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The Digital Engineering Vision for DOME: Facilitating Design, Deployment, and Operations [Poster]

DOME is a planned microreactor test facility at INL’s Materials and Fuels Complex. It is a complex system with several interdependent sub-systems such as the reactor (up to 20 MWth), radioactive confinement, temperature and pressure regulation system, ventilation system, etc. The engineering design process for such a system traditionally involves several documents from various sources and the system information is scattered across these documents. Digital engineering represents a paradigm shift through which systems are designed using digital models and integrated data. The digital engineering vision for DOME utilizes a model-based systems engineering (MBSE) approach. The system architecture, physical components, control logic, and verification experiments are all designed using MathWorks MATLAB and Simulink. This hierarchical model can combine data from multiple sources at various levels of abstraction. It can be used to simulate the facility’s operations and to test the system using different sets of parameters. Its capabilities can be expanded by interfacing it with high-fidelity multi-physics models, risk analysis tools, etc. The same model can evolve into a digital twin that can monitor operations and conduct predictive analysis using real-time sensor data from the facility. The eventual goal of this effort is to transform the end-to-end engineering of nuclear facilities in every phase of their lifecycle, including design, deployment, and operations.

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SinhaRoy_TechPresentation_2024 [Slides]

DOME is a planned microreactor test facility at INL’s Materials and Fuels Complex. It is a complex system with several interdependent sub-systems such as the reactor (up to 20 MWth), radioactive confinement, temperature and pressure regulation system, ventilation system, etc. The engineering design process for such a system traditionally involves several documents from various sources and the system information is scattered across these documents. Digital engineering represents a paradigm shift through which systems are designed using digital models and integrated data. The digital engineering vision for DOME utilizes a model-based systems engineering (MBSE) approach. The system architecture, physical components, control logic, and verification experiments are all designed using MathWorks MATLAB and Simulink. This hierarchical model can combine data from multiple sources at various levels of abstraction. It can be used to simulate the facility’s operations and to test the system using different sets of parameters. Its capabilities can be expanded by interfacing it with high-fidelity multi-physics models, risk analysis tools, etc. The same model can evolve into a digital twin that can monitor operations and conduct predictive analysis using real-time sensor data from the facility. The eventual goal of this effort is to transform the end-to-end engineering of nuclear facilities in every phase of their lifecycle, including design, deployment, and operations.

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Performance Improvements for the Griffin Transport Solvers

Griffin is a Multiphysics Object-Oriented Simulation Environment based reactor multiphysics analysis application jointly developed by Idaho National Laboratory and Argonne National Laboratory. Griffin includes a variety of deterministic radiation transport solvers for fixed source, k-eigenvalue, adjoint, and subcritical multiplication, as well as transient solvers for point-kinetics, improved quasi-static, and spatial dynamics. A code assessment performed in FY-20 identified two significant issues with the transport solvers in Griffin: first, the primary heterogeneous SN (discrete ordinates) transport solver based on continuous finite element methods required significant mesh refinement and higher memory usage compared to solvers based on the method of characteristic for equivalent accuracy. Second, the homogeneous PN (spherical harmonics expansion) transport solver did not adequately support polynomial refinement, which is a feature usually required for problems with spatial homogenization and pronounced streaming, typical in fast or gas-cooled reactor systems. To address the first issue, the development effort focused on the more promising discontinuous finite element method (DFEM)-based SN transport solver in Griffin. The addition of an asynchronous parallel transport sweeper and coarse mesh finite difference (CMFD) acceleration have rendered a superior heterogeneous SN transport capability for multiphysics problems that requires far less computing resources in terms of both CPU time and memory usage. This is demonstrated with typical thermal- and fast-spectrum reactor benchmark problems, including 2D Transient Reactor Test, 3D Advanced Burner Test Reactor (ABTR), and 2D and 3D Empire microreactor. For the second issue, the development effort focused on a new transport solver based on the hybrid finite element PN method (HFEM-PN), equivalent to the variational nodal method, as well as a new diffusion solver based on HFEM-Diffusion. This solver is intended for homogenized domains with multiphysics coupling (i.e., supports mesh displacement, seamless temperature feedback, etc.). Initial calculations with the HFEM-Diffusion implementation show very good parallel efficiency for the residual evaluations with the 2D ABTR benchmark. A future development effort will be centered on further improvements to the CMFD, HFEM-PN, and DFEM diffusion solvers to ensure Griffin meets performance and software quality assurance requirements for advanced reactor design and analysis.

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ECAR-6415 Rev 0 CFD Analysis of the Primary Coolant Apparatus Test Core with Wire Spacers for Heterogeneous Power Distributions

Primary Coolant Apparatus Test (PCAT) is a thermal-hydraulic test loop for Microreactor Applications Research Validation and Evaluation (MARVEL) reactor. The heater elements were manufactured within a straightness tolerance for the designated gap thickness of 1.0 mm, but several elements have been distorted out of tolerance during the welding process. The distortion of heater rods can lead to flow maldistribution and excessive hotspot where the gap between two heater rods is too tight. In order to secure the heater-to-heater gap in an acceptable range, wire spacers are adopted for the PCAT. The wire spacers affect the thermal-hydraulic performance of the PCAT because they enhance the flow mixing among the flow subchannels in the core region. The objectives of this ECAR is to evaluate the effects of the wire spacers on the thermal-hydraulic performance of the PCAT core region by assuming several heterogeneous power distributions.

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MARVEL Technical Overview: Breakdown of cost and scope growth through 90% Final Design

This report presents a breakdown of cost and scope growth for the Microreactor Applications Research Validation and Evaluation (MARVEL) project through the design phase, and includes observations, lessons learned, and the results from an independent project assessment. It presents the status and history of the project. Technology maturity is considered in high-level, qualitative comparison to other microreactor design efforts. Its purpose is to record MARVEL’s evolution and lessons learned from the planning and design phases through completion of 90% final design. Analyses included a detailed review of project cost, schedule, and periodic project reports and management documents. The Primary Coolant Apparatus Test (PCAT) is specifically highlighted. It was concluded that MARVEL would have benefited from more extensive planning early in the project to better define cost and schedule to provide more certainty in the total project cost and delivery date. Modest cost and schedule improvements may have been possible, but compared qualitatively, MARVEL’s total cost and schedule performance are consistent with that of other efforts currently underway. Better planning would have provided more certainty, improved risk mitigations, and potentially eliminated delays due to funding shortfalls. A recommended path forward is presented that addresses recommendations in the independent project assessment.

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SPC-71260 Rev 0 MARVEL Heat Extraction Subsystem Secondary Coolant Equipment (SCE) Design/Build

A. The Microreactor Applications Research Validation and Evaluation (MARVEL) reactor will offer experimental capabilities that are not currently available at DOE’s national laboratories. Idaho National Laboratory (INL), operated for the U.S. Department of Energy (DOE) by Battelle Energy Alliance, LLC (BEA) (Contractor hereafter) is procuring services for the design, analysis, fabrication, testing and delivery of a Secondary Coolant Equipment system (SCE). This specification contains the requirements for design, analysis, fabrication, testing and delivery of the SCE as described herein. The MARVEL reactor is a microreactor which uses eutectic sodium-potassium alloy (NaK) as a primary coolant. The primary coolant is circulated through four primary loops by natural convection of the coolant. In each loop is a closed well which will accommodate an intermediate heat exchanger (IHX) for extracting heat from the loop. These wells will be referred to in this specification as the “IHX wells.” It is intended for the IHX containment to also be filled with NaK. The MARVEL design team has determined that a Heat Extraction System (HES) using pumped NaK will be used to extract heat from the IHXs and deliver it to a downstream system for power generation or alternate process heat users. This Heat Extraction System will enable MARVEL operations including the ability to test, demonstrate, and address issues related to installation, startup, and operations. In addition, it will allow down-stream utilization of process heat for various uses. The objective of this specification is to develop the final design for the HES Secondary Coolant Equipment system (SCE) that will be used as the core of the HES. This system provides control of the NaK circulation between the MARVEL reactor and the subsequent process heat utilization systems. It does not include design of the Intermediate Heat Exchangers and piping inside the T-REXc pit in which the reactor is located. B. The MARVEL microreactor will be installed in the Transient Reactor Test Facility (TREAT) building in the Transient Reactor Test (TREAT) Micro-Reactor Experiment Cell (T-REXc) C. An INL Subcontractor has developed a conceptual design for this system per SPC-71145, referred to in that specification as the Process Heat Extraction System. SPC-71260 is based on the pumped NaK loop concept developed under SPC-71145. D. The SCE system design and (as option scope) fabrication shall be provided by the awardee of the subcontract (Subcontractor hereafter) pertaining to this Specification. Prior to shipment, the SCE will be fabricated, assembled, and tested at the Subcontractor’s facility. After successful completion of acceptance testing, the SCE and associated equipment will be shipped to the Materials and Fuels Complex (MFC) at the INL (Contractor’s Facility hereafter) to be installed by others in TREAT/T-REXc.

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Autonomous control for Heat-Pipe microreactor using Data-Driven model predictive control

To enable a self-regulating capability for heat pipe (HP) microreactors, an anticipatory control strategy achieved via model predictive control (MPC) could proactively respond to potential disturbances and deviations in operating setpoints. This paper demonstrates data-driven methods for predicting the distribution and transient of temperatures and heat fluxes at selected components and regions in a 37-HP system, based on which the optimal control actions in response to changes in user-defined setpoints can be found. We present the development and validation of linear state-space model, feedfoward, and recurrent neural networks. Here, we compare the performance of MPCs with different modeling approaches in terms of following setpoints for temperatures and averaged output heat fluxes. The accuracies of the three data-driven models are similar, but the control actions initiated by neural-network-based MPC can better adapt to drastic changes in setpoints yet generate the smallest errors.

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NRIC Integrated Energy Systems Demonstration Pre-Conceptual Designs

This report presents pre-conceptual design scenarios for a potential multiphase demonstration program for innovative uses of nuclear energy with the National Reactor Innovation Center (NRIC) and the Crosscutting Technology Development Integrated Energy Systems (CTD IES) program in the U.S. Department of Energy’s Office of Nuclear Energy. The demonstration program would address the need for low-carbon energy sources among industry stakeholders by identifying and implementing high-impact advanced nuclear projects within a holistic systems perspective. Battelle Energy Alliance, LLC, the managing and operating contractor for the U.S. Department of Energy’s Idaho National Laboratory (INL) in Idaho Falls, Idaho, is seeking Expressions of Interest (EOI) for industry stakeholder participation in the potential demonstration program. Funding sources have not yet been identified for the demonstration program. Responses to the EOI will shape the development and funding requirements for the potential program and inform the down-selection of project designs for further planning and analysis from the wide set of pre-conceptual design scenarios shown in this report. This introductory section summarizes the need for low-carbon energy sources, describes the phases envisioned for the demonstration program, and outlines the organization of this report.

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ECAR-6589 Reflector Support Structure Analysis: Project #33526

The MARVEL microreactor consists of five main systems: MRS (MARVEL Reactor Structure), PGS (Power Generation System), FCS (Fuel Core System), RCS (Reactivity Control System), and ICS (Instrument Control System). The RSS (Reflector Control System) is a sub system of the MRS which contains the upper and lower reflector support plates which support and locate the stationary core reflector and provide vertical support for the control drums. They are suspended from the Primary Coolant System by bolted structural straps which utilize a turnbuckle to allow for adjustment and leveling of the support plates. The stainless-steel support plates are each formed from four quarter circle segments which are bolted together around the lower core barrel. Bearing plates of non-galling Nitronic 60 alloy are fitted to the inner diameter of the support plates to prevent adhesive wear between the plates and the core barrel as the barrel expands and contracts due to changes in the temperature of the reactor.

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Stability margin analysis of the Holos-quad microreactor design

A simplified point model of the Holos-Quad microreactor is introduced. The model is based on the point kinetics equations coupled to three heat balance equations, representing the mean temperatures of the fuel particles, the graphite moderator and the helium coolant. The differential equations are converted to the frequency domain, enabling the construction of the closed-loop reactor transfer function. Using this function the stability margins of the core design is analyzed for various power levels. It is shown that the gain margins approaches infinity, demonstrating the stability of the reactor for all power levels. The phase margin at nominal power is about 60 degrees, however it shows a non-monotonous dependence on power, with minimal value obtained for about 10% of nominal power. As power level is further increased, the phase margin also increases, demonstrating the reactor becomes more stable. This behavior may be of high importance in load-follow scenarios, where the power level of the reactor changes with time. (authors)

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SPC-71145 Rev 0 MARVEL Process Heat Extraction System Conceptual Design

The Microreactor Applications Research Validation and Evaluation (MARVEL) reactor will offer experimental capabilities that are not currently available at DOE’s national laboratories. The MARVEL reactor is a microreactor which uses eutectic sodium-potassium alloy (NaK) as a primary coolant. The primary coolant is circulated through four primary loops by natural convection of the coolant. In each loop is a closed well which will accommodate an intermediate heat exchanger (IHX) for extracting heat from the loop. These wells will be referred to in this specification as the “IHX wells”. It is intended for the IHX containment to also be filled with NaK. The MARVEL design team is currently looking for alternative means of extracting heat from these wells to be utilized in downstream applications. This Heat Utilization System (HUS) will enable MARVEL operations including the ability to test, demonstrate, and address issues related to installation, startup, and operations. In addition, it will allow down-stream utilization of process heat for various uses. Depending on the methodology used, the interface between the secondary coolant and the HUS is the Process Heat Extraction System (PHES) and is the subject of this specification.

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Development of Hydrogen Permeation Barrier and Matrix Interaction Protection Coatings for TZM Enclosure of Hydride Moderators (Microreactor Program M3 Report)

It is important to develop a high-performance enclosure solution for hydride-based microreactor moderation components to effectively suppress hydride thermal decomposition and prevent hydrogen loss in harsh in-reactor environments. Currently, the DOE-NE Microreactor Program (MR program) is investigating the titanium-zirconium-molybdenum (TZM) canned yttrium hydride (YH 2-x ) solution, which provides acceptable hydrogen retainment performance up to ~700 °C. However, improvements in the enclosure are necessary for increasing long-term operation temperature beyond 700 °C and enhancing short-term survivability at even higher temperatures during power transients. One potential solution is the addition of a dedicated hydrogen permeation barrier, which can potentially improve the enclosure's performance. Furthermore, the hydride moderator components will be inserted into the microreactor matrix, which may consist of materials that are not chemically inert against TZM. Therefore, the TZM might need to be protected from the external environment through the application of another surface protection coating. To address these critical issues, two types of barrier coatings optimized for TZM-based moderator enclosure has been developed. A multilayer coating approach has been used to identify TZM-compatible barrier materials. Behavior of these coating designs against H 2 permeation and long-term high-temperature graphite matrix interactions has been examined in detail. Additionally, the developed coatings' behavior when exposed to both high-temperature thermal cycling and heavy-ion irradiation has also been investigated. Overall, the development of these barrier coatings is essential for achieving maturity for the metal hydride moderator technology. The results in this report will provide crucial insights into the behavior of the developed coatings and their potential for improving the long-term performance of TZM-based moderator enclosures.

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Laser Powder Bed Fusion Additive Manufacture Nb1Zr Development

Next generation fission and fusion nuclear reactors require materials that can withstand operating temperatures greater than 500 °C, neutron irradiation doses of up to 200 displacements per atom (dpa), and potentially corrosive coolants such as the alkali liquid metals sodium, lithium, and NaK (Na33K eutectic alloy). Refractory alloys, such as Nb1Zr (Nb-1wt%Zr) and Molybdenum alloy TZM (Mo-0.5wt%Ti-0.08wt%Zr) have been traditionally considered viable candidates for advanced fission and fusion reactor concepts. However, it is relatively difficult to generate complex geometries of interest from these alloys using traditional manufacturing methods. In addition, there needs to be a concentrated effort to address refractory metal challenges at elevated temperature operation. In order to generate complex geometries of interest, modern manufacturing techniques are considered to increase the technological readiness level (TRL), cost-effectiveness, and schedule savings. This work focused on the continued development of laser powder bed fusion (L-PBF) additive manufacturing (AM) to improve both design flexibility, evaluate microstructure and properties, and ultimately accelerate the TRL and qualification of these processes and alloys for components to potentially be put into service. Niobium alloy Nb1Zr was identified through a down-selection process outlined in previous reports as a candidate to develop in L-PBF AM. Historically, Nb1Zr had been explored for high temperature fast spectrum fission reactors for both terrestrial and space applications. Molybdenum alloy TZM has also been considered for these reactor concepts due to exceptional high-temperature strength, creep resistance, and stability under irradiation. L-PBF AM of TZM has previously been investigated at LANL under the Microreactor program, NASA, ORNL, and in academia. However, due to the crack prone nature of TZM, L-PBF AM of TZM resulted in significant microcracking and additional development is required to pursue viable maturation. Other AM methods have been found to be more successful in printing TZM, and those alternatives approaches are discussed in this effort. The efforts detailed in this report focused on continued development of Nb1Zr through L-PBF and development of TZM via L-PBF and electron powder bed fusion (E-PBF). The objective of this work was to further the development of these AM techniques for the chosen refractory alloys, elucidating and addressing associated challenges through characterization of several demonstration builds. At LANL, Nb1Zr builds were completed using an EOS M290 and M400 machines, and a refractory alloy-dedicated L-PBF system, the Xact Metal XM200G, was installed. The XM200G primary purpose was to do the Nb1Zr parameter development process; however, due to difficulties associated with the machine installation and qualification process, it was decided to pivot development to the larger M400 and M290 machines. Although the supply of Nb1Zr powder was limited, it was sufficient to generate sub-scale metallographic specimens for the purpose of parameter development. This was first accomplished on the EOS M400 then the M290 due to machine schedule availability. Further development of TZM has been initiated at the University of Texas El Paso (UTEP) under contract with LANL to use both a heated build envelope L-PBF machine and E-PBF machine that have been found in the literature to mitigate microcracking. UTEP was provided with TZM powder and build plates to support parallel TZM parameter development across both machines. As part of the contract, UTEP will also be conducting microstructural characterization once optimized process parameters have been identified. The optimized process parameters for each machine will be used to generate a series of metallographic, mechanical, and surface finish specimens for subsequent characterization and testing. In the next section, we provide a detailed discussion of the methodology used for investigating the feasibility of leveraging these alloys for use in advanced reactor applications.

36 MATERIALS SCIENCE↗

Sample problems for Section III, Division 5 design by inelastic analysis of Grade 91 components

This report works through two sample design analyses of representative Grade 91 components using the ASME Boiler & Pressure Vessel Code Section III, Division 5, Appendix HBB-T rules for the strain and deformation and creep-fatigue design criteria using a design by inelastic analysis approach. The component geometries and loadings were selected to span a wide variety of potential applications. The sample components are an endplate geometry, which is fairly representative of typical pressure vessel construction, and a core block, representing a critical component in a heat pipe microreactor, which has a complicated geometry and complex thermal stress history. These sample problems serve several functions. First, they are complete worked examples of how to apply the current design by inelastic analysis rules. Second, they serve as test cases to evaluate the current rules and provide feedback on how they could be optimized to deal with complicated component geometries or to be better automated in modern finite element analysis software. Finally, the analysis here uses an inelastic constitutive model for Grade 91 developed by Argonne National Laboratory and proposed for inclusion in the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules as a reference constitutive model. Using this constitutive model in the sample problem analyses tests the model in the context of the ASME Code rules. The final conclusions of this report are that the material model and the current Code rules are satisfactory, but that the Code rules could be optimized to simplify automation and reduce over conservatism. Future work should address the specific optimization topics discussed in this report.

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The Deimos Experiment: Advanced Reactor Testbed

Advanced reactor initiatives are growing significantly through programs nationwide. This research area includes small modular reactors, microreactors, and space reactors. Many of the reactors being designed are untested concepts. They include unique moderators, varying fuel types, high temperatures, and compact configurations. The shift in fuel type, from highly enriched uranium (HEU) to high assay, low enriched uranium (HALEU), is particularly important as it has driven many of the other changes. For example, lower enrichment requires advanced moderators, which in turn require different reflectors to make the systems compact. The change in materials including the transition from HEU to HALEU affects the temperature feedback of the systems. Additionally, these advanced reactor concepts generally have a thermal neutron spectrum in contrast to earlier fast spectrum advanced reactor. With the extensive changes from previous reactor designs, validation experiments are needed. The National Criticality Experiments Research Center (NCERC) is uniquely equipped to perform such experiments. The Deimos experiment, designed for execution at NCERC, will serve as a testbed for advanced reactor concepts. It will use HALEU fuel in a graphite matrix, provide the ability to use advanced moderators, and allow measurements of temperature reactivity coefficients (TRCs).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

An economics-by-design approach to a radiant integrated thermophotovoltaic microreactor system

This paper presents an application of the economics-by-design approach to the Radiant Integrated Thermo-photovoltaic Microreactor System (RITMS). The RITMS design is unique in that it directly couples a critical fission reactor with thermo-photovoltaic (TPV) panels for high efficiency energy conversion. This significant shift from electric conversion using traditional dynamic heat pumps leads to a simpler and more reliable system without turbomachinery and high pressurization. In working towards wrapping up the early design work, the economics-by-design approach, which centers economic competitiveness as the optimization parameter, is well suited in making a final determination on viability. This paper describes the computational sequence that was developed to couple the radiative and conductive heat transfer and feed operational performance to cost estimation. The framework was applied to maximize the power of the system, while minimizing the fuel enrichment. This method is applied to a reference RITMS design as part of a parametric sensitivity study, which revealed that the system is under moderated and that single unit plants could produce power as low as 300 dollar/MWh. This price point supports the notion that early in the RITMS design implementation, adoption into niche markets as a first-of-a-kind technology is possible. (authors)

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Enhancing Autonomous Control of Microreactors Using Multi-Agent Reinforcement Learning

In order for microreactors to be economically competitive, operation costs will need to be minimized through some degree of autonomous control. Previous work has demonstrated the effectiveness of reinforcement learning (RL) for load-following control in a drum-controlled microreactor. This study extends that work by exploring the potential of RL to independently control each of the reactor’s drums. We compare a single-agent RL approach with a multi-agent RL (MARL) framework, testing them for generalization across different load-following power profiles and control timescales, and for robustness in cases of randomly disabled control drums. Since the point kinetics simulation environment used in this study cannot resolve spatial effects, we assume that in the absence of spatially localized disturbances, optimal drum movements should be symmetrical. We demonstrate that single-agent RL is able to achieve accurate performance only when symmetric actions are ignored; otherwise, it fails to train a useful controller. Meanwhile, the MARL framework performs symmetric actions by design and trains a robust, accurate agent, as evidenced by mean absolute errors in power matching of 0.41% for the training power profile, 0.68% for a profile with half the drums disabled, and 0.21% for a profile on a realistic load-following time horizon.

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Development and assessment of a model predictive controller enabling anticipatory control strategies for a heat-pipe system

To support the reliable and resilient operation of modular reactors and microreactors, anticipatory control strategies have been proposed for achieving faster-than-real-time predictions and decision-making capabilities in anticipation of potential anomalies, including setpoint changes and cyber incidents. Here this work presents how anticipatory control strategies can be implemented via model predictive control (MPC) of a single heat pipe’s temperature. Considering the uncertainty in developing and applying MPC, this work evaluates MPC performance given three different model forms: a linear response surface model, an artificial neural network (ANN), and an autoregressive model with exogenous input (ARX). This work also evaluates the impacts of different input biases and variance on MPC performance in order to account for potential sensor reading variations due to cyber incidents. We observe that nonparametric models such as the ANN and ARX result in more fluctuated control actions compared to the MPC applied to the linear response surface model. However, when the cyber incidents are of a large magnitude, the linear response surface model produces smaller feasible regions than the nonparametric models under identical constraints.

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