Engineering topics

Housley, Gregory K.

Publications and source records attributed to Housley, Gregory K..

6 records

DOE OSTI2022

Experiment design for the neutron irradiation of $\mathrm{PM-HIP}$ alloys for nuclear reactors

Here, this article describes the design of an Advanced Test Reactor (ATR) drop-in neutron irradiation experiment aiming to directly compare the performance of nuclear structural alloys fabricated by powder metallurgy with hot isostatic pressing (PM-HIP) against conventional casting or forging. There is growing interest in PM-HIP alloys for nuclear applications because of their microstructural uniformity, superior mechanical properties, and reduced dependence on welding and machining, compared to cast/forged alloys. Nuclear code-qualification of PM-HIP alloys requires neutron irradiation testing to demonstrate performance under relevant conditions. In this experiment, six nuclear structural alloys were irradiated: Ni-based alloys 625 and 690, Grade 91 ferritic steel, SA508 pressure vessel steel, and 304L and 316L austenitic stainless steels. The experiment is assembled into seven capsules in four test trains and irradiated in three ATR inboard A positions. Both the PM-HIP and cast/forged versions of each alloy were irradiated under nearly identical conditions for comparative purposes, to target doses of 1 ± 0.2 and 3 ± 0.2 dpa at temperatures of 300 ± 50 °C and 400 ± 50 °C. A thorough description of the experiment design and thermal, structural and neutronic analyses performed to ensure the targeted irradiation conditions are met is provided. Specimens were configured as small disks, compact tension specimens and tensile bars to facilitate post-irradiation examination (PIE) that will include mechanical testing, microstructure characterization, and fracture toughness testing. Given the considerations for ASTM standardized mechanical testing, comparative fluence and temperature across specimen pairs, and comprehensive PIE planning herein, this work serves as a template for future nuclear materials qualification experiment designs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

TREAT Neutronics Analysis of Water-Loop Concept Accommodating LWR 9-rod Bundle

Abstract. Simulation of a variety of transient conditions has been successfully achieved in the Transient Reactor Test (TREAT) facility during operation between 1959 and 1994 to support characterization and safety analysis of nuclear fuels and materials. A majority of previously conducted tests were focused on supporting sodium-cooled fast reactor (SFR) designs. Experiments evolved in complexity. Simulation of thermal-hydraulic conditions expected to be encountered by fuels and materials in a reactor environment was realized in the development of TREAT sodium loop experiment vehicles. These loops accommodated up to 7-pin fuel bundles and served to simulate more closely the reactor environment while safely delivering large quantities of energy into the test specimen. Some of the immediate TREAT restart operations will be focused on testing light water reactor (LWR) accident tolerant fuels (ATF). Similar to the sodium loop objectives, a water loop concept, developed and analyzed in the 1990’s, aimed at achieving thermal-hydraulic conditions encountered in commercial power reactors. The historic water loop concept has been analyzed in the context of a reactivity insertion accident (RIA) simulation for high burnup LWR 2-pin and 3-pin fuel bundles. Findings showed sufficient energy could be deposited into the specimens for evaluation. Similar results of experimental feasibility for the water loop concept (past and present) have recently been obtained using MCNP6.1 with ENDF/B-VII.1 nuclear data libraries. The old water loop concept required only two central TREAT core grid spaces. Preparation for future experiments has resulted in a modified water loop conceptual design designated the TREAT water environment recirculating loop (TWERL). The current TWERL design requires nine TREAT core grid spaces in order to place the water recirculating pump under the TREAT core. Due to the effectiveness of water moderation, neutronics analysis shows that removal of seven additional TREAT fuel elements to facilitate the experiment will not inhibit the ability to successfully simulate a RIA for the 2-pin or 3-pin bundle. This new water loop design leaves room for accommodating a larger fuel pin bundle than previously analyzed. The 7-pin fuel bundle in a hexagonal array with similar spacing of fuel pins in a SFR fuel assembly was considered the minimum needed for one central fuel pin to encounter the most correct thermal conditions. The 9-rod fuel bundle in a square array similar in spacing to pins in a LWR fuel assembly would be considered the LWR equivalent. MCNP analysis conducted on a preliminary LWR 9-rod bundle design shows that sufficient energy deposition into the central pin can be achieved well within range to investigate fuel and cladding performance in a simulated RIA. This is achieved by surrounding the flow channel with an additional annulus of water. Findings also show that a highly significant increase in TREAT to specimen power coupling factor (PCF) within the central pin can be achieved by surrounding the experiment with one to two rings of TREAT upgrade fuel assemblies. The experiment design holds promise for the performance evaluation of PWR fuel at extremely high burnup under similar reactor environment conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Experimental design, operation, and results of a 4 kW high temperature steam electrolysis experiment

High temperature steam electrolysis (HTSE) is a promising technology for large-scale hydrogen production. However, research on HTSE performance above the kW level is limited. This paper presents the results of 4 kW HTSE long-term test completed in a multi-kW test facility recently developed at the Idaho National Laboratory (INL). The 4 kW HTSE unit included two solid oxide electrolysis stacks operating in parallel, each of which included 40 electrode-supported planar cells. A current density of 0.41 A/cm2 was used for the long-term operation, resulting in a hydrogen production rate about 25 slpm. A demonstration of 920 hours stable operation was achieved. The paper also includes detailed descriptions of the piping layout, steam generation and delivery system, test fixture, heat recuperation system, hot zone, instrumentation, and operating conditions. As a result, this successful demonstration of multi-kW scale HTSE unit will help to advance the technology toward near-term commercialization.

08 HYDROGEN↗

DOE OSTI2015

Scaling Analysis Techniques to Establish Experimental Infrastructure for Component, Subsystem, and Integrated System Testing

Hybrid energy system research has the potential to expand the application for nuclear reactor technology beyond electricity. The purpose of this research is to reduce both technical and economic risks associated with energy systems of the future. Nuclear hybrid energy systems (NHES) mitigate the variability of renewable energy sources, provide opportunities to produce revenue from different product streams, and avoid capital inefficiencies by matching electrical output to demand by using excess generation capacity for other purposes when it is available. An essential step in the commercialization and deployment of this advanced technology is scaled testing to demonstrate integrated dynamic performance of advanced systems and components when risks cannot be mitigated adequately by analysis or simulation. Further testing in a prototypical environment is needed for validation and higher confidence. This research supports the development of advanced nuclear reactor technology and NHES, and their adaptation to commercial industrial applications that will potentially advance U.S. energy security, economy, and reliability and further reduce carbon emissions. Experimental infrastructure development for testing and feasibility studies of coupled systems can similarly support other projects having similar developmental needs and can generate data required for validation of models in thermal energy storage and transport, energy, and conversion process development. Experiments performed in the Systems Integration Laboratory will acquire performance data, identify scalability issues, and quantify technology gaps and needs for various hybrid or other energy systems. This report discusses detailed scaling (component and integrated system) and heat transfer figures of merit that will establish the experimental infrastructure for component, subsystem, and integrated system testing to advance the technology readiness of components and systems to the level required for commercial application and demonstration under NHES.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2014

Strategic need for a multi-purpose thermal hydraulic loop for support of advanced reactor technologies

This report presents a conceptual design for a new high-temperature multi fluid, multi loop test facility for the INL to support thermal hydraulic, materials, and thermal energy storage research for nuclear and nuclear-hybrid applications. In its initial configuration, the facility will include a high-temperature helium loop, a liquid salt loop, and a hot water/steam loop. The three loops will be thermally coupled through an intermediate heat exchanger (IHX) and a secondary heat exchanger (SHX). Research topics to be addressed with this facility include the characterization and performance evaluation of candidate compact heat exchangers such as printed circuit heat exchangers (PCHEs) at prototypical operating conditions, flow and heat transfer issues related to core thermal hydraulics in advanced helium-cooled and salt-cooled reactors, and evaluation of corrosion behavior of new cladding materials and accident-tolerant fuels for LWRs at prototypical conditions. Based on its relevance to advanced reactor systems, the new facility has been named the Advanced Reactor Technology Integral System Test (ARTIST) facility. Research performed in this facility will advance the state of the art and technology readiness level of high temperature intermediate heat exchangers (IHXs) for nuclear applications while establishing the INL as a center of excellence for the development and certification of this technology. The thermal energy storage capability will support research and demonstration activities related to process heat delivery for a variety of hybrid energy systems and grid stabilization strategies. Experimental results obtained from this research will assist in development of reliable predictive models for thermal hydraulic design and safety codes over the range of expected advanced reactor operating conditions. Proposed/existing IHX heat transfer and friction correlations and criteria will be assessed with information on materials compatibility and instrumentation needs. The experimental database will guide development of appropriate predictive methods and be available for code verification and validation (V&V) related to these systems.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2013

Durability Evaluation of Reversible Solid Oxide Cells

An experimental investigation on the performance and durability of single solid oxide cells (SOCs) is under way at the Idaho National Laboratory. Reversible operation of SOCs includes electricity generation in the fuel cell mode and hydrogen generation in the electrolysis mode. Degradation is a more significant issue when operating SOCs in the electrolysis mode. In order to understand and mitigate the degradation issues in high temperature electrolysis, single SOCs with different configurations from several manufacturers have been evaluated for initial performance and long-term durability. A new test apparatus for single cell and small stack tests has been developed for this purpose. Cells were obtained from four industrial partners. Cells from Ceramatec Inc. and Materials and Systems Research Inc. (MSRI) showed improved durability in electrolysis mode compared to previous stack tests. Cells from Saint Gobain Advanced Materials Inc. (St. Gobain) and SOFCPower Inc. demonstrated stable performance in the fuel cell mode, but rapid degradation in the electrolysis mode, especially at high current density. Electrolyte-electrode delamination was found to have a significant impact on degradation in some cases. Enhanced bonding between electrolyte and electrode and modification of the electrode microstructure helped to mitigate degradation. Polarization scans and AC impedance measurements were performed during the tests to characterize cell performance and degradation.

08 HYDROGEN↗