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DOE OSTI2022

Assessing the Impact of Effective Thermal Conductivity on Gas-cooled Reactor Transients in RELAP5-3D

High-temperature gas-cooled reactors (HTGRs) are a relatively mature advanced reactor concept that are of interest to industry and government for near-term deployment. These systems feature passive safety through low power density, coated particle fuels, and large graphite volumes that lead to slow heatup. In loss of flow transients, cooldown is achieved through conduction and radiation heat transfer. In prismatic block-type reactors, such as the mHTGR-350, the presence of coolant holes and fuel compacts alters the flow of heat through the blocks. To capture this effect in systems codes like RELAP5-3D, relationships for effective thermal conductivity (ETC) must be used to appropriately degrade the thermal conductivity. This work presents an assessment of the impact of ETC on performance of block-type gas-cooled reactors in a pressurized conduction cooldown (PCC) and depressurized conduction cooldown (DCC) transients. Models for PCC and DCC with bulk material thermal conductivity and ETC were run for both the mHTGR-350 and the High-Temperature Test Facility (HTTF) to determine the impact of ETC on transient performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Transient Kinetic Experiments within the High Conversion Domain: The Case of Ammonia Decomposition

In the development of catalytic materials, a set of standard conditions is needed where the kinetic performance of many samples can be compared. This can be challenging when a sample set covers a broad range of activity. Precise kinetic characterization requires uniformity in the gas and catalyst bed composition. This limits the range of convecting devices to low conversion (generally <20%). While steady-state kinetics offer a snapshot of conversion, yield and apparent rates of the slow reaction steps, transient techniques offer much greater detail of rate processes and hence more information as to why certain catalyst compositions offer better performance. In this work, transient experiments in two transport regimes are compared: an advecting differential plug flow reactor (PFR) and a pure-diffusion temporal analysis of products (TAP) reactor. The decomposition of ammonia was used as a model reaction to test three simple materials: polycrystalline iron, cobalt and a bimetallic preparation of the two. These materials presented a wide range of activity and it was not possible to capture transient information in the advecting device for all samples at the same conditions while ensuring uniformity. We push the boundary for the theoretical estimates of uniformity in the TAP device and find reliable kinetic measurement up to 90% conversion. However, what is more advantageous from this technique is the ability to observe the time-dependence of the reaction rate rather than just singular points of conversion and yield. For example, on the iron sample we observed reversible adsorption of ammonia and on cobalt materials we identify two routes for hydrogen production. From the time-dependence of reactants and product, the dynamic accumulation was calculated. This was used to understand the atomic distribution of H and N species regulated by the surface of different materials. When ammonia was pulsed at 550 °C, the surface hydrogen/nitrogen, (H/N), ratios that evolved for Fe, CoFe and Co were 2.4, 0.25 and 0.3 respectively. This indicates that iron will store a mixture of hydrogenated species while materials with cobalt will predominantly store NH and N. While much is already known about iron, cobalt and ammonia decomposition, the goal of this work was to demonstrate new tools for comparing materials over a wider window of conversion and with much greater kinetic detail. As a result, this provides an approach for detailed kinetic discrimination of more complex industrial samples beyond conversion and yield.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Inspection of a LOCA test rod at the Halden reactor project using gamma emission tomography

The LOCA test series IFA-650 conducted at the OECD Halden Reactor Project (HRP) has provided unique data on the performance of fuel rods during LOCA transients. One focus of the current investigations is the performance of the fuel in the ballooning stage of the LOCA transient. In this stage, relocation of fuel material is a possibility, in which case pellet fragments fall down to fill the void introduced by the increased volume of the ballooned cladding. This increases the heat load in that region, further promoting corrosion of the cladding. A special concern in the case of high-burnup fuels is the increasing number of small fuel fragments, which may be expected to cause a higher packing fraction in the ballooned region. In this work, a novel technique is presented for assessing the average density of the fuel material in the ballooned region of LOCA test rods. The investigation is based on non-destructive gamma emission tomography measurements, using the dedicated instrument recently developed at the HRP in collaboration with Westinghouse (Sweden) and Uppsala University. In this approach, the gamma radiation field surrounding the test rod has been measured with a narrowly collimated HPGe detector. Tomographic reconstruction of the data was performed, providing the radial gamma-ray source distribution within the measured volume, which reveals the fuel fragment distribution. From this, the density of the fuel in the measured volume (i.e., the packing fraction) may be calculated. The technique has been used to investigate a LOCA test rod of the Halden Reactor Project LOCA series. The LOCA experiment was carried out about one month prior to the gamma tomography examination. The results show that the distribution of the relocated fuel can be imaged using gamma rays from fission products. The reconstructions of the 662 keV rays from {sup 137}Cs and 1596 keV from {sup 140}Ba/La are demonstrated. In addition, the peaks of activation products offer valuable information on the location of the test rig structures, which may be utilized in a quantitative tomographic reconstruction to assess the spatially resolved packing fraction. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2019

Benchmark Evaluation of TREAT Reactor M2 and M3 Transient Experiments

The objective of this project is to evaluate and produce TREAT reactor benchmarks under steady state and transient conditions. The benchmarks support the TREAT restart effort and are to be contributed to the International Reactor Physics Experiment Evaluation Project (IRPhEP) for inclusion in the International Handbook of Evaluated Reactor Physics Benchmark Experiments. The benchmark evaluation is performed using data generated during the “Power Calibration Experiment for test M2” and “IFR Safety Tests M2 and M3”. The evaluations are conducted using the high fidelity Serpent-OpenFOAM code system. Both the steady state and transient conditions of the M2 and M3 tests were investigated. Furthermore, TREAT has a graphitic core. Historical work has shown that the predictions of the outcomes of TREAT tests are highly sensitive to the graphite thermal neutron scattering cross sections. Therefore, in this project, thermal neutron scattering (i.e., S(α,β)) libraries of graphite, tailored to the specifics of the TREAT core, were generated and utilized in the evaluation

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Benchmark Specification for Select Experiments Conducted at the University of Wisconsin-Madison Thermal Stratification Test Facility

The Department of Energy (DOE)-Nuclear Energy University Programs (NEUP) supported the creation and operation of the Thermal Stratification Test Facility (TSTF) at the University of Wisconsin Madison (UWM) as part of a larger effort to understand thermal stratification behavior in liquid-metal-cooled reactors. The TSTF was designed to simulate transients in a reactor plenum that are known to cause thermal stratification. High-reliability and high-resolution measurements of the flow and temperature were collected for use as experimental benchmarks to support validation efforts for computational models. The results of these tests contribute to the greater understanding of thermal stratification behavior of liquid sodium under various configurations and operating conditions. The six TSTF tests selected for benchmarking are a set of forced circulation tests at a fixed flow rate with different Upper Internal Structure (UIS) configurations in the test section (no UIS, solid UIS, and a UIS with flow area of 4, 8, 12, and 100%). This report provides a complete description of the benchmark problems, including all key test facility details, descriptions of each test condition, and measured data for comparison with modeled results.

42 ENGINEERING↗

DOE OSTI2025

FIDES-II/P2M Simulation Exercise on AN3 and AN10 bump tests: main results

This paper presents simulations of bump tests conducted as part of the P2M (Power to Melt and Maneuverability) project within the OECD/NEA FIDES-II framework (Framework for Irradiation Experiments). To prepare fuel performance codes for analyzing the P2M experiments, an international Simulation Exercise (SE) was initiated under the P2M project. The objective of this exercise was to model the AN3 and AN10 bump tests carried out in the 1980s at the DR3 reactor (3rd RISØ Fission Gas Project), during which instrumented fuel rodlets (equipped with thermocouples and pressure sensors) were subjected to prolonged power transients and power dips. The ongoing simulation exercise involves seven organizations from industry, research, and regulatory bodies, each using different fuel performance codes. This paper provides detailed descriptions of the test cases and simulation results from six fuel performance codes (ALCYONE, BISON, FAST, FEMAXI, FRAPCON, and TRANSURANUS), with a particular focus on fission gas release kinetics.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Advanced Reactors-Intermediate Heat Exchanger (IHX) Coupling: Theoretical Modeling and Experimental Validation

The overall goal of the research project was to model the behavior of the advanced reactorintermediate heat exchange system and to develop advanced control techniques for off-normal conditions. The specific objectives defined for the project were: 1. To develop the steady-state thermal hydraulic design of the intermediate heat exchanger (IHX); 2. To develop mathematical models to describe the advanced nuclear reactor-IHX-chemical process/power generation coupling during normal and off-normal operations, and to simulate models using multiphysics software; 3. To develop control strategies using genetic algorithm or neural network techniques and couple these techniques with the multiphysics software; 4. To validate the models experimentally The project objectives were accomplished by defining and executing four different tasks corresponding to these specific objectives. The first task involved selection of IHX candidates and developing steady state designs for those. The second task involved modeling of the transient and offnormal operation of the reactor-IHX system. The subsequent task dealt with the development of control strategies and involved algorithm development and simulation. The last task involved experimental validation of the thermal hydraulic performances of the two prototype heat exchangers designed and fabricated for the project at steady state and transient conditions to simulate the coupling of the reactor- IHX-process plant system. The experimental work utilized the two test facilities at The Ohio State University (OSU) including one existing High-Temperature Helium Test Facility (HTHF) and the newly developed high-temperature molten salt facility.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

FUEL PERFORMANCE STUDIES AT IDAHO NATIONAL LABORATORY MAKING USE OF THE BYRON FUEL SHIPMENT

In December of 2023 a shipment of commercially irradiated fuel rods from the Byron Generating Station in Illinois was successfully shipped to the Materials and Fuels Complex (MFC) at Idaho National Laboratory (INL). The make-up of the rods includes a mix of cladding types from traditional ZirloTM, advanced zirconium alloys, and chrome coated ZirloTM. Burnups range from regular end of life values to over 70 GWd/MTU rod average. The R&D plan for the rods involves multiple projects from developing licensing data for new claddings to integral transient tests to support burnup extension efforts in the United States. The R&D began in early 2024 with the nondestructive examinations of the rods after which they will be sectioned for microscopy, mechanical testing, and analytical chemistry. Additionally, many rod segments will be refabricated into new test pins and inserted into a static water capsule for integral Reactivity Initiated Accident (RIA) and Loss of Coolant Accident (LOCA) testing at the TREAT reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Benchmarking FFTF LOFWOS Test# 13 using SAM code: Baseline model development and uncertainty quantification

The development and deployment of advanced reactors, such as the sodium-cooled fast reactor (SFR), relies on sophisticated modeling tools to ensure the safety of the design under various transients. The predictive capability of these advanced modeling tools requires validation to garner trust in supporting the licensing of the advanced reactors. For this reason, the International Atomic Energy Agency (IAEA) initiated a coordinated research project (CRP) in 2018 for the analysis of the Fast Flux Test Facility (FFTF) Loss of Flow Without Scram (LOFWOS) Test #13.In this study, we present and discuss the benchmarking efforts of the modern system code SAM on the FFTF LOFWOS Test #13. Further, the SAM baseline model was developed according to the benchmark specification, which included a detailed core model with reactivity feedback. Generally, good agreement was observed between the baseline results and benchmark measurements; however, discrepancies persisted, particularly in predicted fuel assembly coolant outlet temperatures. Utilizing the baseline model, uncertainty quantification (UQ) and sensitivity analysis (SA) were conducted with the assistance of various statistical learning and machine learning methods, including kernel density estimation, Gaussian processes, and Sobol indices. Following the baseline model prediction and UQ and SA results, we discuss the reasons for the simulation discrepancies and propose further improvements to the model. This benchmarking effort adheres to the best-estimate plus uncertainty approach and can serve as a valuable example for supporting risk-informed licensing of advanced reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Finish development, test and then demonstrate new baseline fuel performance capability for UN fuel swelling models under steady-state and transient conditions

Uranium mononitride (UN) has emerged as a promising candidate for advanced nuclear reactor fuels, particularly for high-temperature and high-power applications such as sodium-cooled fast reactors, space power systems, and TRISO particle fuel designs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

PARET/ANL (V.7.7) Verification and Validation Report

This report documents the software testing which has been performed for the PARET/ANL version 7.7 software. The software testing is based on code capabilities identified by research reactor analysts as frequently used in their safety analyses. The verification and validation procedures have been performed and documented to address the steady-state capabilities of the software, as described in Chapter 2, and the transient capabilities, as described in Chapter 3. Testing based on the comparison between PARET/ANL calculations and analytical solutions, hand calculations, or other code calculations of the test cases confirms that all the identified capabilities of the software were implemented correctly. In addition, results from code comparisons against SPERT-I and SPERT-IV experiments for various flow rates are reported for the peak power, energy release and cladding surface temperature. The comparisons showed overall good agreement for the peak power and conservative predictions of the cladding surface temperature

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

PARET/ANL v7.7 Verification and Validation Report

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

HTTR 3 D Cross Section Generation with Serpent and MAMMOTH

The High Temperature Test Reactor (HTTR) is a graphite moderated thermal reactor with a nominal power output of 30 MWth. The purpose of this work is to prepare a set of neutron cross sections for use in the transient analyses of three Loss of Forced Cooling (LOFC) events planned for this reactor. The cross sections are generated with the Serpent 2 3 D Monte Carlo code to include the axial heterogeneity and the strong axial coupling of this core. The approach yields good agreement of results when compared to previously used 2 D lattice models, which require a fine spatial discretization and, surprisingly, comes at a higher computational cost. In addition, the temperature distribution must be considered to obtain reasonable cross sections and the axial leakage component dominates the spectral effects in the core. Consequently, a temperature model as a function of the fuel and moderator temperatures is adopted, and the core is depleted to 390 effective full-power days (EFPDs). A full tabulation of cross sections is prepared at this burnup point for a variety of fuel and moderator temperatures. Next, the multiphysics reactor application MAMMOTH is used to evaluate the quality of these cross sections using a diffusion solver. As expected, the homogenization error in the cross sections is significant and the Super Homogenization (SPH) correction from MAMMOTH is necessary to preserve key reaction rates. The SPH corrected MAMMOTH results are in excellent agreement with the Serpent results and reproduce both the reference power profile and temperature coefficients at each tabulation point. This fact confirms the accuracy of the SPH corrected cross sections and demonstrates the maturity of using Serpent 2 and MAMMOTH for 3 D cross section generation, even for reactors as complex as the HTTR. Finally, the authors recommend that the cross sections should be parametrized with the local burnup and that a full core burnup calculation with coupled thermal fluids would provide a better estimate of the initial condition for any subsequent transient analysis. Unfortunately, this was not within the scope of this work, and direct analysis with these tabulations should be considered as a first order approximation, at best.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Benchmark Specification for FFTF LOFWOS Test #13

The Fast Flux Test Facility (FFTF) at the Hanford site in Washington was designed by the Westinghouse Electric Corporation for the U.S. Department of Energy. FFTF was a 400 MW thermal, oxide-fueled, liquid sodium cooled test reactor, built to assist development and testing of advanced fuels and materials for fast breeder reactors. After reaching criticality in 1980, FFTF operated until 1992, providing the U.S. Department of Energy (DOE) with the means to test fuels, materials, and other components in a fast neutron flux environment. In July 1986, a series of unprotected transients (with the plant protection system intentionally disabled) were performed in FFTF as part of the passive safety demonstration program. Among these were thirteen loss of flow without scram (LOFWOS) tests. The goals of this program included confirming the liquid metal reactor safety margins, providing data for computer code validation, and demonstrating the inherent and passive safety benefits of specific design features. The test defined in this benchmark is LOFWOS Test #13, which was initiated at 50% power and 100% flow with the pump pony motors turned off. This benchmark specification is intended to support collaborative efforts within international partnerships on the validation of simulation tools and models in the area of Sodium-cooled Fast Reactor (SFR) safety. Validated tools and models are needed to evaluate SFR inherent safety characteristics and assess the impact of passive design features in response to accident initiators. Comparisons with experimental data and the results of safety analyses from other groups create unique opportunities to improve predictive capabilities of computational codes and methods for SFR modeling and simulation. The conditions of the LOFWOS test along with the feedback from FFTF’s limited free bow core restraint system and the novel passive reactivity control Gas-Expansion Modules (GEMs) pose a very challenging and uniquely valuable benchmark exercise.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Characterization of Simulated BWR and Steam Exposed FeCrAl Coated Zircaloy 2

To combat the rapid oxidation that occurs in nuclear reactors during transient scenarios, investigations into modifying or replacing the existing zirconium based cladding and structural material have become a focus. Aside from testing these alternatives in the transient scenarios, verification of performance under normal operation is necessary. This work will examine the effect of normal BWR water chemistry over two time periods on FeCrAl coated Zircaloy 2 (Zry2) and its response to high temperature steam. X-ray diffraction (XRD), Scanning Electron Microscopy (SEM), Energy-dispersive X-ray Spectroscopy (EDS), and Thermogravimetric (TG) analysis are utilized to analyze the chemical and physical changes caused by these exposures. These tests show that under short time periods, normal water chemistry BWR conditions do not adversely change the effectiveness of a FeCrAl coating. A spinel structure was formed using Ni from an external source, however it did not have a major impact on the coatings performance in high temperature steam. Additional autoclave exposures up to 40 hours are ongoing, including coatings which were proton irradiated up to 5 dpa. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2020

Report Summarizing Boiling Transition (Dryout) Testing of FeCrAl Cladding

Nuclear fuel and cladding in a light water reactor must maintain integrity under all normal operational and anticipated operational occurrences. In a Boiling Water Reactor (BWR) some Anticipated Operational Occurrences (AOOs) and Anticipated Transients Without SCRAM (ATWS) events have been known to result in cladding damage due to dryout with conventional Zircaloy-2 claddings. This work presents an assessment of commercially-fabricated, accident tolerant iron-chromium-aluminum (FeCrAl) alloy C26M cladding in such events with regard to the ballooning failure mode for unirradiated cladding In the severe accident test station (SATS), an experiment has been developed to gauge accident tolerance of fuel cladding materials under simulated cyclic dryout conditions. Thermal cycling from 300°C to 650°C was implemented on C26M and Zircaloy-2 tubes. The C26M tube did not fail after 54 cycles. The Zircaloy- 2 tube run under the same parameters as the C26M tube failed during the fourth cycle, consistent with expectations from the literature. Due to thermal gradients present in the furnace, both tubes experienced a maximum temperature at ~780°C. Due to differences in tube geometry, the hoop stress of the C26M tube was significantly higher than that of the Zircaloy-2 tube, 76 MPa at the maximum peak temperature compared to 55 MPa at burst, respectively. The cyclic dryout experiments show an increased performance of C26M over Zircaloy-2 under simulated conditions, an indication of C26M possessing superior high temperature oxidation resistance, mechanical properties and potentially resistance to fatigue.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Signature Analysis Utilizing a Dynamic Molten Salt Reactor Model for MC&A

Moving from traditional fixed fuel nuclear reactor systems to a mobile, dynamic fuel system that has dissolved special nuclear material in a molten salt is a paradigm shift in several respects. One major consideration is how to develop effective nuclear material controls and accounting for these novel reactor systems. The Molten Salt Reactor Experiment is one example of a critical molten salt system and provided a significant reference library based on the documented effort. But it was low thermal power that was not intended to reflect a commercial scale electricity production design. Therefore, to facilitate and assist vendors with domestic licensing considerations, research is underway to identify methods that could be used for domestic safeguards approaches for these novel reactor systems. This research presents the results of a signature analysis of data generated from three simulated scenarios using the molten salt demonstration reactor model defined in the Transient Simulation Framework of Reconfigurable Modules. Each scenario provides 1 hour isotope inventories over a 180 day period. The scenarios investigated provide test cases to examine if direct gamma-ray spectroscopy of the fuel can be used to identify changes comparing a base case (no reactivity control and fixed fission contribution) to an insertion of reactivity (10 pcm no change in fission composition) and a change in fission composition. The analysis demonstrates that monitoring the total count rate in a highly collimated high-resolution photon energy spectrum is sensitive to perturbations imposed into the reactor model. The total photon count rate changes ≈2% for the fission composition change and ≈4.5% for the reactivity insertion compared to the base case. However, both scenarios show an increase in the total photon count rate. The total photon count rate can be used to identify changes due to power (number of fissions) but not due to a change in the material undergoing fission. To distinguish between the two cases of increased power, the photon spectrum would require an intensive analysis technique. A photon peak count rate ratio analysis could be used to identify changes in the fissile material fission generation in the core through identification of a static peak that shows little variation to the source of fission and a highly varying peak. The photon peak strength will ultimately be determined by the isotope’s fission yield. A preliminary analysis investigating the coupling of the isotope’s fission yield and its concentration in the fuel salt derived from the modeling has been performed. A ratio analysis of the photon peak count rates of 140 La to 99 Mo demonstrated that the reactivity insertion creates a distinct difference in the ratio compared to the fission composition change scenario.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Space Nuclear Power Autonomous Control Algorithm and Control Element Test Bed

Nuclear thermal rockets are currently NASA’s preferred option for use in a manned mission to Mars in the 2040s. The communication delay between an Earth ground station and a spacecraft heading toward Mars can be up to 20 min. Therefore, controlling the nuclear rocket engine would require either a full-time reactor operator on the mission or an autonomous control system for the reactor. The latter idea of making space nuclear reactors fully autonomous has drawn more interest from stakeholders, but such an autonomous control system must be rigorously tested and validated before it is certified for human use. The cost of a full ground test for a space nuclear reactor is tremendous, so a nonnuclear mock reactor test bed was created to test and validate control elements and control algorithms for space nuclear reactors. The test bed consists of control element hardware that inputs physical measurement data into a reactor emulator to produce the reactor’s performance under steady-state, transient, and fault conditions. The control element hardware consists of six full-sized control drums equipped with servo drives and motors and is instrumented with optical encoders, resolvers, and torque sensors for drum movement characterization. In addition to the drums, a two-phase flow loop was designed and built to mimic the valves and turbomachinery associated with the propellant flow through a nuclear thermal rocket engine; components such as pressure sensors, flow meters, thermocouples, and tachometers are instrumented throughout the loop to characterize the fluid flow, valve, and turbomachinery behavior of the system. The data from the physical hardware (e.g., drum position, propellant flow rates) are input to a nuclear reactor simulator to determine the actual nuclear reactor parameters, and the data are sent back to a control algorithm to complete the control loop. The ability to conduct numerous tests of the control systems and autonomous algorithms can help validate the instrumentation and control aspects for a space nuclear reactor for every possible fault situation.

Wilson, Brandon↗