests to determine whether treatment calibrations are significantly different from their respective base calibrations. All files are .csv, .txt, .Rmd, or .pdf.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Strain gauge for testing microreactor hexagonal core blocks in the Single Primary Heat Extraction and Removal Emulator

To support the development and deployment of microreactor technologies, experiments that help verify and validate reactor systems and components are performed at non-nuclear test facilities. The Single Primary Heat Extraction Removal Emulator at Idaho National Laboratory is one of these test facilities and was used to monitor a test article that has a prototypic geometry of a heat-pipe cooled microreactor core block. To collect crucial temperature and strain data during testing, temperature and strain sensing fiber optics were embedded to the surface of the test article using an ultrasonic additive manufacturing technique. To support and provide benchmark strain data for the embedded sensors, a commercial resistive strain gauge was attached. This report will discuss the results from the deployment of the commercial strain gauge which includes the setup/attachment strategies, data acquisition, and analysis of the strain data.

36 MATERIALS SCIENCE↗

NASA NTRS1971

Shock and vibration tests of a SNAP-8 NaK pump

The pump used for reactor cooling in the SNAP 8 space power system was subjected to the expected vehicle launch vibration, and shock loading in accordance with the SNAP 8 environmental specification. Subsequent disassembly revealed damage to the thrust bearing pins, which should be redesigned and strengthened. The unit was operational, however, when run in a test loop after reassembly.

Stromquist, A. J.↗

DOE OSTI2024

Flow Sensor Test Article (F-STAr) - Water Testing and Commissioning Report for FY2024

Argonne National Laboratory’s Mechanism Engineering Test Loop (METL) facility is developing new experimental testing capabilities with the Flow Sensor Test Article (F-STAr). F-STAr’s mission is to provide high flowrate, sodium submersible testing capabilities to support the development of sodium cooled nuclear fission reactors. Figure 1 shows a model of F-STAr (left) and a photo of the partially assembled test article (right) with several of the main components labeled. The system currently includes a large pump with desired flowrates of up to 100 GPM; an immersion heater with a maximum power of 5 kW; an immersion cooler with an estimated maximum cooling power of 2 kW; and an experimental test section to support sub-test articles. Initially, F-STAr will be setup for testing flow sensors, specifically Eddy Current Flow Sensors (ECFS). However, the system can be reconfigured to support a wide range of testing needs. For example, F-STAr could be setup to complete testing of hydraulic components, heat exchangers, hydrodynamic bearings, seals, and more. This report will provide an update on the development of F-STAr with a focus on the water testing and commissioning activities during Fiscal Year 2024 (FY24). First, the report will focus on describing the pump development. Specifically, updates will be provided on troubleshooting the pump’s excessive vibrational issues. In addition to updates on the pump, pressure-flowrate performance testing in water will be described. Furthermore, updates will be provided on a pump shaft bushing development as well as rigging procedures. Future work and paths forward for F-STAr will be described. Finally, a short summary on the ECFS development will be described at the end of the report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

The Advanced Scale Up Reactor Experiment (ASURE) Facility: A Testbed for Advancing the Art of Biomass and Waste Co-Gasification Systems.

This paper was an executive summary for an oral presentation to be included in the conference proceedings of the 2024 Clearwater Clean Energy conference. It includes a brief discussion of the plans to construct a small pilot-scale co-gasification test facility known as the Advanced Scale Up Reactor Experiment (ASURE) Facility at NETL’s Morgantown, WV site in support of FECM’s goals for advancing biomass and waste co-gasification systems for carbon-neutral hydrogen production.

Rowan, Steven↗

NASA NTRS2011

Hyperthermal Environments Simulator for Nuclear Rocket Engine Development

An arc-heater driven hyperthermal convective environments simulator was recently developed and commissioned for long duration hot hydrogen exposure of nuclear thermal rocket materials. This newly established non-nuclear testing capability uses a high-power, multi-gas, wall-stabilized constricted arc-heater to produce hightemperature pressurized hydrogen flows representative of nuclear reactor core environments, excepting radiation effects, and is intended to serve as a low-cost facility for supporting non-nuclear developmental testing of hightemperature fissile fuels and structural materials. The resulting reactor environments simulator represents a valuable addition to the available inventory of non-nuclear test facilities and is uniquely capable of investigating and characterizing candidate fuel/structural materials, improving associated processing/fabrication techniques, and simulating reactor thermal hydraulics. This paper summarizes facility design and engineering development efforts and reports baseline operational characteristics as determined from a series of performance mapping and long duration capability demonstration tests. Potential follow-on developmental strategies are also suggested in view of the technical and policy challenges ahead. Keywords: Nuclear Rocket Engine, Reactor Environments, Non-Nuclear Testing, Fissile Fuel Development.

Litchford, Ron J.↗

NASA NTRS1982

Low and medium heating value coal gas catalytic combustor characterization

Catalytic combustion with both low and medium heating value coal gases obtained from an operating gasifier was demonstrated. A practical operating range for efficient operation was determined, and also to identify potential problem areas were identified for consideration during stationary gas turbine engine design. The test rig consists of fuel injectors, a fuel-air premixing section, a catalytic reactor with thermocouple instrumentation and a single point, water cooled sample probe. The test rig included inlet and outlet transition pieces and was designed for installation into an existing test loop.

Schwab, J. A.↗

DOE OSTI2023

CSPlib: A performance portable parallel software toolkit for analyzing complex kinetic mechanisms

Computational singular perturbation (CSP) is a method to analyze dynamical systems. It targets the decoupling of fast and slow dynamics using an alternate linear expansion of the right-hand side of the governing equations based on eigenanalysis of the associated Jacobian matrix. This representation facilitates diagnostic analysis, detection and control of stiffness, and the development of simplified models. For this work, we have implemented CSP in a C++ open-source library CSPlib using the Kokkos parallel programming model to address portability across diverse heterogeneous computing platforms, i.e., multi/many-core CPUs and GPUs. We describe the CSPlib implementation and present its computational performance across different computing platforms using several test problems. Specifically, we test the CSPlib performance for a constant pressure ignition reactor model on different architectures, including IBM Power 9, Intel Xeon Skylake, and NVIDIA V100 GPU. The size of the chemical kinetic mechanism is varied in these tests. As expected, the Jacobian matrix evaluation, the eigensolution of the Jacobian matrix, and matrix inversion are the most expensive computational tasks. When considering the higher throughput characteristic of GPUs, GPUs performs better for small matrices with higher occupancy rate. CPUs gain more advantages from the higher performance of well-tuned and optimized linear algebra libraries such as OpenBLAS.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2020

Surrogate Assembly 30 cm Drop Test

The 30 cm drop is the remaining NRC normal conditions of transport (NCT) regulatory requirement (10 CFR 71.71) for which there are no data on the actual surrogate fuel. While obtaining data on the actual fuel is not a direct requirement, it provides definitive information which aids in quantifying the risk of fuel breakage resulting from a cask drop from a height of 30 cm or less. The 30 cm drop test with the full-scale surrogate assembly conducted in May 2020 was the last step needed for quantifying the strains on the surrogate assembly rods under NCT. The full-scale surrogate assembly used in the 2020 30 cm drop test was built using a new 17x17 Pressurized Water Reactor (PWR) Westinghouse skeleton filled with the copper rods and 3 zircaloy rods from the full-scale surrogate assembly used in the Multi-Modal Transportation Test (MMTT). Felt pads were attached to the surrogate assembly bottom prior to the 30 cm drop to adequately represent the effects of the impact limiters and the cask. Note that felt "programming material" has been used extensively in past drop tests and is known to be a good material for programming a desired shock pulse. The felt pad configuration was determined during a previous series of tests reported in. The acceleration pulses observed on the surrogate assembly during the test were in good agreement with the expected pulses. This confirmed that during the 30 cm drop the surrogate assembly experienced the same conditions as it would if it was dropped in the cask with the impact limiters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Hardware-Based Demonstration of Temperature Control Functions for Reactor Systems

Establishing autonomy in reactor control systems has become essential for the expansion of nuclear technologies. Thermal regulation in particular remains crucial for maintaining stable operation and ensuring the integrity of fuel. To alleviate public skepticism of the safety of nuclear reactors, demonstrating control over this key factor is pivotal. Utilizing electric heat pads to simulate the heat released in a reactor core, thermocouples for temperature monitoring, and an Arduino micro programmable logic controller (PLC) for control, a hardware-based demonstration of a reactor heating system validates the efficacy of reactor control over this key parameter. To improve precision, a proportional-integral-derivative (PID) algorithm was implemented in the heating control loop to ensure meticulous control of reactor functions. In addition, the integration of this physical system with a digital simulator tool such as RELAP5-3D establishes a foundation for a comprehensive testing environment. This allows for a refinement of temperature control under various simulated reactor conditions, bringing another layer of reliability to the operation of the system. By facilitating a physical demonstration of reactor thermal management and control strategies, this project provides a foundation for expanded testing and educational outreach. Ultimately, this system advances the broader goal of demonstrating the safety and viability of autonomous reactor operations, contributing to public trust and future reactor deployment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Numerical investigation of the AP1000 response following loss-of-coolant accident using PCTRAN and CFD to support R&D of SMRs

Small Modular Reactors (SMRs) present a promising solution for the future of sustainable energy, offering advantages such as reduced waste generation, advanced passive safety features, and potential cost efficiencies. Ongoing research focuses on the design and development of SMRs, addressing challenges through numerical simulations and experimental test data. Given that many next-generation reactors are first-of-a-kind (FOK), current operational reactors serve as valuable benchmarks for understanding various thermal-hydraulic phenomena during postulated design basis accidents (DBAs), including loss-of-coolant accidents (LOCA), main steam line breaks (MSLB), and steam generator tube ruptures (SGTR). This study employs the AP1000 model Personal Computer Transient Analyzer (PCTRAN) to simulate reactor responses to small-break LOCA scenarios, specifically analyzing break sizes of 2 and 10 inches. Additionally, ANSYS FLUENT software is utilized to assess containment responses to large-break LOCAs, focusing on the quantification of decay heat removal via natural convection. Verification of the PCTRAN results is achieved using Westinghouse data, with CFD results corroborating the findings. The outcomes demonstrate strong agreement with Westinghouse data, confirming the accuracy of the simulations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1999

Composting on Mars or the Moon: II. Temperature feedback control with top-wise introduction of waste material and air

Whereas Earth-based composting reactors that effectively control the process are batch operations with bottom-to-top airflow, in extraterrestrial application both the fresh waste and the air need to be introduced from above. Stabilized compost and used air would exit below. This materials flow pattern permits the addition of waste whenever generated, obviating the need for multiple reactors, and the incorporation of a commode in the lid. Top loading in turn dictates top-down aeration, so that the most actively decomposing material (greatest need for heat removal and O2 replenishment) is first encountered. This novel material and aeration pattern was tested in conjunction with temperature feedback process control. Reactor characteristics were: working, volume, 0.15 m3; charge, 2 kg dry biomass per day (comparable to a 3-4 person self-sufficient bioregenerative habitat); retention time, 7 days. Judging from temperature profile, O2 level, air usage, pressure head loss, moisture, and odor, the system was effectively controlled over a 35-day period. Dry matter disappearance averaged 25% (10-42%). The compost product was substantially, though not completely, stabilized. This demonstrates the compatibility of top-wise introduction of waste and air with temperature feedback process control.

NASA Discipline Life Support Systems↗

DOE OSTI2022

AGR Program TRISO Fuel Topical Report Dialog

AGR Program Overview and Current Activities Fission Product Transport Data Short-Lived Fission Product Release Fuel Performance Margin Data Oxidation Testing Data

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2014

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Upgrade Activities

Over the past year the Nuclear Thermal Rocket Element Environmental Simulator (NTREES) has been undergoing a significant upgrade beyond its initial configuration. The NTREES facility is designed to perform realistic non-nuclear testing of nuclear thermal rocket (NTR) fuel elements and fuel materials. Although the NTREES facility cannot mimic the neutron and gamma environment of an operating NTR, it can simulate the thermal hydraulic environment within an NTR fuel element to provide critical information on material performance and compatibility. The first phase of the upgrade activities which was completed in 2012 in part consisted of an extensive modification to the hydrogen system to permit computer controlled operations outside the building through the use of pneumatically operated variable position valves. This setup also allows the hydrogen flow rate to be increased to over 200 g/sec and reduced the operation complexity of the system. The second stage of modifications to NTREES which has just been completed expands the capabilities of the facility significantly. In particular, the previous 50 kW induction power supply has been replaced with a 1.2 MW unit which should allow more prototypical fuel element temperatures to be reached. The water cooling system was also upgraded to so as to be capable of removing 100% of the heat generated during. This new setup required that the NTREES vessel be raised onto a platform along with most of its associated gas and vent lines. In this arrangement, the induction heater and water systems are now located underneath the platform. In this new configuration, the 1.2 MW NTREES induction heater will be capable of testing fuel elements and fuel materials in flowing hydrogen at pressures up to 1000 psi at temperatures up to and beyond 3000 K and at near-prototypic reactor channel power densities. NTREES is also capable of testing potential fuel elements with a variety of propellants, including hydrogen with additives to inhibit corrosion of certain potential NTR fuel forms. Additional diagnostic upgrades included in the present NTREES set up include the addition of a gamma ray spectrometer located near the vent filter to detect uranium fuel particles exiting the fuel element in the propellant exhaust stream to provide additional information any material loss occurring during testing. Other aspects of the upgrade included reworking NTREES to reduce the operational complexity of the system despite the increased complexity of the induction heating system. To this end, many of the controls were consolidated on fewer panels. As part of this upgrade activity, the Safety Assessment (SA) and the Standard Operating Procedures (SOPs) for NTREES were extensively rewritten. The new 1.2 MW induction heater consists of three physical units consisting of a transformer, rectifier, and inverter. This multiunit arrangement facilitated increasing the flexibility of the induction heater by more easily allowing variable frequency operation. Frequency ranges between 20 and 60 kHz can be accommodated in the new induction heater allowing more representative power distributions to be generated within the test elements.

Emrich, William J., Jr.↗