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DOE OSTI2021

High-throughput ion irradiation of additively manufactured compositionally complex alloys

Several advanced nuclear reactor designs promise efficiency and safety improvements over the current reactor fleet but are limited by the current set of ASME code-qualified materials. Novel alloys including high-entropy alloys (HEAs), and more broadly compositionally complex alloys (CCAs), have shown promising irradiation-tolerance. However, the vast range of alloy compositions adds to an already time-consuming alloy development process. In this study, to accelerate the development of novel alloys for nuclear applications, a high-throughput (HTP) methodology has been employed. Additive manufacturing has been used to produce a compositional array of unary, binary, ternary, and quaternary alloys, including several CCAs, which span the Cr-Fe-Mn-Ni composition space. Additionally, the compositional array was homogenized at 1000°C for 24 hours and each sample was irradiated using 4-MeV Ni2+ ions at room temperature to a peak damage of 50 dpa, as estimated using SRIM, at the University of Wisconsin Ion Beam Laboratory. A custom XY stage was built to accommodate the large compositional array and half of each sample was masked during irradiation enabling both the irradiated and unirradiated properties of each alloy to be characterized side-by-side. Each alloy was characterized using X-ray fluorescence (XRF), X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and nanoindentation. CALPHAD simulations spanning the entire Cr-Fe-Mn-Ni composition space at 1000°C were performed to compare predicted equilibrium phases with phases identified experimentally from the unirradiated regions of each alloy. Nanoindentation measurements indicate radiation-induced hardening ranging from ~1-1.5 GPa in each of Cr-Fe-Mn-Ni CCAs, which is relatively insensitive to modest changes in alloy composition and comparable to hardening observed in neutron irradiated Cr-Fe-Mn-Ni CCAs in the literature. Overall, a substantial time savings was realized by employing HTP synthesis, irradiation, and characterization in this study compared to conventional techniques, the implications of which are discussed.

36 MATERIALS SCIENCE↗

NASA NTRS1991

An interagency space nuclear propulsion safety policy for SEI - Issues and discussion

An interagency Nuclear Safety Policy Working Group (NSPWG) was chartered to recommend nuclear safety policy, requirements, and guidelines for the Space Exploration Initiative nuclear propulsion program to facilitate the implementation of mission planning and conceptual design studies. The NSPWG developed a top level policy to provide the guiding principles for the development and implementation of the nuclear propulsion safety program and the development of Safety Functional Requirements. In addition, the NSPWG reviewed safety issues for nuclear propulsion and recommended top level safety requirements and guidelines to address these issues. Safety topics include reactor start-up, inadvertent criticality, radiological release and exposure, disposal, entry, safeguards, risk/reliability, operational safety, ground testing, and other considerations. In this paper the emphasis is placed on the safety policy and the issues and considerations that are addressed by the NSPWG recommendations.

Marshall, A. C.↗

DOE OSTI2021

Conceptual Design of Temperature-Controlled Fueled-Salt Irradiation Experiment to Support Demonstration of Advanced Nuclear Reactors

The irradiation testing of fuel-bearing molten salts is critical to supporting the development and demonstration of molten salt reactors (MSRs). These experiments can inform several important reactor design and safety parameters, including source term modeling, evolution of thermophysical properties with burn-up, and the degradation of structural materials under reactor relevant conditions. Idaho National Laboratory is designing an instrumented and heated high temperature molten salt-fueled irradiation capsule to study the behavior of the fuel salt during in-pile irradiation. This paper details the neutronics, thermal, and mechanical analysis performed to-date. Parametric studies are performed to assess a range of material, different experiment dimensions, two in-reactor positions, and the fuel enrichment used. Principal recommendations are to opt for a peripheral reactor position to alleviate neutronic constraints, a thin salt annulus to alleviate thermal constraints, and high-temperature alloys that provide additional safety margins.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Numerical Simulation and Experimental Comparison of System Analysis Module 1D Mixing Model for Cold Shock Transients in the Gallium Thermal-Hydraulic Mixing Facility

Abstract Liquid metals are being investigated as coolants in many advanced reactor designs because of their high thermal conductivity and effectiveness at high temperatures. However, they often pose challenges to reactor operation and safety because of the complex thermal mixing and stratification in the plenum of pool-type reactor designs. The advanced system analysis code System Analysis Module (SAM) currently under development at Argonne National Laboratory aims to develop and implement thermal mixing models to accurately capture these complex thermal fluid behaviors. In this study, the SAM thermal mixing model was compared against experimental data from the Gallium Thermal-Hydraulic Experiment facility, a scaled liquid metal test facility that uses gallium as a surrogate fluid to investigate the stratification and thermal mixing of low-Prandtl-number fluids in the upper plenum of a liquid metal-cooled reactor. Two cold shock transient cases were used: one with stable stratified flow (Ri = 32) and one with stronger thermal mixing (Ri = 0.5). The resultant temperatures were then compared with the experimental temperatures over the entire plenum to assess the ability of the mixing models to capture the thermal behavior and to better correspond mixing parameters to various flow scenarios. Generally, the zero-dimensional mixing model was more capable of capturing the bulk temperature of the component modeled assuming that an accurate mass flow rate was provided, but it was inherently unable to capture thermal gradients in space. The one-dimensional mixing model was capable of capturing that the thermal gradients provided accurate selection of the mixing coefficients. Further, the temperature at the outlet junction was compared over time for each of the mixing models with the recorded experimental temperature. The implemented mixing models demonstrated the ability to effectively capture the overall thermal behavior for stronger mixing scenarios but struggled with more stably stratified flows. It was found that a system analysis code's covering of the entire range of different operating conditions still remains a challenging task, and it is suggested that further model and closure improvements are necessary to accurately capture complex thermal mixing and stratification phenomena.

stratification↗

DOE OSTI2021

Mapping the scattered family tree of fission neutrons

A statistically predicted tendency for neutrons produced inside fission reactors to form in clusters can cause asymmetrical energy production that is counterbalanced, at least in part, by the spontaneous fission of radioactive material in the reactor. This neutron-clustering effect theory has been demonstrated in a nuclear reactor for the first time and was described in an article published by Los Alamos National Laboratory. The findings of a study supported by the Department of Energy’s Nuclear Criticality Safety Program, funded through the National Nuclear Security Administration, and carried out in collaboration with two French nuclear agencies—the Institute for Radiological Protection and Nuclear Safety (IRSN) and the Atomic Energy Commission (CEA)—could improve reactor safety and lead to more accurate simulations, according to LANL. The team found that a complete die-off was avoided in the small reactor because spontaneous fission—nuclear splitting of radioactive material inside reactors that is not caused by direct impact from a fission neutron—creates more neutrons. The balance of fission chain reactions and spontaneous fission lessens the impact of energy bursts created by clustering neutrons.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

Project Presentation: Hardware-Based Demonstration of Temperature Control Functions for Reactor Systems

Autonomous thermal regulation in nuclear reactors 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) with an embedded proportional-integral-derivative (PID) algorithm for control, a hardware-based demonstration of a reactor heating system will validate the efficacy of reactor control over this key parameter. This report covers internship project presentation as well as relevant experience with nuclear and proposal for project upgrade.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Poster: Hardware-Based Demonstration of Temperature Control Functions for Reactor Systems

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2022

ARC-100 Conceptual Design Phase Level 1 PSA Early Draft

This report represents the initial structure and content created for the ARC-100 nuclear reactor initial conceptual design Probabilistic Safety Assessment. The objective of the study is to assess the safety of the ARC-100 nuclear reactor conceptual design using a risk-informed approach. This early draft report is the first transmittal of the Probabilistic Safety Assessment approach and will be expanded over the remainder of the projects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Impact of Heaters on Molten Salt Reactors Dynamics

Recently, there has been renewed interest in the Molten Salt Reactor (MSR) concept. This interest is mainly due to its advantages over Light Water Reactors (LWRs). Among these advantages are the flexibility in the fuel choice and the possibility to burn actinides [1]. Currently, two molten research reactors are under development. A 2 MW molten salt experimental reactor has been constructed and is planned for operation in China. A 1 MW Molten Salt Research Reactor is under construction in the United States [2]. Thus, Research and Development (R&D) programs are needed for the MSR technology. Reactor dynamics studies are crucial safety evaluation studies. The development of reactor dynamics tools for MSRs started during the Molten Salt Reactor Program (MSRP) at ORNL, focusing on the Molten Salt Reactor Experiment (MSRE) [3]. Although various dynamic simulation tools are available, R&D efforts to develop specialized tools for MSRs are still ongoing [4]. The primary motivation for this interest is the goal of commercializing MSRs. Developing a dynamics tool for MSRs is crucial for analyzing their safety and supporting their demonstration efforts. A crucial safety issue in MSRs is ensuring that the fuel salt in the primary loop remains molten. This concern becomes particularly important when the reactor operates at lower power levels. Most chloride and fluoride salts used as fuel have a melting point of approximately 450 °C [5]. Therefore, maintaining fuel salt temperatures above this melting point is essential to prevent it from freezing. Freezing of the fuel salt can lead to volume expansion, potentially causing damage to reactor components [6]. Moreover, it can create local blockages within fuel salt channels, reducing cooling efficiency and resulting in hot spots [7]. Various methods can prevent fuel salt from freezing at low power levels. These include reducing the fuel mass flow rate in the primary loop, decreasing heat exchange between the primary and secondary loops in the reactor, and using electric fuel salt heaters. Reducing the mass flow rate of fuel salt in the primary loop can increase the fuel salt transit time in the core, enhancing heat production and increasing temperature. However, it can potentially lead to challenges. These include increasing the potential for fuel salt deposition on the reactor channel walls [8], affecting the overall heat transfer processes. Thus, alternative methods should be used [9]. This research investigates the effects of fuel salt heaters on the dynamics and stability during MSR operation. The investigation includes studying the reactor stability with the fuel salt heaters on and off. In addition, the reactor response to transients is compared with and without the operation of fuel salt heaters. These transients include reactivity insertion, primary and secondary pump failure, and heat sink temperature increase. The results of the reactivity insertion transient are presented in the summary.

73 - NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Ab Initio Evaluation of Plutonium Dioxide $S(α,β)$ and Thermal Neutron Cross Sections

Plutonium Dioxide (PuO 2 ) is an advanced fuel-cycle nuclear fuel material for thermal and fast reactors, with a melting point at 3261.8 K and thermal conductivity above 3 Wm -1 K -1 for temperatures below 1500 K. Plutonium from spent UO 2 is reprocessed to form chemically stable mixed oxide (MOX) fuel. In contrast to metallic fuels, the low PuO 2 conductivity results in high thermal gradients between fuel center and surface, resulting in structural annealing and efficient fission product migration over burnup. Crystal binding affects the doppler broadening of epithermal resonances for nuclear fuels and scattering behavior of thermal neutrons. Currently, there is no ENDF/B Thermal Scattering Law, i.e., $S(α,β)$, evaluation for PuO 2 , only free atom cross sections for Plutonium and Oxygen, respectively, which neglect lattice contributions to total cross section. Herein, ab initio lattice dynamics (AILD) techniques are employed to calculate the phonon density of states (DOS) using spin-orbit-coupling density functional theory (DFT) to predict the PuO2 paramagnetic ground-state structure. These results highlight the evaluation of $S(α,β)$ for Plutonium and Oxygen, respectively in PuO 2 and consequential generation of thermal neutron scattering cross sections for high fidelity criticality safety analysis and reactor calculations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Source Term Reduction for Advanced and Small Modular Boiling Water Reactors

The United States Department of Energy (US DOE) is currently supporting the development of various advanced and small modular reactor (SMR) designs. Several of these designs have commenced license application with the US Nuclear Regulatory Commission (US NRC). These reactors have improved safety features that may significantly reduce radiological source terms in the event of design and beyond-design basis accidents. Specifically, some reactors feature a smaller containment volume relative to the available fission product depositional surface area, which supports increased fission product retention in the containment vessel. Pressurized water reactors (PWR) and boiling water reactors (BWR) with this feature include the integral pressurized water reactor (iPWR) and the BWRX-300 design by General Electric. A prior research program supported by the US DOE quantified the source term reduction associated with light water iPWRs and developed iPWR-specific theoretical models for fission product deposition rates. This program included a sequence of research projects that started with a feasibility study, development of theoretical models that predict higher deposition rates, and finally, development of empirical data for verification and validation of the theoretical models. The current project, which is a feasibility study, is the first step in a similar program to quantify the source term reduction associated with small and advanced light water BWRs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Evaluation of δ-Phase ZrH1.4 to ZrH1.7 Thermal Neutron Scattering Laws Using Ab Initio Molecular Dynamics Simulations

Zirconium hydride is commonly used for next-generation reactor designs due to its excellent hydrogen retention capacity at temperatures below 1000 K. These types of reactors operate at thermal neutron energies and require accurate representation of thermal scattering laws (TSLs) to optimize moderator performance and evaluate the safety indicators for reactor design. In this work, we present an atomic-scale representation of sub-stoichiometric ZrH2−x(0.3≤x≤0.6), which relies on ab initio molecular dynamics (AIMD) in tandem with velocity auto-correlation (VAC) analysis to generate phonon density of states (DOS) for TSL development. The novel NJOY+NCrystal tool, developed by the European Spallation Source community, was utilized to generate the TSL formulations in the A Compact ENDF (ACE) format for its utility in neutron transport software. First, stoichiometric zirconium hydride cross sections were benchmarked with experiments. Then sub-stoichiometric zirconium hydride TSLs were developed. Significant deviations were observed between the new δ-phase ZrH2−x TSLs and the TSLs in the current ENDF release. It was also observed that varying the hydrogen vacancy defect concentration and sites did not cause as significant a change in the TSLs (e.g., ZrH1.4 vs. ZrH1.7) as was caused by the lattice transformation from ϵ- to δ-phase.

42 ENGINEERING↗

DOE OSTI2023

Modeling and Simulation of Fuel Burnup in Pebble Bed Reactors

Modeling and simulation of fuel burnup plays important roles in reactor design, operation, safety, and security as well as nuclear material control and accounting (MC&A) [1]. This task is uniquely challenging for pebble bed reactors (PBR) because the pebbles are continuously added and recycled into the reactor core, and their paths through the core are random. To address this problem, we present two simulation models in this paper. Brookhaven National Laboratory (BNL) developed a simple lattice model of a PBR in Serpent software to generate used pebble isotopic concentrations. The benefit of using Serpent software in this specific application is that it helps streamline the data generation process without having to use too many independent software codes in combination to achieve a simple task. For example, transport, burnup and zero power decay can be implemented in a single pass. Three-dimensional core models were developed using Serpent to simulate the burnup process of 5 subject pebbles starting from fresh till they reach nearly target burnup, with each pebble placed in one of the five artificially designated radial channels to capture the changing neutron spectra along the core radius. Equilibrium isotopic concentrations were assumed in all other pebbles in the core. To provide a verification for the Serpent isotope transmutation and decay results, Oak Ridge National Laboratory (ORNL) performed simple SCALE/ORIGEN calculations using the average neutron spectra calculated by Serpent for each of the 5 pebbles. The 252-group neutron spectra from Serpent were then used by ORIGEN to produce the one-group library for depletion and decay calculations. The isotopic concentrations of a few nuclides of interest and neutron and gamma source terms produced from the ORIGEN calculations were compared with the ones from the Serpent calculations. The model simulated in this work was based on the Pebble Bed Modular Reactor (PBMR)-400 design because many data needed for the simulation such as core power profiles, fuel and reflector temperatures, and equilibrium core composition are publicly available. In this paper, we will compare the results between these two approaches and benchmark the results against a set of well-established simulation results for PBMR-400.

Dim, Odera↗

DOE OSTI2023

Modeling and Simulation of Fuel Burnup in Pebble Bed Reactors

Modeling and simulation of fuel burnup plays important roles in reactor design, operation, safety, and security as well as nuclear material control and accounting (MC&A) [1]. This task is uniquely challenging for pebble bed reactors (PBR) because the pebbles are continuously added and recycled into the reactor core, and their paths through the core are random. To address this problem, we present two simulation models in this paper. Brookhaven National Laboratory (BNL) developed a simple lattice model of a PBR in Serpent software to generate used pebble isotopic concentrations. The benefit of using Serpent software in this specific application is that it helps streamline the data generation process without having to use too many independent software codes in combination to achieve a simple task. For example, transport, burnup and zero power decay can be implemented in a single pass. Three-dimensional core models were developed using Serpent to simulate the burnup process of five subject pebbles starting from fresh till they reach nearly target burnup, with each pebble placed in one of the five artificially designated radial channels to capture the changing neutron spectra along the core radius. Equilibrium isotopic concentrations were assumed in all other pebbles in the core. To provide a verification for the Serpent isotope transmutation and decay results, Oak Ridge National Laboratory (ORNL) performed simple SCALE/ORIGEN calculations using the average neutron spectra calculated by Serpent for each of the five pebbles. The 252-group neutron spectra from Serpent were then used by ORIGEN to produce the one-group library for depletion and decay calculations. The isotopic concentrations of a few nuclides of interest and neutron and gamma source terms produced from the ORIGEN calculations were compared with the ones from the Serpent calculations. The model simulated in this work was based on the Pebble Bed Modular Reactor (PBMR)-400 design because many data needed for the simulation such as core power profiles, fuel and reflector temperatures, and equilibrium core composition are publicly available. In this paper, we will compare the results between these two approaches and benchmark the results against a set of well-established simulation results for PBMR-400.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2023

Safety Analysis of FeCrAl Accident-Tolerant Fuels with Increased Enrichment and Extended Burnup

The U.S. nuclear industry is facing a strong challenge to maintain regulatory-required levels of safety while ensuring economic competitiveness to stay in business. Safety remains a key parameter for all aspects related to the operation of light water reactor nuclear power plants (NPPs), and it can be achieved more economically by using a risk-informed ecosystem, such as that being developed by the Risk-Informed Systems Analysis Pathway under the U.S. Department of Energy Light Water Reactor Sustainability Program. This program is promoting a wide range of research and development activities to maximize both the safety and economically efficient performance of NPPs through improved scientific understanding, especially given that many plants are considering a second license renewal. The Risk-Informed Systems Analysis Pathway has two main goals: (1) The deployment of methodologies and technologies that enable a better representation of the safety margins and factors that contribute to cost and safety, and (2) The development of advanced applications that enable cost-effective plant operation. As part of this pathway, the Enhanced Resilient Plant project refers to an NPP where safety is improved by implementing various measures, such as accident-tolerant fuels, diverse and flexible coping strategies, enhancements to plant components and systems, incorporation of augmented or new passive cooling systems, and utilization of advanced battery technologies. The objective of the Enhanced Resilient Plant project is to use novel methods and computational tools to enhance existing reactors’ safety while reducing operational costs. This report documents research and development conducted in support of deployment of accident-tolerant fuels. This project performed safety analyses for the steady-state normal operation, anticipated operational occurrences, and design-basis accidents of a representative four-loop pressurized water reactor model with Zr and FeCrAl accident-tolerant fuel clad with higher enrichment and burnup supporting plant refueling cycles of 18 and 24 months. The source terms and environmental impacts were studied for a large-break loss of coolant accident, including uncertainty analyses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Explicit modeling of pebble temperature in the porous-media model for pebble-bed reactors

In this study, we developed a multiscale model to include an explicit pebble-temperature model nested in the porous-media model for pebble-bed reactor applications. The multiscale solid-phase energy balance model, including the pebble surface energy balance equation and an explicit modeling of pebble temperature, can predict the macroscopic (pebble bed) and microscopic (pebble) temperature distributions under both steady-state and transient conditions. The proposed multiscale model is solved in a fully coupled manner using the Newton- Krylov method, and therefore iterations between the macroscopic (pebble-bed-scale) and microscopic (pebble- scale) model are avoided. Extensive code verifications, validation, and demonstrations have been performed for this newly developed model. By explicitly modeling pebble temperatures, this new model addresses a major deficiency of the basic porous-media model, which assumes homogeneous solid-phase temperature and is not appropriate for pebble-bed reactor design and safety analyses.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Explicit Modeling of Pebble Temperature in the Porous-medium Framework for Pebble-bed Reactors Applications

In this study, an explicit model for pebble temperature calculations in the framework of a porous-medium approach has been developed and implemented in the SAM code. The solid-phase energy conservation equation, including the explicit modeling of pebble temperature, is a multi-scale model, which can predict the macroscopic (pebble-bed) and microscopic (pebble) temperature distributions under both steady-state and transient conditions. Extensive and successful code verifications and demonstrations have been performed for this newly developed model. By explicitly modeling pebble temperatures, this new model addresses a major deficiency of the previously implemented model, which assumed a local solid-phase thermal equilibrium that is not appropriate for pebble-bed reactor design and safety analysis applications.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

SCALE 6.3.2 User Manual

SCALE is a comprehensive modeling and simulation suite for nuclear safety analysis and design developed and maintained by Oak Ridge National Laboratory under contract with the U.S. Nuclear Regulatory Commission, U.S. Department of Energy, and the National Nuclear Security Administration to perform reactor physics, criticality safety, radiation shielding, and spent fuel characterization for nuclear facilities and transportation/storage package designs. Visit the SCALE website for additional information.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗