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DOE OSTI2018

Thermomechanical design optimization for low metal footprint in hybrid metal-polymer heat exchanger

Material and maintenance costs of metal-based heat exchangers surpass profits in waste heat recovery (WHR) from ultra-low temperature (<100C) sources [1]. A low-cost alternative like polymer pipes suffer from poor thermal conductivity (~0.2 W/mK), and a low overall heat transfer coefficient. Polymers’ thermal conductivity have previously been enhanced through systematic molecular alignment by stretching [2], chemical vapor deposition of extended polymers [3], surface grating [4], etc. However, these approaches suffer from scalability issues for WHR heat exchangers in terms of cost [3], and thermomechanical considerations [5]. In this work, we propose novel hybrid metal-polymer heat exchangers that are made from polymer-copper strips. Through finite element method (FEM) simulations, we first optimize the placement of copper around polymer strips to enhance the transverse thermal conductivity of the strips. The copper cladded polymer strips are wound helically in a roll-to-roll system to form the pipes for a heat exchanger. We then optimize the design of helically wound pipes to reduce thermomechanical strains to < 0.2 % at 100C and 40 psi working conditions. At 25 % volume fraction of copper in the pipe, we predict up to 20 % enhancement in overall heat transfer from a base polymer with a thermal conductivity of 0.2 W/mK. We also compare and contrast the thermomechanical performance of the optimized metal-polymer strips to random metal matrix composites. Finally, we experimentally verify the thermal conductivity of the optimized strips through bulk thermal conductivity and thermal interface resistance measurement setup. By systematically improving the design through FEM and experimental measurements, we provide an optimized design of hybrid metal-polymer pipes that provides a low metal footprint and cost-effective means for harvesting waste heat from ultra-low temperature sources. Thekdi, Arvind, and Sachin U. Nimbalkar. Oak Ridge National Lab, 2015 Shen, Sheng, et al. Nature nanotechnology 5.4 (2010): 251. Xu, Yanfei, et al. Science advances 4.3 (2018): 3031. Smith, M. K., Singh, V., Kalaitzidou, K., & Cola, B. A. (2015). ACS nano, 9(2), 1080-1088. Aymonier, C., Bortzmeyer, D., Thomann, R., & Mülhaupt, R. (2003). Chemistry of Materials, 15(25), 4874-4878.

C Rajagopal, Manjunath↗

DOE OSTI2012

Linear variable differential transformer (LVDT)-based elongation measurements in Advanced Test Reactor high temperature irradiation testing

New materials are being considered for fuel, cladding and structures in next generation and existing nuclear reactors. These materials can undergo significant dimensional and physical changes during high temperature irradiations. Currently, such changes are determined by repeatedly irradiating a specimen for a specified period of time in the Advanced Test Reactor (ATR) and then removing it from the reactor for evaluation. The labor and time to remove, examine and return irradiated samples for each measurement make this approach very expensive. In addition, such techniques provide limited data and may disturb the phenomena of interest. To resolve these issues, an instrumented creep testing capability is being developed for specimens irradiated under pressurized water reactor coolant conditions in the ATR at the Idaho National Laboratory (INL). This paper reports the status of INL efforts to develop this testing capability. In addition to providing an overview of in-pile creep test capabilities available at other test reactors, this paper focuses on efforts to design and evaluate a prototype test rig in an autoclave at INL’s High Temperature Test Laboratory.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2015

AREVA Team Enhanced Accident Tolerant Fuels Concepts (Phase 1A Final Report)

In response to the Department of Energy (DOE) funded initiative to develop and deploy lead fuel assemblies (LFAs) of Enhanced Accident Tolerant Fuel (EATF) into a US reactor within 10 years, AREVA put together a team to develop promising technologies for improved fuel performance during off normal operations. This team consisted of the University of Florida (UF) and the University of Wisconsin (UW), Savannah River National Laboratory (SRNL), Duke Energy and Tennessee Valley Authority (TVA). This team brought broad experience and expertise to bear on EATF development. AREVA has been designing; manufacturing and testing nuclear fuel for over 50 years and is one of the 3 large international companies supplying fuel to the nuclear industry. The university and National Laboratory team members brought expertise in nuclear fuel concepts and materials development. Duke and TVA brought practical utility operating experience. This report documents the results from the initial “discovery phase” where the team explored options for EATF concepts that provide enhanced accident tolerance for both Design Basis (DB) and Beyond Design Basis Events (BDB). The main driver for the concepts under development were that they could be implemented in a 10 year time frame and be economically viable and acceptable to the nuclear fuel marketplace. The economics of fuel design make this DOE funded project very important to the nuclear industry. Even incremental changes to an existing fuel design can cost in the range of $100M to implement through to LFAs. If this money is invested evenly over 10 years then it can take the fuel vendor several decades after the start of the project to recover their initial investment and reach a breakeven point on the initial investment. Step or radical changes to a fuel assembly design can cost upwards of $500M and will take even longer for the fuel vendor to recover their investment. With the projected lifetimes of the current generation of nuclear power plants large scale investment by the fuel vendors is difficult to justify. Specific EATF enhancements considered by the AREVA team were; Improved performance in DB and BDB conditions; Reduced release to the environment in a catastrophic accident; Improved performance during normal operating conditions; Improved performance if US reactors start to load follow; Equal or improved economics of the fuel; and Improvements to the fuel behavior to support future transportation and storage of the used nuclear fuel (UNF). In pursuit of the above enhancements, EATF technology concepts that our team considered were; Additives to the fuel pellets which included; Chromia doping to increase fission gas retention. Chromia doping has the potential to improve load following characteristics, improve performance of the fuel pellet during clad failure, and potentially lock up cesium into the fuel matrix; Silicon Carbide (SiC) Fibers to improve thermal heat transfer in normal operating conditions which also improves margin in accident conditions and the potential to lock up iodine into the fuel matrix; Nano-diamond particles to enhance thermal conductivity; Coatings on the fuel cladding; and Nine coatings on the existing Zircaloy cladding to increase coping time and reduce clad oxidation and hydrogen generation during accident conditions, as well as reduce hydrogen pickup and mitigate hydride reorientation in the cladding. To facilitate the development process AREVA adopted a formal “Gate Review Process” (GR) that was used to review results and focus resources onto promising technologies to reduce costs and identify the technologies that would potentially be carried forward to LFAs within a 10 year period. During the initial discovery phase of the project AREVA took the decision to be relatively hands off and allow our university and National Laboratory partners to be free thinking and consider options that would not be constrained by preconceived ideas from the fuel vendor. To counter this and to keep the partners focused, the GR process was utilized. During this GR process each of the team members presented their findings to a board made up of technical experts from utilities, fuel manufacturing experts, fuel technical experts, and fuel research and development (R&D) experts. During the initial 2 years of the project there were several major accomplishments. These accomplishments, along with the implications for successfully implementing EATF, are; The experimental spark plasma sintering process (SPS) process was successfully used to produce fuel pellets containing either 10% SiC whiskers or nano-diamond particles. The ability to use this process enables the thermal margin enhancements of the fuel additives to be realized. Without the SPS process, the conventional process cannot support adding pellet additives in the required quantities; Coatings of Ti2AlC were successfully applied to Zircaloy-4 cladding. Testing of Ti2AlC coatings at Loss of Cooling Accident (LOCA) conditions showed reduced cladding oxidation compared to present un-coated Zircaloy-4 cladding. This achievement allows the presently used cladding system to be retained so that the 10 year schedule can be met. Having to implement a new cladding material will extend the development schedule beyond 10 years; Several documents were produced to support future development, testing, and licensing of EATF, including a design requirements traceability matrix, a draft business plan, a draft test plan, a draft regulatory plan, and the acceptance criteria for lead fuel assembly insertion into a commercial reactor. This preparatory work lays the foundation for ensuring the future development plans address all the areas required to test, license, and manufacture the new EATF; and In addition, the high velocity oxy-fuel and electrophoretic deposition (EPD) coating application processes were dropped from further consideration due to their inability to meet manufacturing criteria. This allows the resources to be focused on the most promising EATF concepts identified. Future development opportunities that were identified during this work include; The use of SiC or diamond requires that a new pellet production technique (Spark Plasma Sintering), be developed. This entails investment in developing, proving and implementing a new commercial pellet production process. Development of the process to apply thinner coatings is required; Coatings cannot be too “thick” or they will displace a significant volume of water in the core resulting in reduced thermal hydraulic characteristics; Application of the coating at high temperature can affect the Zircaloy substrate. This will require the development and implementation of a new cladding coating manufacturing process; and Replace the Cold Spray (CS) cladding coating application with the Physical Vapor Deposition (PVD) process to eliminate duplication of work and provide greater control over coating thicknesses. This can result in a reduction in the final cycle economic penalty of coatings.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Assembly of Capsules for Irradiation of Silicon Carbide Joint Specimens in the High Flux Isotope Reactor

This report provides a summary of the test matrix and assembly of thirteen capsules containing silicon carbide joint specimens, where the goal of this experiment is to investigate the effects of irradiation on such joints. Two capsule designs are used to accommodate two different specimen geometries: a small torsion specimen to measure basic thermomechanical properties, and a cladding-style “end plug” specimen to demonstrate the strength and integrity of such cladding under typical thermal gradients and stresses. The assembled capsules are scheduled for two cycles of irradiation in the flux trap of the High Flux Isotope Reactor with two different target temperatures: 350 and 750°C.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

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 OSTI2026

Characterization of ceramic fuel powder packing fractions to support INFLUX

Triply periodic minimal surface (TPMS)-based structures show marked potential in novel nuclear reactor fuel designs, as their high surface area-to-volume ratio increases the efficiency of heat transfer out of the fuel, enabling safer, more innovative reactor designs. This milestone report addresses the role of dUO 2 powder processing route on the fill behavior of TPMS-based cladding shells to understand and advance the feasibility of manufacturing TPMS-based nuclear fuel forms. dUO 2 powder was processed through either a dry granulation route, varying consolidation pressure, or through milling, varying milling time, milling method and milled size distribution. The lowest tapped bulk densities (TBD), but best powder flowabilities, were obtained when testing unprocessed dUO 2 powder which was prone to self-agglomeration and formed low-density spheroids. The highest TBD and lowest flowabilities were obtained when using powder produced by hammer-milling dUO 2 powder to pass through a 200-mesh sieve, which led to particles with angular morphologies. Powder produced by dry granulation exhibited TBD that varied according to the consolidation pressure used to form the initial pellets and exhibited improved flowabilities when compared to hammer-milled material. Because of the large span of granule sizes formed as well as the irregular shape associated with the granules, a packing fraction of 0.69 was achieved, exceeding the analytical solution for random close packing of mono-sized spheres. TPMS polymer shells were loaded with unprocessed, granulated, and hammer-milled dUO 2 powders, and their qualitative packing behaviors were analyzed using x-ray computed tomography (xCT). TBDs calculated after loading TPMS polymer shells were 10-20% lower when compared to tapped bulk density measurements taken in a glass graduated cylinder, indicating a non-trivial impact on the tapped bulk density of either the TPMS channel size, TPMS channel surface material, powder cohesiveness, or a combination of the two parameters. A metallic zircaloy-4 TPMS shell will be loaded with hammer-milled dUO 2 powder upon receipt of the shell from Oak Ridge National Laboratory (ORNL) and shipped to Idaho National Labs (INL) for subsequent hot isostatic pressing (HIP) densification experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

DISSOLUTION OF SURROGATE U-Zr FUEL USING ALNIFLEX CONDITIONS

Non-aluminum clad spent nuclear fuel (NASNF) stored in L Basin at the Savannah River Site (SRS) is widely varied in fuel composition, design, packaging, and physical condition. The complexity of the NASNF inventory presents significant challenges, and technology development is necessary for successful disposition. One such fuel in the inventory is metallic uranium-zirconium (U-Zr) alloy fuel, the focus of this study. Electrolytic or nitric acid only dissolution of metallic U-Zr alloy can form insoluble zirconium oxide, which results in up to 52% loss of U to insoluble solids, and can be subject to potentially uncontrolled oxidation reactions [1, 2]. The AlNiflex process was determined to be a viable dissolution flowsheet for the U-Zr alloy fuel. Under a narrow set of solution concentrations, a combination of hydrofluoric acid (HF), nitric acid (HNO3), aluminum nitrate (Al(NO3)3), and hexavalent chromium can safely dissolve U-Zr intermetallic alloys, keep Zr soluble, and not significantly corrode stainless steel (SS) vessels [3, 4.

Gogolski, Jarrod M. [Savannah River National Labor↗

DOE OSTI2012

DEVELOPMENT OF METHODOLOGY AND FIELD DEPLOYABLE SAMPLING TOOLS FOR SPENT NUCLEAR FUEL INTERROGATION IN LIQUID STORAGE

This project developed methodology and field deployable tools (test kits) to analyze the chemical and microbiological condition of the fuel storage medium and determine the oxide thickness on the spent fuel basin materials. The overall objective of this project was to determine the amount of time fuel has spent in a storage basin to determine if the operation of the reactor and storage basin is consistent with safeguard declarations or expectations. This project developed and validated forensic tools that can be used to predict the age and condition of spent nuclear fuels stored in liquid basins based on key physical, chemical and microbiological basin characteristics. Key parameters were identified based on a literature review, the parameters were used to design test cells for corrosion analyses, tools were purchased to analyze the key parameters, and these were used to characterize an active spent fuel basin, the Savannah River Site (SRS) L-Area basin. The key parameters identified in the literature review included chloride concentration, conductivity, and total organic carbon level. Focus was also placed on aluminum based cladding because of their application to weapons production. The literature review was helpful in identifying important parameters, but relationships between these parameters and corrosion rates were not available. Bench scale test systems were designed, operated, harvested, and analyzed to determine corrosion relationships between water parameters and water conditions, chemistry and microbiological conditions. The data from the bench scale system indicated that corrosion rates were dependent on total organic carbon levels and chloride concentrations. The highest corrosion rates were observed in test cells amended with sediment, a large microbial inoculum and an organic carbon source. A complete characterization test kit was field tested to characterize the SRS L-Area spent fuel basin. The sampling kit consisted of a TOC analyzer, a YSI multiprobe, and a thickness probe. The tools were field tested to determine their ease of use, reliability, and determine the quality of data that each tool could provide. Characterization was done over a two day period in June 2011, and confirmed that the L Area basin is a well operated facility with low corrosion potential.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Accelerated Fuel Qualification of Fast Modular Reactor Fuel in a Thermal Reactor: Modeling and Simulation Paired with Irradiation Testing

The accelerated fuel qualification (AFQ) methodology is applied by simulating accelerated fuel tests of the General Atomics Electromagnetic Systems’ fuel system for its 44-MW(electric) gas-cooled, fast-spectrum fast modular reactor (FMR). This fuel is comprised of UO 2 pellets in SiGA® cladding, a silicon carbide ceramic matrix composite. Fast reactors, like the FMR, offer many benefits, including high fuel utilization and flexibility, but may require a lengthy material design process if tests are performed using fast neutron irradiation alone. A thermal neutron irradiation can instead be used to rapidly test how well key components of the current material models extend to high burnup. Thermal neutrons produce a different radial power distribution within the pin than fast neutrons. However, the temperature and burnup values for the two neutron types are comparable, and the differences between the simulated fuel responses are relatively small, demonstrating the weak sensitivity of the physics-based fuel model calculations on the neutron type and the irradiation rate. Furthermore, the deformation of the SiGA cladding saturates after about 1 displacement per atom for both neutron spectra. In an accelerated fuel test, the irradiation time required to reach the target fuel burnup can be reduced by a factor of 3 by using a small rodlet with a 45% smaller pellet diameter while maintaining the same linear power. Therefore, the time for data collection up to high burnup can be significantly reduced while maintaining the same temperature profile, which largely determines the material response. Tests of fuel rodlets of standard and compact size will be carried out in the Idaho National Laboratory’s Advanced Test Reactor (ATR), including full size and compact rodlets with varying gap sizes. By applying physics-based mechanistic modeling and simulation in accordance with the AFQ methodology, this type of compact rodlet testing in a thermal test reactor captures the necessary phenomena to test fuel material models up to high burnup and to simulate the expected impact of fast neutron radiation on the fuel in FMR operations. Finally, this approach to testing fast reactor fuels in existing thermal test reactors, paired with advanced physics-based mechanistic modeling and simulation, is expected to be applicable to a range of advanced fuels and will decrease the overall fuel qualification timeframe from decades to years.

Advanced test reactor (ATR)↗

DOE OSTI2024

Modeling and design of a separate effects irradiation test targeting fission gas release from Cr-doped UO 2

Fission gas release (FGR) from nuclear fuel during operation can diminish heat transfer properties across the pellet-cladding gap and increase the fuel rod internal pressure, thereby posing a concern to fuel reliability and safety during an accident. Enlarging the fuel grain size, which has been shown to improve fission gas retention, can be achieved by doping the fuel feedstock prior to sintering. In this work, the BISON fuel performance code was used to predict FGR from undoped and chromia-doped UO 2 (referred to as Cr-doped UO 2 ) fuel specimens with different grain sizes and across various temperatures. The BISON models identified the irradiation conditions for which FGR is most significant, and a separate effects irradiation experiment in the High Flux Isotope Reactor (HFIR) was then developed targeting those conditions. Further, the experiment leveraged the MiniFuel irradiation capability at Oak Ridge National Laboratory and consisted of 12 fuel specimens of varying grain size and Cr content. A coupling scheme between BISON FGR results and the ANSYS finite element thermal model used for experiment design was formulated to predict cumulative FGR from each fuel specimen based on expected irradiation temperature histories. The fuel samples were fabricated and characterized as a part of this work, and the fuel compositions modeled in BISON were representative of the specimens used in the experiment. This combined modeling and experimental effort aims to study the effect of fuel grain size and Cr content on FGR and to provide simulated BISON FGR results that can be used for future model validation activities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2013

Irradiation Performance of U-Mo Alloy Based ‘Monolithic’ Plate-Type—Design Selection Update

Based on data available in 2009, a decision was made to focus U–Mo monolithic fuel development and qualification efforts on a single fuel design. This fuel design consists of a U–10Mo (wt.%) monolithic fuel foil, a zirconium barrier layer applied to the faces of the foil, and 6061 aluminum cladding. This document updates the basis for the selection of that fuel system, drawing on additional fuel-performance data available as of May 2013. This update also applies recently developed GTRI (Global Threat Reduction Initiative) requirements for fuel qualification to the selection process. Because of its inherent gamma-phase stability and qualitatively better rolling behavior, U–10Mo was selected as the fuel alloy of choice, exhibiting reasonable uranium density and good irradiation performance. A zirconium barrier layer between the fuel and cladding was chosen to provide a predictable, well-bonded, fuel-cladding interface, greatly reducing fuel-cladding chemical interaction. The fuel plate testing conducted to inform this selection was based on the use of U–10Mo foils fabricated by hot- and cold co-rolling with a Zr foil. The foils were subsequently bonded to the Al–6061 cladding by hot isostatic pressing or friction stir welding. Since the original down-select decision was made, additional information has become available on fuel performance and on the cost of the fuel system. Preliminary cost estimates indicate that U–Mo-Zr waste generated during fabrication is difficult to recycle and adds substantially to the production cost. It is the purpose of this report to review fuel-performance data available as of May 2013, outline data and observations that are significant to informing the down-selection process, review the data against down-select requirements, and update the recommendation on a fuel system suitable for fuel qualification. In addition, this report assesses the potential of a fuel system without a zirconium barrier layer for use in USNRC-licensed research reactors. This revised report is issued as a working draft for discussion by the United States High Performance Research Reactor (USHPRR) program. The document will continue to be revised as additional information becomes available. This may include updates to information about normal and anticipated transient fuel operating conditions as conversion fuel-element designs evolve or additional information on fuel performance gained from U.S. or international testing programs. In particular, information from the RERTR–12 experiment will be included when available.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Advanced Fuels Campaign FY 2014 Accomplishments Report

The mission of the Advanced Fuels Campaign (AFC) is to perform Research, Development, and Demonstration (RD&D) activities for advanced fuel forms (including cladding) to enhance the performance and safety of the nation’s current and future reactors; enhance proliferation resistance of nuclear fuel; effectively utilize nuclear energy resources; and address the longer-term waste management challenges. This includes development of a state-of-the art Research and Development (R&D) infrastructure to support the use of a “goal-oriented science-based approach.” In support of the Fuel Cycle Research and Development (FCRD) program, AFC is responsible for developing advanced fuels technologies to support the various fuel cycle options defined in the Department of Energy (DOE) Nuclear Energy Research and Development Roadmap, Report to Congress, April 2010. AFC uses a “goal-oriented, science-based approach” aimed at a fundamental understanding of fuel and cladding fabrication methods and performance under irradiation, enabling the pursuit of multiple fuel forms for future fuel cycle options. This approach includes fundamental experiments, theory, and advanced modeling and simulation. The modeling and simulation activities for fuel performance are carried out under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, which is closely coordinated with AFC. In this report, the word “fuel” is used generically to include fuels, targets, and their associated cladding materials. R&D of light water reactor (LWR) fuels with enhanced accident tolerance is also conducted by AFC. These fuel systems are designed to achieve significantly higher fuel and plant performance to allow operation to significantly higher burnup, and to provide enhanced safety during design basis and beyond design basis accident conditions. The overarching goal is to develop advanced nuclear fuels and materials that are robust, have high performance capability, and are more tolerant to accident conditions than traditional fuel systems. AFC management and integration activities included continued support for international collaborations, primarily with France, Japan, the European Union, Republic of Korea, and China, as well as various working group and expert group activities in the Organization for Economic Cooperation and Development Nuclear Energy Agency (OECD-NEA) and the International Atomic Energy Agency (IAEA). Three industry-led Funding Opportunity Announcements (FOAs) and two university-led Integrated Research Projects (IRPs), funded in 2013, made significant progress in fuels and materials development. All are closely integrated with AFC and Accident Tolerant Fuels (ATF) research. Accomplishments made during fiscal year (FY) 2014 are highlighted in this report, which focuses on completed work and results. The process details leading up to the results are not included; however, the lead technical contact is provided for each section.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Fundamental approaches for analysis thermal hydraulic parameter for Puspati Research Reactor

The 1-MW PUSPATI Research Reactor (RTP) is the one and only nuclear pool type research reactor developed by General Atomic (GA) in Malaysia. It was installed at Malaysian Nuclear Agency and has reached the first criticality on 8 June 1982. Based on the initial core which comprised of 80 standard TRIGA fuel elements, the very fundamental thermal hydraulic model was investigated during steady state operation using the PARET-code. The main objective of this paper is to determine the variation of temperature profiles and Departure of Nucleate Boiling Ratio (DNBR) of RTP at full power operation. The second objective is to confirm that the values obtained from PARET-code are in agreement with Safety Analysis Report (SAR) for RTP. The code was employed for the hot and average channels in the core in order to calculate of fuel’s center and surface, cladding, coolant temperatures as well as DNBR’s values. In this study, it was found that the results obtained from the PARET-code showed that the thermal hydraulic parameters related to safety for initial core which was cooled by natural convection was in agreement with the designed values and safety limit in SAR.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2019

Status Report on Development of TREAT Water Loop

The Transient Reactor Test (TREAT) facility is a graphite based transient test reactor at the Idaho National Laboratory (INL). TREAT started operation in 1959 and performed thousands of transient irradiations for the primary purpose of nuclear fuel safety research. TREAT operations were suspended in 1994, and then, several years later, resumed reactor operations in 2017 to support development of advanced nuclear fuels. TREAT’s more recent historic focus had been for transients with relevance to sodium cooled fast spectrum reactors. TREAT’s first year of modern experiment work performed in 2018, however, saw the demonstration of new kinds of transients focused on light water reactor (LWR) needs including reactivity initiated accidents (RIA) and loss of coolant accidents (LOCA). The successful outcome of these efforts confirmed TREAT’s viability as a transient neutron source for LWR safety research. Since TREAT’s core is air cooled and provides no “built-in” thermal hydraulic boundary conditions for tests specimens, efforts have been underway to establish water-environment capabilities for testing specimens. Small static water capsules have been established to support single rod RIA testing where transient heating is brief. Similarly, deployment of enhanced water capsules with blowdown capability is nearing completion to support single rod LOCA testing. With careful experiment design these capsules can provide representative temperature response histories and water phase transitions for some experiment parameters. The capsule approach is appropriate for cost-effective early phase phenomena identification studies on novel fuels, or when the important test variables are thought to be fairly well understood so that they can be precisely targeted (such as they are for current fleet fuels with moderate burnup UO2 in uncoated zirconium alloy cladding). Due to lack of forced convection, however, the capsule approach cannot achieve representative temperature histories in all regions of the test fuel simultaneously (e.g. cladding and fuel centerline temperatures) while providing representative timing in water phase transitions. Nor can the capsule approach provide appropriate hydraulic conditions for multi-rod bundle testing. For these reasons, design and development has been undertaken for the TREAT Water-Environment Recirculating Loop (TWERL).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Irradiation Response of the Ferrite Phase in CF3 Cast Stainless Steel

Extending service of Light Water Reactors (LWRs) to beyond 60 years will demand a high integrity of materials and components in reactors. The accurate evaluation and prediction of materials performance under anticipated operation conditions are of particular importance for ensuring the safe operation of nuclear power plants over their extended lifetime. The duplex structure stainless steels including cast austenitic stainless steels (CASS) and welds of austenitic stainless steels are widely used in LWRs. The CASS alloys are mainly used in LWRs primary pressure boundary and for some limited core structural components. The type 308/309 welds are used for welding the reactor components made of 304 and 316 stainless steels and as a cladding layer on the inner surface of reactor pressure vessel. The core support columns made of CF8 CASS in a B and W design PWR are expected to be exposed to a fluence of between 1x10{sup 21} and 1x10{sup 22} n/cm{sup 2}, E>1.0 MeV, and the austenitic stainless steel welds can potentially receive a fluence up to 5x10{sup 22} n/cm{sup 2}, E>1.0 MeV. In addition to the thermal aging effect, the radiation induced fracture toughness in those duplex structure stainless steel components located in the high neutron fluence regions in LWRs hasn't be fully evaluated. Previous studies showed that the spinodal decomposition in the delta ferrite phase in CASS or type 308/309 welds is the primary embrittlement mechanism, and the G-phase precipitates were also identified but with less impact on the reduction of fracture toughness. It is generally agreed that the irradiation induced fracture toughness decrease in CASS and weld steels saturates after 10 dpa (∼1x10{sup 22} n/cm{sup 2}, E>1.0 MeV). Nevertheless, there are not enough high dose data points to confirm the lower bound in measured fracture toughness as the reported doses are limited to 15 dpa. The work in this paper is to present a more comprehensive study on the microstructural evolution in the ferrite phase in a CF3 CASS, and the results provide a scientific basis for extrapolating the change of fracture toughness to a high dose range.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Titanium and/or Aluminum Rod-Replacement Experiments in Fully-Reflected Water-Moderated Square-Pitched U(6.90)O 2 Fuel Rod Lattices with 0.67 Fuel to Water Volume Ratio (0.800 CM Pitch)

The US Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories. The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5% 235 U. The 7uPCX assembly is a water-moderated and -reflected array of aluminum-clad square-pitched UO2 fuel rods. The uranium is enriched to 6.90% by mass. Sets of 36 titanium and aluminum experiment rods with the same nominal outside diameter as the fuel rods were fabricated and used as replacements for fuel rods in the array. The twenty-four 7uPCX critical experiments reported here compare the effects of the titanium and aluminum replacement rods on nearly critical fuel rod arrays. The fuel used in these experiments was fabricated using unirradiated UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The nominal outside diameter of the fuel pellets is 0.207 in (0.52578 cm). The nominal outside diameter of the fuel rod cladding is 0.250 in (0.635 cm). The distance between the fuel rods in the square-pitched array is 0.315 in (0.8001 cm). This geometry gives a fuel-to-water volume ratio of 0.67 in the array. The twenty-four critical experiments in this series were performed in 2015 and 2016 at the Sandia Critical Experiments Facility. The first of the experiments had no replacement rods in the array and was intended to provide a baseline against which the experiments containing replacement rods could be compared. Eight critical experiments had titanium replacement rods in various numbers and arrangements near the center of the fuel array. Eight critical experiments had aluminum replacement rods in the same numbers and arrangements as in the eight experiments containing titanium experiment rods. In the final four experiments, fuel rods were removed from a central region of the array so that the pitch of the fuel rods in this part of the array was effectively doubled. This softened the neutron spectrum in the central part of the fuel array. Thirty-six replacement rods in different combinations of titanium and/or aluminum were placed in the interstices created in the center of the array. All twenty-four critical experiments are judged to be acceptable as benchmark experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Evaluation of Irradiation Creep Effects in HT9 Cladding for FAST Experiments

The push for advanced reactor fuels for improved reactor safety and efficiency had led to a renewed interest in metallic fuel for nuclear reactor applications. Experimental investigation is necessary to ensure a robust understanding of the thermomechanical properties of new metallic fuel designs. Unfortunately, with the current experimental facilities, thoroughly investigating the responses of metallic fuel burnup would take a prohibitively long time. To alleviate this, the Fission Accelerated Steady State Test (FAST) was developed to accelerate the irradiation testing while simultaneously decreasing the sensitivity to fabrication tolerances by reducing the fuel diameter and scaling the experiment. This method successfully scales the radiation effects on the fuel, but the HT9 cladding is not exposed to prototypic radiation conditions. This raises questions on whether the FAST experiment results are truly indicative of the HT9 cladding performance due to radiation induced creep effects not being appropriately accounted for. Using BISON fuel performance code, the simulated FAST cladding strain is compared to simulated EBR-II cladding strain. This is done through a sensitivity study of input parameters and scaling of neutron fluence on the cladding. This allows a parametric comparison of physical phenomena on the effective difference between cladding strains between FAST and equivalent burnup EBR-II fuel pins. The results show that the irradiation induced deformation (creep or swelling) is insignificant compared to the thermal-mechanical deformation. Therefore, the difference between the FAST experiment cladding and the EBR-II experiment cladding is negligible and comparison of fuel system performance between the two experiments is appropriate.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Failure investigation and mitigation after experimental research reactor fuel plate deformation in an irradiation device

Experimental research reactor fuel testing is conducted in the Belgian Reactor 2 (BR2) of the Belgian Nuclear Research Centre (SCK CEN) in dedicated irradiation vehicles or rigs. One such vehicle allows flat full-size fuel plates to be irradiated by inserting them into slotted baskets that captures a narrow portion of the longitudinal edges of the plates. The motion of the fuel plates within the baskets is possible within the narrow slots and thus, the plate is considered to be unattached. The design intentionally omits fixing mechanisms of the fuel plates to the baskets to facilitate the inspection and repositioning of the plates between the irradiation cycles and the accommodation of thermal expansion of the plates in the lateral direction. However, loosely inserted fuel plates have weak structural boundary conditions allowing for larger out-of-plane deflections caused by hydrodynamic loads exerted by the flowing coolant, as compared to those of fixed plates. Unexpected large deformations of plates occurred in several irradiation cycles that further resulted in a loss of cladding integrity. These deformations could not be attributed to a single source. This triggered a series of thermal hydraulic, structural, and fluid-structure interaction analyses aiming at understanding the observed phenomenon. The analyses revealed that, for a certain combination of unfavorable manufacturing and assembly tolerances, fuel plate edges could escape out of the slots in the irradiation basket due to the hydrodynamic load. Subsequently, the plate could become wedged inside the basket coolant channel opening. This resulted in reduced coolant flow and accelerated temperature increase and thermal expansion of the plate while under irradiation. This unfavorable feedback loop could then lead to excessive plate surface temperatures, deformed plates and cladding failure, as was observed in the experiments. These analyses not only provided a probable cause of the fuel plate failures, but also resulted in a new and improved design of the irradiation basket to avoid these issues in the future. In conclusion, a series of recent successful irradiations confirm that the sources of failures were identified correctly, and the implemented mitigations were adequate.

BR2↗