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DOE OSTI2015

Assessment of Startup Fuel Options for a Test or Demonstration Fast Reactor

This document explores startup fuel options for a proposed test/demonstration fast reactor. The fuel options considered are the metallic fuels U-Zr and U-Pu-Zr and the ceramic fuels UO 2 and UO 2 -PuO 2 (MOX). Attributes of the candidate fuel choices considered were feedstock availability, fabrication feasibility, rough order of magnitude cost and schedule, and the existing irradiation performance database. The reactor-grade plutonium bearing fuels (U-Pu-Zr and MOX) were eliminated from consideration as the initial startup fuels because the availability and isotopics of domestic plutonium feedstock is uncertain. There are international sources of reactor grade plutonium feedstock but isotopics and availability are also uncertain. Weapons grade plutonium is the only possible source of Pu feedstock in sufficient quantities needed to fuel a startup core. Currently, the available U.S. source of (excess) weapons-grade plutonium is designated for irradiation in commercial light water reactors (LWR) to a level that would preclude diversion. Weapons-grade plutonium also contains a significant concentration of gallium. Gallium presents a potential issue for both the fabrication of MOX fuel as well as possible performance issues for metallic fuel. Also, the construction of a fuel fabrication line for plutonium fuels, with or without a line to remove gallium, is expected to be considerably more expensive than for uranium fuels. In the case of U-Pu-Zr, a relatively small number of fuel pins have been irradiated to high burnup, and in no case has a full assembly been irradiated to high burnup without disassembly and re-constitution. For MOX fuel, the irradiation database from the Fast Flux Test Facility (FFTF) is extensive. If a significant source of either weapons-grade or reactor-grade Pu became available (i.e., from an international source), a startup core based on Pu could be reconsidered.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2011

Irradiation Data for the MFF-3 and MFF-5 Tests in the FFTF

The Fast Flux Test Facility is the most recent Liquid Metal Reactor to be designed, constructed, and operated by the U.S. Department of Energy (DOE). A variety of fuel tests were irradiated in FFTF to provide performance data over a range of conditions. The MFF-3 and MFF-5 tests were U10Zr metal fuel tests with HT9 cladding. A group of fuel pins from these two tests have been selected by DOE for post irradiation examination at Idaho National Laboratory (INL) as part of the Fuel Cycle Research and Development Program. At the request of INL, this report provides a data package of key information on the irradiation environment for these tests that will be useful in interpreting the results of these examinations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Preliminary Analysis of FFTF Loss-of-Flow Tests with SAS4A/SASSYS-1

The Fast Flux Test Facility (FFTF) was the most recent Sodium-cooled Fast Reactor (SFR) built in the United States. The Passive Safety Test (PST) program was carried out on FFTF between 1984 and 1986 to demonstrate the capability of passive reactor shutdown and decay heat removal in response to protected and unprotected transients. In order to recover the information and knowledge that has been gained from FFTF, a research project was initiated focusing on the simulation of Unprotected Loss of Flow Without Scram (LOFWOS) tests similar to the knowledge preservation activities conducted for EBR-II by Argonne National Laboratory in earlier years. These knowledge preservation activities are intended to support the validation of computational tools and methods in the area of SFR passive safety. Comparisons with experimental data and other safety codes provide opportunities to improve SFR design and safety analysis codes and methods.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Technical Documents for Gateway for Accelerated Innovation in Nuclear (GAIN)

The Gateway for Accelerated Innovation in Nuclear (GAIN) provides the nuclear energy community with access to the technical, regulatory, and financial support necessary to move new or advanced nuclear reactor designs toward commercialization. GAIN provides the nuclear community with a single point of access to the broad range of capabilities (i.e., people, facilities, materials, and data) across the U.S. Department of Energy (DOE) complex and its National Lab capabilities. The Fast Flux Test Facility (FFTF) is the most recent liquid metal reactor (LMR) to be designed, constructed, and operated by DOE. The 400-MWt sodium-cooled, fast-neutron flux reactor plant was designed for irradiation testing of nuclear reactor fuels and materials for liquid metal fast breeder reactors. Following the demise of the breeder reactor program in the United States, FFTF continued to play a key role in providing a test bed for demonstrating performance of advanced fuel designs and demonstrating operation, maintenance, and safety of advanced liquid metal reactors. The FFTF Program provides valuable information for potential follow-on reactor projects in the areas of plant system and component design, component fabrication, fuel design and performance, reactor control, prototype testing, and site construction. This report provides documents related to three important aspects of FFTF design and operation: 1) irradiation behavior of structural alloys and absorber materials, 2) thermohydraulics of rod bundles (i.e., coolant mixing), and 3) natural circulation heat transfer in the areas of modeling and validation. These technical documents are believed to be of interest to the nuclear industry and in particular to designers of new liquid metal reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

FFTF main heat transport system/dump heat exchanger testing and performance evaluation (initial pub date April 1978)

This report covers testing of a Main Heat Transport System/Dump Heat Exchanger (MHTS/DHX) for the Fast Flux Test Facility. The primary objective of the test program was to verify the design and generate experience in the installation, operation, and control of the DHX for FFTF. This report discusses test results related to erection, preoperational testing, in-service inspections, and steady-state and transient performance. Emphasis is placed on the effect of the test results on successful DHX operation at FFTF. 36 figures, 9 tables.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

NUBOW-3D Demonstration on LFR: Final CRADA Report

The NUBOW-3D software was developed to assist in designing a core restraint system for sodium-cooled fast spectrum reactors. Originally conceived during the FFTF design activities, the United States has been a proponent of limited free bow reactor design ever since to improve safety performance. In fast spectrum reactors, successful safety performance during reactor transients requires favorable reactivity feedback that leads to safe power stabilization or even natural system shutdown. In fast spectrum reactors, one key mechanism that designers use to improve the performance is to make thermal expansion inject negative feedback into the reactor system. While most fast reactor systems generally have a negative reactivity response to geometric expansion, the NUBOW-3D software allows the designers to better explore the impact on reactivity and optimize the system to maximize its impact.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2011

Securing Operating Data From Passive Safety Tests at the Fast Flux Test Facility

The Fast Flux Test Facility (FFTF) is the most recent Liquid Metal Reactor (LMR) to operate in the United States, from 1982 to 1992. The technologies employed in designing and constructing this reactor, along with information obtained from tests conducted during its operation, are currently being secured and archived by the Department of Energy's Office of Nuclear Energy Fuel Cycle Research and Development Program. This report is one in a series documenting the overall project efforts to retrieve and preserve critical information related to advanced reactors. A previous report summarized the initial efforts to review, retrieve and preserve the most salient documents related to Passive Safety Testing (PST) in the FFTF. Efforts continue to locate, secure, and retrieve record copies of original plant data tapes for the series of passive safety tests conducted between 1986 and 1991.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2013

Pyroprocessing of fast flux test facility nuclear fuel

Used nuclear fuel from the Fast Flux Test Facility (FFTF) was recently transferred to the Idaho National Laboratory and processed by pyroprocessing in the Fuel Conditioning Facility. Approximately 213 kg of uranium from sodium-bonded metallic FFTF fuel was processed over a one year period with the equipment previously used for the processing of EBR-II used fuel. The peak burnup of the FFTF fuel ranged from 10 to 15 atom% for the 900+ chopped elements processed. Fifteen low-enriched uranium ingots were cast following the electrorefining and distillation operations to recover approximately 192 kg of uranium. A material balance on the primary fuel constituents, uranium and zirconium, during the FFTF campaign will be presented along with a brief description of operating parameters. Recoverable uranium during the pyroprocessing of FFTF nuclear fuel was greater than 95% while the purity of the final electro-refined uranium products exceeded 99%. (authors)

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 OSTI2012

Impact properties of irradiated HT9 from the fuel duct of FFTF

This paper reports Charpy impact test data for the ACO-3 duct material (HT9) from the Fast Flux Test Facility (FFTF) and its archive material. Irradiation doses for the specimens were in the range of 3– 148 dpa and irradiation temperatures in the range of 378–504 *C. The impact tests were performed for the small V-notched Charpy specimens with dimensions of 3 * 4 * 27 mm at an impact speed of 3.2 m/s in a 25 J capacity machine. Irradiation lowered the upper-shelf energy (USE) and increased the transition temperatures significantly. The shift of ductile–brittle transition temperatures (DDBTT) was greater after relatively low temperature irradiation. The USE values were in the range of 5.5–6.7 J before irradiation and decreased to the range of 2–5 J after irradiation. Lower USEs were measured for lower irradiation temperatures and specimens with T-L orientation. The dose dependences of transition temperature and USE were not significant because of the radiation effect on impact behavior nearly saturated at the lowest dose of about 3 dpa. A comparison showed that the lateral expansion of specimens showed a linear correlation with absorbed impact energy, but with large scatter in the results. Size effect was also discussed to clarify the differences in the impact property data from subsize and standard specimens as well as to provide a basis for comparison of data from different specimens. The USE and DDBTT data from different studies were compared.

Byun, Thak Sang↗
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 OSTI2020

Joint Development of SAS4A Code in Application to Oxide-fueled LFR Severe Accident Analysis

The scope of this project was to pursue specific SAS4A liquid-metal cooled reactor (LMR) safety analysis software extensions to simulate postulated accidents with fuel failures for oxide-fueled Lead-cooled Fast Reactors (LFRs). Since most U.S. LMR experience is on sodium-cooled fast reactor options based on past testing and operation experience with EBR-II and FFTF, the DOE’s legacy fast reactor safety analysis capabilities were focused on metal-fueled pool-type concepts with sodium coolant. In recent years, Westinghouse Electric Company (WEC) has decided to pursue an LFR design as one of their next generation nuclear technology options because of its favorable safety and economics attributes. Oxide fuel is considered among other fuel options due to previous WEC experience with this fuel form. Development of this new technology requires the availability of adequately accurate computational tools, some of which can be adapted from versions of similar software used for analysis of other LMRs. Although Argonne National Laboratory’s (ANL) SAS4A/SASSYS-1 safety analysis software suite (shortened as SAS4A code hereafter for brevity) has the basic capabilities to model LFR system designs, the SAS4A code modules used in the analysis of accidents with fuel/cladding failures lack appropriate models for the unique phenomena that govern as-irradiated oxide-fuel damage mechanisms in lead coolant. Therefore, the objective of this project was to extend the capabilities of SAS4A with mechanistic oxide-fuel failure models in lead coolant for margin to failure assessments, analysis of failure modes, location and timing of failures under different accident scenarios consistent with the whole-plant dynamic response including the reactivity feedback, and assessment of the potential for fuel damage propagation due to potential fission gas jet and fuel-fragment/molten fuel impingement to neighboring fuel pins in an assembly. This report provides mainly a summary of Argonne’s technical contributions in the joint project, but the reports and publications by the Participant team are included as references at the end of the report.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Fuel Performance Analysis of Fast Flux Test Facility MFF-3 and -5 Fuel Pins Using BISON with Post Irradiation Examination Data

Using the BISON fuel-performance code, simulations were conducted of an automated process to read initial and operating conditions from the Pacific Northwest National Laboratory (PNNL) database and reports, which contain metallic-fuel data from the Fast Flux Test Facility (FFTF) MFF Experiments. This work builds on previous modeling efforts involving 1977 EBR-II metallic fuel pins from experiments. Coupling the FFTF PNNL reports to BISON allowed for all 338 pins from MFF-3 and MFF-5 campaigns to be simulated. Each BISON simulation contains unique power and flux histories, axial power and flux profiles, and coolant-channel flow rates. Fission-gas release (FGR), fuel axial swelling, cladding profilometry, and burnup were all simulated in BISON and compared to available post-irradiation examination (PIE) data. Cladding profilometry, FGR, and fuel axial swelling simulation results for full-length MFF metallic pins were found to be in agreement with PIE measurements using FFTF physics and models used previously for EBR-II simulations. The main two peaks observed within the cladding profilometry were able to be simulated, with fuel-cladding mechanical interaction (FCMI), fuel-cladding chemical interaction (FCCI), and thermal and irradiation-induced creep being the cause. A U-Pu-Zr hot-pressing model was included in this work to allow pore collapse within the fuel matrix. This allowed better agreement between BISON-simulated cladding profilometry and PIE measurements for the peak caused by FCMI. This work shows that metallic fuel models used to accurately represent fuel performance for smaller EBR-II pins may be used for full-length metallic fuel, such as FFTF MFF assemblies and the Versatile Test Reactor (VTR). As new material models and PIE measurements become available, FFTF MFF assessment cases will be reassessed to further BISON model development.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Burnup Predictions for Metal Fuel Tests in the Fast Flux Test Facility

The Fast Flux Test Facility (FFTF) is the most recent Liquid Metal Reactor (LMR) to be designed, constructed, and operated by the U.S. Department of Energy (DOE). The FFTF operated successfully from initial startup in 1980 through the end of the last operating cycle in March, 1992. A variety of fuel tests were irradiated in FFTF to provide performance data over a range of conditions. The MFF-3 and MFF-5 tests were U10Zr metal fuel tests with HT9 cladding. The MFF-3 and MFF-5 tests were both aggressive irradiation tests of U10Zr metal fuel pins with HT9 cladding that were prototypic of full scale LMR designs. MFF-3 was irradiated for 726 Effective Full Power Days (EFPD), starting from Cycle 10C1 (from November 1988 through March 1992), and MFF-5 was irradiated for 503 EFPD starting from Cycle 11B1 (from January 1990 through March 1992). A group of fuel pins from these two tests are undergoing post irradiation examination at the Idaho National Laboratory (INL) for the Fuel Cycle Research and Development Program (FCRD). The generation of a data package of key information on the irradiation environment and current pin detailed compositions for these tests is described. This information will be used in interpreting the results of these examinations.

burnup↗
DOE OSTI2011

Knowledge Preservation at the Fast Flux Test Facility

One of the goals of the Department of Energy's Office of Nuclear Energy Fuel Cycle Research and Development Program (FCRD) is to preserve the knowledge that has been gained in the United States on Liquid Metal Reactors (LMRs) that could support the development of an environmentally and economically sound nuclear fuel cycle. The Fast Flux Test Facility (FFTF) is the most recent LMR to operate in the United States, from 1982 to 1992, and was designed as a fully instrumented test reactor with on-line, real time test control and performance monitoring of components and tests installed in the reactor. Knowledge preservation at the FFTF is focused on the areas of design, construction, and startup of the reactor, as well as on preserving information obtained from 10 years of successful operating history and extensive irradiation testing of fuels and materials. In order to ensure protection of information at risk, the program to date has sequestered reports, files, tapes, and drawings to allow for secure retrieval. A disciplined and orderly approach has been developed to respond to client's requests for documents and data in order to minimize the search effort and ensure that future requests for this information can be readily accommodated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Argonne Reactor Code Software Verification and Validation Plan for the Versatile Test Reactor

This Argonne Reactor Code (ARC) software has taken a pivotal role in the design work of the Versatile Test Reactor. The ARC software itself consists of several independent or semiindependent pieces of software that are used in concert to carry out specific analysis and design objectives. In this report, we discuss the validation that is needed for the ARC software overall and discuss available, usable experimental data and how it relates to the VTR project. We also discuss the verification that is required for the ARC software with respect to its usage in the VTR project and give some concrete examples as to what it must accomplish. A list of goals for the verification and validation work are presented as the general procedure that will be implemented for every individual piece of software in ARC. The ARC software has been continuously developed for over 50 years and many of the features used for the VTR project have thus been rigorously tested for accuracy during that timeframe. The ARC software is presently under source code control and undergoes nightly regression testing of not only the individual pieces, but the interconnected aspects that are common to most analysis projects. Its greatest weakness, from a software verification and validation perspective, is both a lack of documentation and outdated documentation. As an example, much of the previous validation work will require contemporary effort to re-evaluate given the updated base data libraries and modifications to the software that have occurred since. This requires new documentation to be produced to support the usage of the software in the VTR project. The bulk of the ARC software is focused on steady state neutronics and TH behavior of a reactor system. In this regard, we have identified the ZPPR, FFTF, and EBR-II programs as the best candidates for sources of validation data for the VTR project. The ZPPR-15 series in the ZPPR program was chosen as it is the best representation of the VTR fuel form and reactor core layout of all of the ZPPR measurements. Additional support for it comes from the fact that most of the data has already been processed into usable ARC models for VTR validation. The FFTF and EBR-II reactors were both functional reactors that provide reactor scale measurements. FFTF is clearly a closer match to VTR and its startup measurements would be a very valuable validation basis. EBR-II has invaluable burnup related measurements that will play a key role in the ARC software validation work. Each piece of ARC software will require a report detailing the software verification. The validation work will be logically split into the results of modeling each identified experimental resource (ZPPR, EBR-II, FFTF). The intended timeline for the VTR project is to have the ARC software verified and validated by the end of fiscal year 2020. This is incumbent on sufficient funding allocated to V&V activities and no change in programmatic priorities.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2012

Preserving physics knowledge at the fast flux test facility

One of the goals of the Dept. of Energy's Office of Nuclear Energy, initiated under the Fuel Cycle Research and Development Program (FCRD) and continued under the Advanced Reactor Concepts Program (ARC) is to preserve the knowledge that has been gained in the United States on Liquid Metal Reactors (LMRs) that could support the development of an environmentally and economically sound nuclear fuel cycle. The Fast Flux Test Facility (FFTF) is the most recent LMR to operate in the United States, from 1982 to 1992, and was designed as a fully instrumented test reactor with on-line, real time test control and performance monitoring of components and tests installed in the reactor. The 10 years of operation of the FFTF provided a very useful framework for testing the advances in LMR safety technology based on passive safety features that may be of increased importance to new designs after the events at Fukushima. Knowledge preservation at the FFTF is focused on the areas of design, construction, and startup of the reactor, as well as on preserving information obtained from 10 years of successful operating history and extensive irradiation testing of fuels and materials. In order to ensure protection of information at risk, the program to date has sequestered reports, files, tapes, and drawings to allow for secure retrieval. A disciplined and orderly approach has been developed to respond to client's requests for documents and data in order to minimize the search effort and ensure that future requests for this information can be readily accommodated. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗