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At least 379 records · Page 21

Technical Assessment of the Application of Digital Twin and Prognostic Tools for Condition Monitoring

This report was prepared for the U.S. Nuclear Regulatory Commission (NRC) to present use cases of the application of advanced technologies toward meeting the current and future regulatory requirements for maintenance and condition monitoring of structures, systems, and components (SSCs). The advanced technologies considered in this work, collectively referred to as digital twin (DT) technologies, are advanced sensors and instrumentation, data analytics, machine learning and artificial intelligence (ML/AI), and physics-based models. The report presents two use cases of reactor coolant pumps (RCPs) and heat pipes in nuclear power plants (NPPs) with technical and regulatory considerations and opportunities in using advanced technologies for conditional monitoring. Key findings from the exploration of these considerations are as follows: - Uncertainties in sensor data and model predictions must be rigorously addressed through validation and verification processes - Regulatory compliance is paramount, necessitating data driven models to be developed in line with existing codes and standards, as well as considering potential future guidelines for advanced reactors - Explainability and transparency in ML/AI models are essential for developing operator trust and regulatory review, including methods that enhance the interpretability of complex data-driven predictions - Condition monitoring programs must be evaluated for their effectiveness in reducing maintenance-preventable function failures (MPFF) and aligning with plant performance criteria - The deployment of advanced technologies for condition monitoring could lead to a transition from periodic to continuous monitoring, thereby optimizing maintenance schedules - Collaborative efforts between industry stakeholders, regulatory bodies, and technology developers are crucial for the successful adoption of advanced technologies for condition monitoring systems in nuclear facilities In summary, the introduction of advanced technologies into condition monitoring programs represents a significant leap forward in the domain of NPP maintenance. By harnessing the capabilities of advanced sensors, data analytics, and ML/AI, NPP operators can transition from a time-based to a condition-based maintenance approach. This shift can potentially enhance the reliability and safety of critical plant components while optimizing maintenance efforts and minimizing unnecessary outages. The NRC is continuing to explore the regulatory aspects of advanced technologies as part of inservice inspection and inservice testing (ISI and IST) programs by pursuing additional research in this technical area.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Development of Explainable Data-Driven Turbulence Models with Application to Liquid Fuel Nuclear Reactors

Liquid fuel nuclear reactors offer innovative possibilities in terms of nuclear reactor designs and passive safety systems. Molten Salts Reactors (MSRs) with a fast spectrum are a particular type of these reactors using liquid fuel. MSFRs often involve large open cavities in their core in which the liquid fuel circulates at a high speed to transport the heat generated by the nuclear reactions into the heat exchangers. This high-speed flow yields a turbulent field with large Reynolds numbers in the reactor core. Since the nuclear power, the neutron precursor’s transport and the thermal exchanges are strongly coupled in the MSFR’s core cavity, having accurate turbulent models for the liquid fuel flow is necessary to avoid introducing significant errors in the numerical simulations of these reactors. Nonetheless, high-accuracy simulations of the turbulent flow field in the reactor cavity of these reactors are usually prohibitively expensive in terms of computational resources, especially when performing multiphysics numerical calculations. Therefore, in this work, we propose a novel method using a modified genetic algorithm to optimize the calculation of the Reynolds Shear Stress Tensor (RST) used for turbulence modeling. The proposed optimization methodology is particularly suitable for advanced liquid fuel reactors such as the MSFRs since it allows the development of high-accuracy but still low-computational-cost turbulence models for the liquid fuel. We demonstrate the applicability of this approach by developing high accuracy Reynolds-Averaged Navier–Stokes (RANS) models (averaged flow error less than 5%) for a low and a large aspect ratio in a Backward-Facing Step (BFS) section particularly challenging for RANS models. The newly developed turbulence models better capture the flow field after the boundary layer tipping, over the extent of the recirculation bubble, and near the boundary layer reattachment region in both BFS configurations. The main reason for these improvements is that the developed models better capture the flow field turbulent anisotropy in the bulk region of the BFS. Then, we illustrate the interest in using this turbulence modeling approach for the case of an MSFR by quantifying the impact of the turbulence modeling on the reactor key parameters.

42 ENGINEERING↗

The MOOSE fluid properties module

The fluid properties module in MOOSE~\cite{lindsay2022moose} serves a variety of fluid simulation applications based on MOOSE, including the MOOSE Navier Stokes module~\cite{moose_ns}, Pronghorn~\cite{pgh}, the MOOSE thermal hydraulics module, SAM~\cite{sam}, RELAP-7~\cite{relap7}, Sockeye~\cite{sockeye}, Pronghorn-subchannel~\cite{subchannel} and the MOOSE porous flow module~\cite{porous}. These applications are used to solve coarse mesh multi-dimensional thermal-hydraulics~\cite{pgh}, 1D systems analysis~\cite{sam,relap7} in nuclear reactor analysis, heat pipe modeling~\cite{sockeye} and porous flow simulations~\cite{porous} for underground gas storage and water seepage. The use of consistent fluid properties across fluid flow applications facilitates coupled flow simulations~\cite{anl_sam_pgh,osti_1889653}. Each application has historically driven the implementation of several fluid properties, which were later extended to be compatible with other applications. The unique diversity of applications of the module, due to its presence in MOOSE, has driven its expansion to new fluids, such as advanced nuclear reactor coolants and, more recently, arbitrary functions or tables-based property definitions, as detailed in section~\ref{content}, as well as numerous thermophysical properties and variable sets, as detailed in subsection~\ref{sec:prop}. The need for different discretizations of flow equations based on the compressibility of the fluid has motivated support for both primitive (pressure- and temperature-based) and conservative (internal energy- and specific volume-based) flow variables in the module. Thermodynamic relations are used to convert between these two formulations, as needed. The module serves a dual purpose of providing fluid properties for direct use in flow simulations and facilitating the implementation of user-specific fluid properties. Contributions of new properties for existing fluids or new fluids are strongly encouraged.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Stirling Power Conversion for Lunar Applications

NASA is developing Stirling power convertors for use in nuclear power systems that would provide electricity to users on the lunar surface. NASA’s Radioisotope Power Systems (RPS) Program is maturing advanced dynamic convertor technologies that would increase the efficiency beyond the heritage systems for missions to the Moon and other solar system bodies of interest. Development efforts have focus on Stirling and Brayton designs that meet reliability and robustness requirements for operation in the lunar environment. GRC is also maturing low power convertors in the range of 1-40 watts to power micro-spacecraft or a network of distributed probes and include basic demonstration of in-house designs for convertors and controllers. In addition to RPS applications, conceptual fission systems have been demonstrated using Stirling convertors in multiple electrically heated tests and one test heated by a nuclear reactor. The Stirling convertors used in these fission system concepts include 100 We convertors to enable a 1 kWe system, 1 kWe convertors to enable a 10 kWe system, and 6 kWe convertors to enable a 40 kWe system. The maturation of Stirling power convertors for nuclear applications includes verification of performance in relevant environments and validation of the design with a focus on high reliability and robustness. Over 1 million hours of testing has been accumulated on dozens of convertors since 1999 in the Stirling Research Laboratory at the NASA Glenn Research Center located in Cleveland Ohio, where the longest running convertor is the work record holder at 137,000 hours, or 15.5 years. These maturation efforts have been instrumental in increasing the technology readiness level of Stirling technologies for space applications.

S. Wilson↗

Nuclear Thermal Propulsion Scoping Analysis of Fuel Plate Core Configurations

Nuclear thermal propulsion (NTP) engines use a nuclear reactor to heat up hydrogen to high temperatures. Thrust is generated as the hydrogen is ejected at high velocity through a nozzle. NTP has the potential of reducing travel times for deep space missions, such as to Mars. The United States studied NTP early in the space age and the National Aeronautics and Space Administration (NASA) is currently revisiting the potential of the technology to enable its missions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Technical and economic evaluation of heat transfer fluids for a TES system integrated to an advanced nuclear reactor

The utilization of thermal energy storage technology has emerged as a potential enhancement for nuclear power plants. Although nuclear energy systems possess the ability to adjust their energy output, prolonged variations in production can impact the plant's overall efficiency and economic viability. However, the nuclear industry can capitalize on thermal energy storage to bolster the power plant's economics by leveraging ancillary services and market hedging strategies. Here this research aims to advance the development of thermal energy storage for advanced nuclear reactors by assessing the thermophysical properties of various heat transfer fluids, including FLiNaK, KCl-MgCl 2 , LiCl-KCl, (LiNaK) 2 CO 3 , NaF-ZrF 4 , and KF-ZrF 4 , at temperatures ranging from 500 to 900oC. The assessment is conducted based on thermophysical correlations established in previous studies and employs figures of merit as a metric to evaluate the heat transfer performance of different salt candidates. Additionally, a cost analysis is conducted to provide an idea of the potential cost associated with each salt candidate.

25 ENERGY STORAGE↗

Affordable Development and Qualification Strategy for Nuclear Thermal Propulsion

Nuclear Thermal Propulsion (NTP) is a concept which uses a nuclear reactor to heat a propellant to high temperatures without combustion and can achieve significantly greater specific impulse than chemical engines. NTP has been considered many times for human and cargo missions beyond low earth orbit. A lot of development and technical maturation of NTP components took place during the Rover/NERVA program of the 60's and early 70's. Other NTP programs and studies followed attempting to further mature the NTP concept and identify a champion customer willing to devote the funds and support the development schedule to a demonstration mission. Budgetary constraints require the use of an affordable development and qualification strategy that takes into account all the previous work performed on NTP to construct an existing database, and include lessons learned and past guidelines followed. Current guidelines and standards NASA uses for human rating chemical rocket engines is referenced. The long lead items for NTP development involve the fuel elements of the reactor and ground testing the engine system, subsystem, and components. Other considerations which greatly impact the development plans includes the National Space Policy, National Environmental Policy Act, Presidential Directive/National Security Council Memorandum #25 (Scientific or Technological Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space), and Safeguards and Security. Ground testing will utilize non-nuclear test capabilities to help down select components and subsystems before testing in a nuclear environment to save time and cost. Existing test facilities with minor modifications will be considered to the maximum extent practical. New facilities will be designed to meet minimum requirements. Engine and test facility requirements are based on the driving mission requirements with added factors of safety for better assurance and reliability. Emphasis will be placed on small engines, since the smaller the NTP engine, the easier it is to transport, assemble/disassemble, and filter the exhaust during tests. A new ground test concept using underground bore holes (modeled after the underground nuclear test program) to filter the NTP engine exhaust is being considered. The NTP engine system design, development, test, and evaluation plan includes many engine components and subsystems, which are very similar to those used in chemical engines, and can be developed in conjunction with them Other less mature NTP engine components and subsystems (e.g., reactor) will be thoroughly analyzed and tested to acceptable levels recommended by the referenced standards and guidelines. The affordable development strategy also considers a prototype flight test, as a final step in the development process. Preliminary development schedule estimates show that an aggressive development schedule (without much margin) will be required to be flight ready for a 2033 human mission to Mars.

Gerrish, Harold P., Jr.↗

Affordable Development and Qualification Strategy for Nuclear Thermal Propulsion

Nuclear Thermal Propulsion (NTP) is a concept which uses a nuclear reactor to heat a propellant to high temperatures without combustion and can achieve significantly greater specific impulse than chemical engines. NTP has been considered many times for human and cargo missions beyond low earth orbit. A lot of development and technical maturation of NTP components took place during the Rover/NERVA program of the 60's and early 70's. Other NTP programs and studies followed attempting to further mature the NTP concept and identify a champion customer willing to devote the funds and support the development schedule to a demonstration mission. Budgetary constraints require the use of an affordable development and qualification strategy that takes into account all the previous work performed on NTP to construct an existing database, and include lessons learned and past guidelines followed. Current guidelines and standards NASA uses for human rating chemical rocket engines is referenced. The long lead items for NTP development involve the fuel elements of the reactor and ground testing the engine system, subsystem, and components. Other considerations which greatly impact the development plans includes the National Space Policy, National Environmental Policy Act, Presidential Directive/National Security Council Memorandum #25 (Scientific or Technological Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space), and Safeguards and Security. Ground testing will utilize non-nuclear test capabilities to help down select components and subsystems before testing in a nuclear environment to save time and cost. Existing test facilities with minor modifications will be considered to the maximum extent practical. New facilities will be designed to meet minimum requirements. Engine and test facility requirements are based on the driving mission requirements with added factors of safety for better assurance and reliability. Emphasis will be placed on small engines, since the smaller the NTP engine, the easier it is to transport, assemble/disassemble, and filter the exhaust during tests. A new ground test concept using underground bore holes (modeled after the underground nuclear test program) to filter the NTP engine exhaust is being considered. The NTP engine system design, development, test, and evaluation plan includes many engine components and subsystems, which are very similar to those used in chemical engines, and can be developed in conjunction with them Other less mature NTP engine components and subsystems (e.g., reactor) will be thoroughly analyzed and tested to acceptable levels recommended by the referenced standards and guidelines. The affordable development strategy also considers a prototype flight test, as a final step in the development process. Preliminary development schedule estimates show that an aggressive development schedule (without much margin) will be required to be flight ready for a 2033 human mission to Mars.

Gerrish, Harold P., Jr.↗

Completely modular Thermionic Reactor Ion Propulsion System (TRIPS)

The nuclear reactor powered ion propulsion system described is an advanced completely modularized system which lends itself to development of prototype and/or flight type components without the need for complete system tests until late in the development program. This modularity is achieved in all of the subsystems and components of the electric propulsion system including (1) the thermionic fuel elements, (2) the heat rejection subsystem (heat pipes), (3) the power conditioning modules, and (4) the ion thrusters. Both flashlight and external fuel type in-core thermionic reactors are considered as the power source. The thermionic fuel elements would be useful over a range of reactor power levels. Electrical heated acceptance testing in their flight configuration is possible for the external fuel case. Nuclear heated testing by sampling methods could be used for acceptance testing of flashlight fuel elements. The use of heat pipes for cooling the collectors and as a means of heat transport to the radiator allows early prototype or flight configuration testing of a small module of the heat rejection subsystem as opposed to full scale liquid metal pumps and radiators in a large vacuum chamber. The power conditioner (p/c) is arranged in modules with passive cooling.

Peelgren, M. L.↗

Direct Air Capture (DAC) With Nuclear Power Sources

The presentation summarizes a recently published report, along with ANL and INL, on utilizing waste heat and power from nuclear power plants (NPP) for direct air capture (DAC) applications. Two DAC technologies are considered – solid sorbent (S-DAC) and liquid solvent (L-DAC). S-DAC uses both heat and power from NPPs, while L-DAC uses only power. The results show that using NPPs for DAC applications results in an economic benefit compared to using fossil fired power plants

Mantripragada, Hari↗

Assessment of Nuclear Energy to Support Negative Emission Technologies

The feasibility and performance of nuclear energy coupled with Negative Emission Technology (NET) processes were investigated in this report. Three overarching questions from nuclear NET systems guided this research: which NET would be able to use heat and/or electricity from nuclear power plants (NPPs); what is the performance and cost of a nuclear NET system; and what would be the market outlook for this system? Among the various NETs that are actively being developed, several were found to potentially benefit from coupling with an NPP via (1) large amounts of decarbonized and constant-output electricity; (2) free waste heat or cheap low-temperature heat; or (3) high-temperature heat. NPPs were found to be compatible with Direct Air Capture (DAC) systems, and a detailed techno-economic analysis of coupled NPP&DAC systems was performed. Preliminary analysis also indicated that biomass and water-based NETs are potentially compatible with NPPs, but further work is needed to quantify the performance of these nuclear NET systems. Design and performance analyses were completed for both liquid solvent DAC (L-DAC) and solid sorbent DAC (S-DAC) technologies. A 1.0-GWth NPP coupled with L-DAC and S-DAC was found to be able to capture 12–15 Mt CO 2 /yr and 1.0–1.5 Mt CO 2 /yr, respectively. While the L-DAC process enables much greater CO 2 capture than the S-DAC process when both are sized with a 1 GWth NPP, the NPP&L-DAC system considered also requires >2 GWth natural gas oxy-combustion to reach adequate temperature in the calciner. CO 2 generated from natural gas combustion is also captured as part of the calcination process, in addition to the CO 2 captured from air, resulting in overall CO 2 sequestration of close to 30% more than what is captured from air. The cost of carbon capture calculated with the levelized cost of DAC (LCOD) had a range of $\$170–260$/tCO 2 for NPP&L-DAC systems and a range of $\$650–680$/tCO 2 for NPP&S-DAC systems. For both DAC systems, the NPP provides economic benefit when compared to previous National Energy Technology Laboratory (NETL) studies of non-nuclear DAC systems, leading to reduction of LCOD by 5–7% for L-DAC, and 8–13% for S-DAC. For the NPP&DAC systems, a preliminary market analysis reviewed potential CO 2 market prices and eligibility for incentives. The estimated potential revenues for CO 2 capture (coming from federal incentive, CO 2 commodity markets, or offset market) is in the range of $\$170–979$ tCO 2 , and the results show that because of lower LCOD, the NPP&L-DAC process would be more attractive to a market than the NPP&S-DAC process. The large investment needed for NPP&DAC processes would require long-term certainty of sufficient market size, CO 2 prices, and incentives. Enabling NPPs to ramp DAC operation up or down based on electricity market price is not expected to significantly increase revenues of the NPP&DAC system. This is because the revenues from CO 2 sequestration are required to be very high to justify the deployment and continuous operation of the very expensive DAC technologies. In this analysis, several new research questions were uncovered, and follow-up analyses are recommended for further investigation, including a detailed feasibility study of NPP coupled with other NET systems such as biomass pyrolysis and gasification with carbon capture and storage, and seawater carbon capture.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Demonstrating autonomous controls on hardware test beds is a necessity for successful missions to Mars and beyond

NASA and the Department of Defense are planning for a mission to Mars in the 2030s–2040s using nuclear thermal propulsion (NTP). NTP uses a nuclear reactor to heat flowing hydrogen and create thrust. A serious concern for crewed and uncrewed missions to Mars is the loss of reactor control. The reactor startup and initial rocket impulse are initiated in cislunar or near-earth orbital regions; therefore, radio communications between ground control and the NTP engine should occur in real time. However, radio communications can take more than 20 min, depending on planet positions, to reach Mars orbiters from ground control. To address this delay, local autonomous controls are implemented onboard the NTP engine to ensure acceptable operation. However, autonomous controls have not been demonstrated or implemented in research or power reactor contexts because of safety and reliability concerns. To enable autonomous controls development, demonstration, and validation, Oak Ridge National Laboratory has created a nonnuclear hardware-in-the-loop test bed. Sensors throughout the test bed relay system status and hardware response to the user control algorithm, including measurements of temperature, flow, pressure of a loop, control drum position, and drum speed. This paper discusses the development of this facility and user accessibility.

33 ADVANCED PROPULSION SYSTEMS↗

Analysis on the Preliminary Gap Conductance Test with Single Primary Heat Extraction and Removal Emulator

Microreactor is a type of nuclear reactor that is intended to produce thermal energy from the micro and integrated design. Among various microreactor roadmaps, microreactor with heat pipes is one of the promising designs that under active development. At Idaho National Laboratory (INL) and supported by the Department of Energy (DOE) Microreactor Program (MRP), a Single Primary Heat Extraction and Removal Emulator (SPHERE) was developed. The main purpose of SPHRE is to understand thermal performance of heat pipe in the conjunction of heat source without using nuclear material. The heat pipe used in the SPHERE has sodium as a working fluid, with Argon gas in the vapor region, thus this heat pipe is variable conductance heat pipe (VCHP). The volume of non-condensable gas changes with power and elapsed time, so the area covered by non-condensable gas changes. This gives an effect that passively controls the cooling capability of condenser section. This preliminary experiment was intended to perform a gap conductance experiment that reveals heat transfer characteristics of gas at the gap around the heat pipe. However, there are not many experimental data that deals with heat transfer of the gas at the gap around heat pipe. In this research, the preliminary experimental result regarding to the heat pipe performance with different composition of gas at the gap, level of power is presented. The experimental data will be used for the validation study of SOCKEYE as a future plan.

42 ENGINEERING↗

Advanced nuclear reactor integration opportunities for the pulp and paper industry in the U.S. context: Technical perspectives, gap analysis, and preliminary technoeconomic assessment

Pulp and paper (P&P) manufacturing requires a large amount of low-pressure (LP) steam to digest, wash wood fibers and dry pulp into paper. Most of the LP steam is extracted from backpressure turbines that produce power from high-pressure (HP) steam. This HP steam is generated from burning wood waste material; bark is burned in hog boilers, and lignin is boiled in a black liquor recovery boiler. In a typical integrated P&P mill, 50–100% of the steam is produced from these sources, while additional steam is produced in natural gas (NG), fuel oil, or coal boilers. The other energy-intensive process in the plant is the chemical-recovery section (e.g., lime kiln), which requires high-temperature processing from NG combustion to retrieve and recirculate spent chemicals. This paper assesses the energy and heat demand and material balances of a typical generic kraft pulp mill, along with the nuclear heat, steam, and power integration opportunities to replace conventional combustion systems. The paper also addresses steam and electricity generation through a comprehensive technical and engineering gap analysis of five different nuclear-integration opportunities and their process economics, thus enabling the lignin and bark to be further processed into biobased chemicals or fuels, as well as the potential to reduce overall emissions from kraft pulping. Preliminary findings have shown that the P&P industry could achieve technological benefits by integrating their current manufacturing process with small modular nuclear reactors (SMNRs) on a national level. This research aims to set the path forward for a cleaner and more resilient P&P industry.

Advanced nuclear reactor↗

Experimental and Multiscale Modeling Insights for Radiation-Driven Neptunium Redox Processes at Elevated Temperatures

Studies of the radiation-driven reactions of actinide elements at elevated temperatures are extremely limited, but important given that radiation heating of used nuclear fuel can affect the radiolytically promoted actinide redox processes occurring in hydroprocessing environments. Under these conditions, the high concentration of nitric acid present makes the reaction of actinides, such as neptunium, with nitric acid radiolysis products significant. Therefore, here we present derivation of the rate coefficients for the reaction of pentavalent neptunium with the nitrate radical at elevated temperature, resulting in Eyring and Arrhenius parameters for this important reaction. Here, we also revisit our previously published multiscale model predictions for radiation-induced neptunium redox chemistry and present an iteration which successfully operates over a wider range of nitric acid concentrations, 0.1–6.0 M.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Data-Driven Model Predictive Control for Temperature Management of Heat Pipe Microreactor

A data-driven model predictive control (MPC) was developed to enable the self-regulating capability of heat pipe (HP) nuclear microreactors. The MPC can proactively respond to potential disturbances of HP microreactors using three approaches for system identifications: linear state-space model, feedforward neural network, and recurrent neural networks with long short-term memory units. We present numerical results of data-driven MPCs to control the temperatures of selected HPs in a 37-HP test article. Our results show qualitatively that all data-driven MPCs produced similar control actions, while quantitatively, with artificial neural nets (especially feedforward neural nets), MPC can better follow drastic changes in setpoints with small errors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Integrated Initiative for Plutonium and Actinide Missions

Recognizing the dynamic environment and challenges facing the plutonium and actinide missions at Los Alamos National Laboratory over the next decade, Laboratory leadership established Fiscal Year (FY) 2020 Laboratory Agenda Item 2.6. This agenda item calls for the development and implementation of an integrated initiative for plutonium and actinide missions at Los Alamos. Over the next decade, Los Alamos has been asked to significantly ramp up pit production to help address nuclear stockpile and nuclear deterrence needs, heat source production to support expansion in space exploration, evaluation of stockpile returns, processing operations in support of nonproliferation, and the actinide science to support all of these efforts. All of this must be accomplished while significantly increasing the size of our plutonium and actinide missions workforce and modernizing and updating critical infrastructure. Only through enhanced integration of science, technology, and engineering (ST&E), manufacturing, and mission operations will we enable achievement of these critical missions. An overall summary of the plutonium and actinide missions is included in Figure 1 on Page 3 and Figure 2 on Page 4 summarizes our goals, objectives, FY 2021 recommended actions and internal strategic priorities that are key elements of our integrated initiative.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗