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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

The Production of Low Ash Coals Using the Hydrophobic-Hydrophilic Separation Process with Novel Developments

Froth flotation is a common mineral processing method in coal preparation. This process becomes less efficient, however, as particle size is reduced, and ultrafine particles are often discarded prior to froth flotation, contributing to a substantial amount of coal waste in impoundments. Because of the land-use and risk of an impoundment failure, these impoundments pose an environmental liability. To address ultrafine coal rejection, researchers at Virginia Tech developed the hydrophobic-hydrophilic separation (HHS) process. Unlike in froth flotation, HHS uses an organic solvent to separate and dewater hydrophobic particles from hydrophilic minerals. Past work on the HHS process yielded promising results. In particular, the HHS process has produced a low-ash (<2%) and low moisture (<8%) product, which is a viable feed stock for carbon products. In this work, an investigation of the effects of auxiliary processes on the HHS process was conducted. The auxiliary processes included grinding, pre-concentration, and reagent conditioning. This work also contains an investigation on the interaction between two primary unit operations in the HHS process: oil agglomeration and de-emulsification. Lastly, to make the HHS process more viable for commercial scale-up, a novel unit operation was developed and tested that performs comparably to the current HHS process.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Whole-Genome Sequencing and Bioinformatic Analysis of Environmental, Agricultural, and Human Campylobacter jejuni Isolates From East Tennessee

As a leading cause of bacterial-derived gastroenteritis worldwide, Campylobacter jejuni has a significant impact on human health in both the developed and developing worlds. Despite its prevalence as a human pathogen, the source of these infections remains poorly understood due to the mutation frequency of the organism and past limitations of whole genome analysis. Recent advances in both whole genome sequencing and computational methods have allowed for the high-resolution analysis of intraspecies diversity, leading multiple groups to postulate that these approaches may be used to identify the sources of Campylobacter jejuni infection. To address this hypothesis, our group conducted a regionally and temporally restricted sampling of agricultural and environmental Campylobacter sources and compared isolated C. jejuni genomes to those that caused human infections in the same region during the same time period. Through a network analysis comparing genomes from various sources, we found that human C. jejuni isolates clustered with those isolated from cattle and chickens, indicating these as potential sources of human infection in the region.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Nevada Higher Education Benefits from US Department of Energy (DOE) Environmental Management (EM) Nevada Program's Transfer of Geologic Samples - 20442

The Nevada National Security Site (NNSS), formerly the Nevada Test Site, was the location of 100 historic atmospheric and 828 historic underground nuclear tests from 1951 to 1992. Related to this historic nuclear testing, geologic and hydrologic studies of the site were conducted utilizing the skills and the expertise of the U.S. Geological Survey (USGS) and national laboratories (Los Alamos National Laboratory, Lawrence Livermore National Laboratory), who were principal in leading the development of weapons and were responsible for specific underground testing programs. The subsurface samples and technical/scientific data associated with NNSS geologic studies (past and present) are preserved and stored at the USGS Mercury Core Library and Data Center located at the NNSS. Currently, the facility stores over 2,000,000 linear feet of cores and cuttings from more than 2,600 drill holes that can be accessed for study. Most of the samples and historic geologic work was focused directly on subsurface geologic settings that relate directly to historic underground nuclear testing. Since 1992, the United States has observed a unilateral moratorium on full-scale nuclear testing, and the U.S. Department of Energy (DOE) Environmental Management (EM) Nevada Program is now responsible for hydrogeologic characterization of the potential impacts to the natural groundwater systems that may have resulted from historic underground nuclear tests. As part of this effort, the EM Nevada Program Underground Test Area (UGTA) Activity has drilled and completed over 58 deep (2,000 - 7,000 ft.) characterization wells, totaling in excess of 170,000 linear feet of cuttings and core samples. Cutting samples were collected as triplicate samples for each respective depth interval, to account for potential later nondestructive/destructive analysis and to preserve samples for regulatory purposes. Recently, it was recognized by the EM Nevada Program that opportunities may exist to reduce the cost and floor space required for the storage of geologic samples at the Mercury Core Library without impacting the integrity and representative nature of the samples necessary for project execution. An initiative was sponsored by EM Nevada Program to evaluate several options: 1) disposal of a portion of cuttings and cores in a land fill setting; 2) reduction in sample volume through skeletonizing core and cuttings from wells to a representative but much smaller number of samples; and 3) solicit potential interest in the academic community where other geoscientists could freely access the samples for studies. The Nevada state university system through the Nevada Bureau of Mines and Geology responded positively to the opportunity to receive these NNSS samples from the EM Nevada Program. In June 2019, approximately 17,000 geologic samples, representing greater than 170,000 linear feet of drilling and weighing over 20,000 pounds, were shipped from the NNSS to the Great Basin Science Sample and Records Library located in Reno, Nevada. The benefits resulting from this transfer were realized by the EM Nevada Program in terms of cost and space savings for geologic sample storage at the NNSS. The transfer did not impact the EM Nevada Program mission as access to representative geologic samples for regulatory and scientific purposes was preserved. Moreover, the Nevada Bureau of Mines and Geology acquired a significant resource of subsurface geologic samples and supporting technical data to support academic and scientific studies in a complex volcanic setting in southwest Nevada. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Predictive coarse-grained (CG) modeling of morphologies in polymer nanocomposites with specific and directional intermolecular interactions (Final Report)

The overarching goal of the proposed work was to develop predictive models for investigating structure and dynamics in soft materials with chemistries that have specific and directional molecular interactions. The motivation behind studying materials with specific and directional interactions lies in the many desirable features these interactions provide when designing novel soft materials. Soft materials with specific and direction interactions (such as hydrogen bonds or H-bonds) can have a) thermally reversible phase behavior with different functions with varying temperature, b) precisely tuned nanostructure with desirable geometries that afford unique physical properties (e.g., color response, mechanical properties) and c) well-mixed/blended morphologies that are useful for variety of applications in energy field (e.g., materials for batteries require use of blended polymers where one domain gives superior mechanical properties and one domain promotes electrical conduction). Notably, biology makes extensive use of specific and directional interactions, in many cases based on H-bonds, to construct materials with precisely defined architectures and properties. Engineered soft materials with precisely tuned nanostructures and improved processiblity through thermoresponsive phase behavior are useful in numerous applications that are relevant to the Department of Energy (DOE) including high efficiency electronic devices, light-weight high-strength composite materials for batteries and fuel cells, and polymer membranes for separations, etc. While past computational studies have been tremendously useful in understanding molecular phenomena and guiding synthesis of new macromolecular soft materials for a wide variety of applications, the inability to capture small scale specific and directional interactions alongside macromolecular length and time scales represented a key limitation of most studies to date. Our work in this project addressed this grand challenge in computational materials chemistry, i.e., ability to model the anisotropic, directional, and specific interactions that govern the behavior of many macromolecular soft matter systems of interest, thus, has greatly expanded the predictive potential of simulations. Specifically the key outcomes were: successful development of new coarse-grained (CG) polymer models to study generic and specific polymer chemistries in which hydrogen-bonding interactions are dominant. These CG models were then used in molecular simulations to study structure and thermodynamics in polymer nanocomposites and blends; some studies were conducted in collaboration with experimentalists. We also published a perspective and a viewpoint which included some of the work we completed in this DOE project; we believe these perspective and viewpoint articles guide other researchers in the soft materials community on how to extend the computational approaches and models we have developed for the purposes of their studies.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A conceptual framework for residential energy security in the context of clean energy transitions

Energy security is a crucial aspect of human well-being. As climate change impacts become more evident, countries are constructing equitable, resilient, and sustainable clean energy transition policies to reduce emissions while ensuring energy security. Climate policies globally highlight the importance of national energy security. Furthermore, adequate and affordable access to household energy is also critical to the continued prioritization of climate mitigation. However, past energy security discussions within the broader climate research and policymaking community primarily focused on national-level energy supply as a critical metric of energy security. Less research has explored the potential implications of energy transitions for residential energy security, often focusing on a single dimension of residential energy security. Thus, we conduct a review of journal articles and governmental plans to develop a conceptual framework of residential energy security and facilitate communication among researchers and policymakers. The framework is designed around four foundational pillars, five metrics measuring residential energy security, and seven drivers influencing the metrics. Additionally, we provide policy examples to show how this framework can be applied to inform decision-making. Thus, this paper makes important contributions to the literature by (a) creating a framework to better understand the concept of energy security at the household level for future research and policy-relevant communications, (b) identifying gaps in the current literature, and (c) highlighting instances where aspects of residential energy security are discussed in policies and governmental plans, which help serve as guiding examples for future applications of our framework in the policymaking processes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Spatial control of perilacunar canalicular remodeling during lactation

Abstract Osteocytes locally remodel their surrounding tissue through perilacunar canalicular remodeling (PLR). During lactation, osteocytes remove minerals to satisfy the metabolic demand, resulting in increased lacunar volume, quantifiable with synchrotron X-ray radiation micro-tomography (SRµCT). Although the effects of lactation on PLR are well-studied, it remains unclear whether PLR occurs uniformly throughout the bone and what mechanisms prevent PLR from undermining bone quality. We used SRµCT imaging to conduct an in-depth spatial analysis of the impact of lactation and osteocyte-intrinsic MMP13 deletion on PLR in murine bone. We found larger lacunae undergoing PLR are located near canals in the mid-cortex or endosteum. We show lactation-induced hypomineralization occurs 14 µm away from lacunar edges, past a hypermineralized barrier. Our findings reveal that osteocyte-intrinsic MMP13 is crucial for lactation-induced PLR near lacunae in the mid-cortex but not for whole-bone resorption. This research highlights the spatial control of PLR on mineral distribution during lactation.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Chapter 8: Searching for Life Beyond Earth

The search for life beyond Earth necessitates a rigorous and comprehensive examination of biosignatures, the types of observable imprints that life produces. These imprints and our ability to detect them with advanced instrumentation hold the key to our understanding of the presence and abundance of life in the universe. Biosignatures are the chemical or physical features associated with past or present life and may include the distribution of elements and molecules, alone or in combination, as well as changes in structural components or physical processes that would be distinct from an abiotic background. The scientific and technical strategies used to search for life on other planets include those that can be conducted in situ to planetary bodies and those that could be observed remotely. Here this chapter discusses numerous strategies that can be employed to look for biosignatures directly on other planetary bodies using robotic exploration including those that have been deployed to other planetary bodies, are currently being developed for flight, or will become a critical technology on future missions. Search strategies for remote observations using current and planned ground-based and space-based telescopes are also described. Evidence from spectral absorption, emission, or transmission features can be used to search for remote biosignatures and technosignatures. Improving our understanding of biosignatures, their production, transformation, and preservation on Earth can enhance our search efforts to detect life on other planets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Cyber100 Compass [SWR 23-64]

Cyber100 Compass ("Compass") is a unique risk assessment framework that will enable grid system planners to understand and mitigate cybersecurity risk for grids transitioning to high levels of renewable generation, including 100%. The idea for Compass was developed by NREL based on past work on high-renewable grids and a series of discussions with DOE. Compass is part of Cyber100, a portfolio of proposed research activities that would greatly expand understanding of cybersecurity for high-renewable grids. Compass is a desktop application designed with a user-friendly interface. The tool gathers information from users, conducts probabilistic backend calculations, and outputs a series of visualizations to help users understand and analyze their cybersecurity risks based on the unique features of their future grid. Compass will take as inputs the values for different conditions and produce a risk score of the resulting grid. By trying different configurations, system planners can compare the resultant risks against their own risk tolerance and decide which system-of-system controls to implement as they transition toward a 100% renewable grid.

Martin, Maurice↗
DOE OSTI2020

Shaker Table Test Plan

Currently, spent nuclear fuel (SNF) is stored in onsite independent spent fuel storage facilities (ISFSIs), which is a dry storage facility, at 55 nuclear power plant sites. The majority of SNF in dry storage is in welded metal canisters (2,917 canisters at the end of 2019). The canisters are loaded for storage in storage overpacks (vertical casks or horizontal storage modules) and placed on outdoor concrete pads. Because the SNF will be stored at ISFSIs for an extended period of time, there is growing concern with regards to the behavior of the SNF within these dry storage systems during earthquakes. To address these concerns, the SFWST program is considering conducting an earthquake shaker table test. The goal of this test is to determine the strains and accelerations on fuel assembly hardware and cladding during earthquakes of different magnitudes to better quantify the potential damage an earthquake could inflict on spent nuclear fuel rods. The seismic integrity of the storage system has been addressed in the past by the US Nuclear Regulatory Commission and is not the focus of this potential test. Instead the DOE would benefit from knowing the condition of the fuel cladding from storage, transportation, to disposal so that it can ascertain repository performance for the fuel and packaging in its final state. A seismic event is part of the possible loading events that the fuel could experience in its lifetime. This report proposes several earthquake shaker table tests with different degrees of complexity. Alternative 1 was defined in the FY20 work scope. Alternatives 2 and 3 were recently developed to take advantage of the NUHOMS 32PTH dry storage canister that may be available in FY21 for this test at a minimum cost to the project. The selection of the alternative(s) will depend on the available budget and the SFWST program priorities for the near future.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Field Insights: Strengthening Digital Assurance Through On-Site Network Monitoring

The accelerating deployment of digital energy infrastructure, ranging from inverter-based resources (IBRs), battery energy storage systems (BESS), to advanced grid control platforms, has brought unprecedented visibility, flexibility, and efficiency to the electric grid. However, this digital transformation also introduces new cybersecurity challenges, particularly in the form of supply chain risks and operational blind spots at the grid edge. Over the past year, the Department of Energy’s Office of Cybersecurity, Energy Security, and Emergency Response (CESER), through its Rapid Risk Assessment initiative, along with the Grid Deployment Office (GDO), through its Technical Assistance for Digital Assurance (TADA) initiative, have supported a series of on-site network engagements led by Idaho National Laboratory (INL). These engagements, conducted in partnership with asset owners across the country, have focused on identifying real-world vulnerabilities and misconfigurations in operational environments, many of which are not detectable through remote assessments or traditional compliance audits. The goal of this report is to distill key findings and lessons learned during network hunt engagements from INL’s fiscal year (FY) 2024 - 2025. It is intended to help asset owners—regardless of their participation in the program—better understand the evolving threat landscape and adopt practical measures to secure their digital energy infrastructure.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Microstructural refinement of cement paste internally cured by polyacrylamide composite hydrogel particles containing silica fume and nanosilica

Supplementary cementitious materials were incorporated into hydrogel-based internal curing agents to improve the hydration, microstructure, and ultimately strength of internally cured high-performance cement paste. Polyacrylamide composite hydrogel particles containing amorphous silica – either silica fume or nanosilica – and two different polymer network crosslink densities were synthesized and incorporated into cement paste. The presence of silica and low crosslink density increased the absorption capacity of the particles in pore solution. Micrographs of internally cured paste indicated a significant improvement in hydrogel-related void-filling ability and an increase in void size for low crosslink density particles containing silica. Compressive strength and electrical resistivity increased at later ages for paste samples containing particles with higher silica dosage. The relationship between extent of hydration, void size, and void-filling activity was found to strongly influence the paste's long-term strength and is thus an important structure-property relationship to consider when selecting hydrogels for internal curing purposes.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Donald J. Trump’s Presidency in Cyberspace: A Case Study of Social Perception and Social Influence in Digital Oligarchy Era

In the past few years, with the rapid growth of digital technologies, Facebook, Twitter, and other social media platforms have become the digital oligarchies, which have the enormous capabilities to potentially control what is discussed in cyberspace. In the digital oligarchy era, social perception and social influence in different complex social systems have evolved quickly. In this article, we conducted large-scale empirical studies on social perception and social influence regarding the Trump phenomenon from personal perception, media, and public attention perspectives. We found that there exist obvious correlations between the posting behavior of Trump and the attention of news media. By constructing public attention networks using complex networks based on Google search information, we further reveal that digital platforms could affect social perception and social influence significantly. Especially, we obtained that the public attention can always be influenced by the political moments.

digital oligarchy↗
DOE OSTI2024

Assessment of Electric Grid Transmission System Simulator for Human Factors Research

Over the past decades, various technologies have been developed for electric grid operations to support clean energy, meet rising electricity demands, and address infrastructure concerns. However, the human factors aspect is often overlooked during rapid integration. Questions persist about how these technologies impact human performance. Simulators play a critical role in supporting investigation of human factors design concepts and conducting comprehensive usability testing to evaluate human performance and assess human reliability. This paper aims to address human factors research simulator requirements and conduct a comparative study of six different simulators. A detailed evaluation reveals that the evaluated simulators lack the ability to customize user interfaces. Additionally, their user interface designs do not fulfill the basic human factors design principles, potentially leading to increased response variability and reduced statistical power when conducting controlled experimental research. In the future, it is essential to develop scripting tools to integrate customizable user interfaces and simulation models, ensuring meeting research requirements.

Li, Ruixuan↗
DOE OSTI2022

Sludge Processing Options for early HLW Treatment at Hanford

The U.S. Department of Energy’s (DOE) Hanford Site has 177 underground storage tanks that contain wastes from past nuclear fuel reprocessing and waste-management operations. Over 20% of this waste is in the form of an insoluble sludge that will require solids concentration and washing prior to vitrification for long-term disposal. An assessment of potential flowsheet operations to support feed preparation activities prior to high level waste (HLW) vitrification has been conducted to better evaluate pretreatment processing options. Settling studies assessing the baseline approach of a settle-decant method were explored as well as a crossflow filtration system to be used alternatively for concentrating and washing HLW sludge. Significant variations in behavior of settling rates and sludge characteristics give reason to evaluate alternative pretreatment options for the HLW. Non-radioactive sludge containing iron oxide, boehmite, and gibbsite were evaluated via gravity settling and crossflow filtration to determine the behavior of these compounds in various tank waste matrices. Understanding the predictive capabilities of HLW solids settling as well as sludge concentration via crossflow filtration can help provide technical guidance during flowsheet planning.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Unconventional Highly Active and Stable Oxygen Reduction Catalysts Informed by Computational Design Strategies

As conventional strategies of engineering new MIEC materials for SOFCs over the past few decades would have eliminated a material like BFCZ75 from contention, this work suggests there is a need to re-think existing design criteria and develop and understand new rational materials design strategies that challenge conventional wisdom and chemical intuition. The ultimate goal of cathode design of SOFCs is to achieve a balance among electrical conductivity, ionic conductivity, oxygen exchange activity and long-term stability. Instead of searching for a replacement for unstable MIEC like LSCF, which works well in a ceria based composite electrode, some stable composites contain a highly conductive material mixing with a less conductive but highly ORR active and stable MIEC such as BFCZ75 or even triple-phase composites could be an alternative way to advance the current SOFC technology. (This work is published in May 2022 issue of Advanced Energy Materials. https://doi.org/10.1002/aenm.202201203 --&gt;)<br>

Liu, Jian↗
DOE OSTI2022

Westinghouse Accident Tolerant Fuel Phase 2B with Higher Enriched and Higher Burnup Add-On Project Final Technical Report Deliverable Volume 1

The Westinghouse Electric Company LLC (Westinghouse) accident tolerant fuel (ATF) program funded by Westinghouse and the US Department of Energy (DOE) utilized chromium (Cr) coated zirconium alloy cladding with doped UO 2 (ADOPT(TM)) and uranium silicide (U 3 Si 2 ) high density/high thermal conductivity fuel for its lead test rod (LTR) program with irradiation beginning in 2019. ADOPT is a Cr 2 O 3 +Al 2 O 3 doped UO 2 pellet with increased oxidation resistance and density, and increased resistance to fission gas release. Due to the issues with U 3 Si 2 fuel reaction in pressurized water reactor (PWR) environments, uranium nitride (U 15 N) has been substituted for U 3 Si 2 as a long-term fuel option. Cr coated cladding with ADOPT fuel is the near-term Westinghouse EnCore fuel product. The long-term EnCore ® fuel product is SiGA ® SiC/SiC composite cladding with high density/high thermal conductivity UN fuel. In 2020, the higher burnup and higher enriched and (HBHE) program was integrated into the ATF program. The objective of this expanded program is to extend ATF burnups to at least 75 MWd/kgU to economically facilitate 24-month cycles in PWRs. The ATF program now includes ADOPT fuel with enrichments >5% 235 U. Over the past several years, Westinghouse has tested the Cr coated zirconium (Zr) and silicon carbide (SiC) claddings in Westinghouse Churchill autoclaves and the Massachusetts Institute of Technology (MIT) reactor. Additionally, the Cr coated cladding has been tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) and in LTR programs at the Doel 4 and Bryon 2 commercial reactors. High temperature tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried out to determine the time and temperature limits for the Cr coated zirconium claddings. These tests indicate that Cr coated Zr cladding can take temperatures up to about 1500°C for short periods of time without becoming totally oxidized. The main issue is the formation of the Cr-Zr eutectic at 1333°C resulting in the migration of this eutectic inward with the formation of ZrCr 2 which rapidly oxidizes to ZrO 2 on the outside of the tube. The Cr coated Zr cladding also delays the bursting of the tube, reduces the burst area, and reduces hydriding and embrittlement of the Zr which is a major benefit for reducing fuel fragmentation, redistribution, and dispersal (FFRD), the major licensing issue faced by HBHE. The manufacturing parameters for the SiC have been found to have a significant effect on the corrosion rate of the SiC in light water reactor (LWR) conditions and significant improvements have been made in the yield, quality, and oxidation resistance of the SiC cladding by identifying and tightening manufacturing process parameters. Current autoclave results for SiC composite claddings indicate that a corrosion rate of fewer than 2 micrometers per year can be achieved which meets corrosion requirements under normal operating conditions. High temperature steam oxidation tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried and determined that SiC cladding can withstand temperatures up to about 1800°C to 1900°C before excessive corrosion reactions begin, and that the SiC will not balloon and burst. ADOPT fuel pellets were incorporated into the Westinghouse ATF program because of their increased density and oxidation resistance. A topical report supporting the use of ADOPT pellets has been submitted to the NRC and will be approved shortly. ADOPT pellets have been a product in Europe for over 15 years. The additives work to make larger grain sizes which appear to reduce fission gas release during transients as well as increase the density of the pellet. Fuel rod and assembly design in preparation for the lead test rod (LTR) and lead test assembly (LTA) programs is underway as well as licensing efforts with the Nuclear Regulatory Commission (NRC). Finally, accident analyses coupled with economic evaluations for both operating savings as well as fuel savings have been initiated. Modular Accident Analysis Program 5 (MAAP5) calculations indicate that both Cr coated cladding and SiC composite cladding can increase the time to fuel rod loss of geometry for up to two hours longer than current Zr based cladding in a station blackout scenario. This additional time is due to the much higher oxidation resistance of the SiC and Cr coated cladding. These two hours can be used to implement additional response options instituted through the Diverse and Flexible Mitigation Capability (FLEX) program by reactor operators. Both ATF cladding options also reduce hydrogen production which dramatically reduces primary system and containment pressure and the risk of fission product release beyond containment in the unlikely event of an accident. The lower pressure in the system allows more time to feed cooling water to the core, resulting in the avoidance of fuel melting. The coping time is extended indefinitely if the modest water flow provided by FLEX continues. Experimental work on methods to rapidly fabricate SiC composite structures with high density and reduce the fabrication price of SiC fibers while maintaining a high level of performance is needed. Methods for mitigating or stopping the Cr-Zr eutectic are also needed to further improve the oxidation resistance of Cr coated Zr. Minimal (<1%) swelling of U 3 Si 2 and subsequent fission gas release has been demonstrated up to 20 MWd/kgU. Irradiation experiments with U 3 Si 2 fuel in ATR to determine these properties at 40 MWd/kgU were completed but post irradiation examinations were not done since U 3 Si 2 has been replaced by UN. UN has three issues that are being addressed. The first is increasing the oxidation resistance so that there is not excessive reaction up to ~1500°C. While UN increases the pellet density and additives to the UN postponed the temperature at which rapid oxidation occurred by ~100°C to 200°C, this is not enough, and pellet coating options are now being pursued. The second is developing a method to manufacture that does not require the multi-step process of UF 6 to UO 2 to UC to UN. Efforts are underway looking at UF 6 to UN 2 to UN and UF 6 to UF 4 to UN 2 to UN reactions. Finally, an economically acceptable process for potentially enriching the 15 N content of the nitrogen used to make UN to >95% 15N was identified though not experimentally validated. In addition to the work supported by the DOE, research and testing activities are being carried on in a world-wide effort funded by many countries such as Sweden, United Kingdom, Belgium, Netherlands, Spain, Germany, Japan, and France. This work is being facilitated through the Westinghouse led Collaboration for Advanced Research on Accident Tolerant Fuel (CARAT) program. Annual meetings were organized in 2018 and 2019 by Westinghouse as a venue for presentation of this work and to provide for the cross-fertilization of ideas among the many outstanding researchers in the ATF area. No meetings were held in 2020 and 2021 due to the COVID-19 related restrictions on traveling and gatherings. Since SiC, coated cladding, and high-density fuel options are not currently used in the nuclear industry; support from the government and industry members is needed to further the significant effort of setting new standards. The same is true for the Nuclear Regulatory Commission (NRC) which must review and approve the commercial use of these new fuels since all current regulations are oriented toward Zr/UO 2 fuel. Several meetings have been held with the NRC to generate a fast-track approach to licensing ATF using a combination of atomic modeling, in-rod sensors, and in-reactor testing. This approach was memorialized in an “Accelerated Fuel Qualification White Paper” prepared by the Accelerated Fuel Qualification Working Group lead by General Atomics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Westinghouse Accident Tolerant Fuel Phase 2B with Higher Enriched and Higher Burnup Add-On Project Final Technical Report Deliverable Volume 2

The Westinghouse Electric Company LLC (Westinghouse) accident tolerant fuel (ATF) program funded by Westinghouse and the US Department of Energy (DOE) utilized chromium (Cr) coated zirconium alloy cladding with doped UO 2 (ADOPT(TM)) and uranium silicide (U 3 Si 2 ) high density/high thermal conductivity fuel for its lead test rod (LTR) program with irradiation beginning in 2019. ADOPT is a Cr 2 O 3 +Al 2 O 3 doped UO 2 pellet with increased oxidation resistance and density, and increased resistance to fission gas release. Due to the issues with U 3 Si 2 fuel reaction in pressurized water reactor (PWR) environments, uranium nitride (U 15 N) has been substituted for U 3 Si 2 as a long-term fuel option. Cr coated cladding with ADOPT fuel is the near-term Westinghouse EnCore ® fuel product. The long-term EnCore fuel product is SiGA ® SiC/SiC composite cladding with high density/high thermal conductivity UN fuel. In 2020, the higher burnup and higher enriched and (HBHE) program was integrated into the ATF program. The objective of this expanded program is to extend ATF burnups to at least 75 MWd/kgU to economically facilitate 24-month cycles in PWRs. The ATF program now includes ADOPT fuel with enrichments >5% 235 U. Over the past several years, Westinghouse has tested the Cr coated zirconium (Zr) and silicon carbide (SiC) claddings in Westinghouse Churchill autoclaves and the Massachusetts Institute of Technology (MIT) reactor. Additionally, the Cr coated cladding has been tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) and in LTR programs at the Doel 4 and Bryon 2 commercial reactors. High temperature tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried out to determine the time and temperature limits for the Cr coated zirconium claddings. These tests indicate that Cr coated Zr cladding can take temperatures up to about 1500°C for short periods of time without becoming totally oxidized. The main issue is the formation of the Cr-Zr eutectic at 1333°C resulting in the migration of this eutectic inward with the formation of ZrCr 2 which rapidly oxidizes to ZrO 2 on the outside of the tube. The Cr coated Zr cladding also delays the bursting of the tube, reduces the burst area, and reduces hydriding and embrittlement of the Zr which is a major benefit for reducing fuel fragmentation, redistribution, and dispersal (FFRD), the major licensing issue faced by HBHE. The manufacturing parameters for the SiC have been found to have a significant effect on the corrosion rate of the SiC in light water reactor (LWR) conditions and significant improvements have been made in the yield, quality, and oxidation resistance of the SiC cladding by identifying and tightening manufacturing process parameters. Current autoclave results for SiC composite claddings indicate that a corrosion rate of fewer than 2 micrometers per year can be achieved which meets corrosion requirements under normal operating conditions. High temperature steam oxidation tests at the state-of-the-art Westinghouse facilities in Churchill, PA and at Karlsruhe Institute of Technology (KIT) have been carried and determined that SiC cladding can withstand temperatures up to about 1800°C to 1900°C before excessive corrosion reactions begin, and that the SiC will not balloon and burst. ADOPT fuel pellets were incorporated into the Westinghouse ATF program because of their increased density and oxidation resistance. A topical report supporting the use of ADOPT pellets has been submitted to the NRC and will be approved shortly. ADOPT pellets have been a product in Europe for over 15 years. The additives work to make larger grain sizes which appear to reduce fission gas release during transients as well as increase the density of the pellet. Fuel rod and assembly design in preparation for the lead test rod (LTR) and lead test assembly (LTA) programs is underway as well as licensing efforts with the Nuclear Regulatory Commission (NRC). Finally, accident analyses coupled with economic evaluations for both operating savings as well as fuel savings have been initiated. Modular Accident Analysis Program 5 (MAAP5) calculations indicate that both Cr coated cladding and SiC composite cladding can increase the time to fuel rod loss of geometry for up to two hours longer than current Zr based cladding in a station blackout scenario. This additional time is due to the much higher oxidation resistance of the SiC and Cr coated cladding. These two hours can be used to implement additional response options instituted through the Diverse and Flexible Mitigation Capability (FLEX) program by reactor operators. Both ATF cladding options also reduce hydrogen production which dramatically reduces primary system and containment pressure and the risk of fission product release beyond containment in the unlikely event of an accident. The lower pressure in the system allows more time to feed cooling water to the core, resulting in the avoidance of fuel melting. The coping time is extended indefinitely if the modest water flow provided by FLEX continues. Experimental work on methods to rapidly fabricate SiC composite structures with high density and reduce the fabrication price of SiC fibers while maintaining a high level of performance is needed. Methods for mitigating or stopping the Cr-Zr eutectic are also needed to further improve the oxidation resistance of Cr coated Zr. Minimal (<1%) swelling of U 3 Si 2 and subsequent fission gas release has been demonstrated up to 20 MWd/kgU. Irradiation experiments with U 3 Si 2 fuel in ATR to determine these properties at 40 MWd/kgU were completed but post irradiation examinations were not done since U 3 Si 2 has been replaced by UN. UN has three issues that are being addressed. The first is increasing the oxidation resistance so that there is not excessive reaction up to ~1500°C. While UN increases the pellet density and additives to the UN postponed the temperature at which rapid oxidation occurred by ~100°C to 200°C, this is not enough, and pellet coating options are now being pursued. The second is developing a method to manufacture that does not require the multi-step process of UF 6 to UO 2 to UC to UN. Efforts are underway looking at UF 6 to UN 2 to UN and UF 6 to UF 4 to UN 2 to UN reactions. Finally, an economically acceptable process for potentially enriching the 15 N content of the nitrogen used to make UN to >95% 15 N was identified though not experimentally validated. In addition to the work supported by the DOE, research and testing activities are being carried on in a world-wide effort funded by many countries such as Sweden, United Kingdom, Belgium, Netherlands, Spain, Germany, Japan, and France. This work is being facilitated through the Westinghouse led Collaboration for Advanced Research on Accident Tolerant Fuel (CARAT) program. Annual meetings were organized in 2018 and 2019 by Westinghouse as a venue for presentation of this work and to provide for the cross-fertilization of ideas among the many outstanding researchers in the ATF area. No meetings were held in 2020 and 2021 due to the COVID-19 related restrictions on traveling and gatherings. Since SiC, coated cladding, and high-density fuel options are not currently used in the nuclear industry; support from the government and industry members is needed to further the significant effort of setting new standards. The same is true for the Nuclear Regulatory Commission (NRC) which must review and approve the commercial use of these new fuels since all current regulations are oriented toward Zr/UO 2 fuel. Several meetings have been held with the NRC to generate a fast-track approach to licensing ATF using a combination of atomic modeling, in-rod sensors, and in-reactor testing. This approach was memorialized in an “Accelerated Fuel Qualification White Paper” prepared by the Accelerated Fuel Qualification Working Group lead by General Atomics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗