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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1974

Simplified cut core inductor design

Although filter inductor designers have routinely tended to specify molypermalloy powder cores for use in high frequency power converters and pulse-width modulated switching regulators, there are sigificant advantages in specifying C cores and cut toroids fabricated from grain oriented silicon steels which should not be overlooked. Such steel cores can develop flux densities of 1.6 tesla, with useful linearity to 1.2 tesla, whereas molypermalloy cores carrying d.c. current have useful flux density capabilities only to about 0.3 tesla. The use of silicon steel cores thus makes it possible to design more compact cores, and therefore inductors of reduced volume, or conversely to provide greater load capacity in inductors of a given volume. Information is available which makes it possible to obtain quick and close approximations of significant parameters such as size, weight and temperature rise for silicon steel cores for breadboarding. Graphs, nomographs and tables are presented for this purpose, but more complete mathematical derivations of some of the important parameters are also included for a more rigorous treatment.

Mclyman, W. T.↗
DOE OSTI2024

Gains in operational flexibility, safety margins, and cost efficiencies via integrated Plant Reload Optimization platform

The U.S. Department of Energy Light Water Reactor Sustainability Program Risk-Informed Systems Analysis Pathway Plant Reload Optimization Project aims to develop an integrated, comprehensive framework offering an all-in-one solution for reload evaluations with a special focus on optimizing core design. Optimizing the fuel loading pattern is one of the most important considerations in reducing the amount of new fuel used in the core. Due to thousands of possible core configuration options, finding optimal solutions is an unachievable task for a human. The Plant ReLoad Optimization platform, which supports artificial-intelligence-based reactor core designing, is now fully capable of handling realistic problems. The Plant ReLoad Optimization platform development project aims to build a reactor core design tool that includes reactor safety and fuel performance analyses and uses artificial intelligence to support the optimization of core design solutions. The NSGA-II (Non-dominated Sorting Genetic Algorithm II) optimizer was developed and tested within RAVEN (Risk Analysis and Virtual ENvironment) to handle many constraints by using an augmented objectives methodology. The demonstration was performed with constrained multiobjective optimization of a 17 × 17 pressurized-water reactor core loading patterns to minimize fuel cost and maximize fuel cycle length.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Coupled Neutronic and Thermal Hydraulic Analysis of a Natural Circulation Based Small Modular Reactor (SMR) Using VERA-CS

As part of the work supported by a US Department of Energy (DOE) Office of Nuclear Energy Gateway for Accelerated Innovation in Nuclear FY 2020 Voucher, Holtec International subsidiary SMR LLC (hereinafter referred to as Holtec) and Oak Ridge National Laboratory entered into a cooperative research and development agreement (CRADA) to develop coupled multiphysics core models of the Holtec developed small modular reactor (SMR), SMR-160. The scope of the 1 year project was to use the DOE–developed tool set, VERA, to analyze several aspects of a representative SMR-160 core design. The goals of the project were to perform the code-to-code benchmarking and to provide Holtec with a confirmatory calculations to compare against the results with the codes used in the SMR-160 design, identify and resolve areas of discrepancy between the two models to give Holtec a basis for selecting certain tool and model options, and develop a workflow so that the VERA model could be adapted easily to any future changes in the design of the SMR-160 core. The work proceeded in four phases: 1. Developing the initial VERA model based on Holtec-provided core design information; 2. Comparing VERA results with Holtec-provided calculations for the first five cycles; 3. Developing a VERA transient model based on the prior model; and 4. Training Holtec personnel on VERA and hand-off the developed models. This report summarizes at a high level the completed tasks. Details of the tasks and results are reserved for the full report, which will not be publicly released for 5 years per the terms of the CRADA. The report is titled “Coupled Neutronic and Thermal Hydraulic Analysis of a Natural Circulation Based Small Modular Reactor (SMR) using VERA-CS” and has the ORNL technical report number ORNL/TM 2021/2303 (NFE-20-08305)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Differences In High Burnup Fuel Management Strategies to Minimize FFRD and Increase Economic Viability

The nuclear industry is pursuing approval of an increase in the length of the pressurized water reactor (PWR) cycle from 18 months to 24 months to reduce reactor downtime and enhance the economic competitiveness of nuclear energy. Such an increase in reactor cycle length will require that the maximum rod average burnup exceeds the current regulatory limit of 62 GWd/MTU, and it could peak at approximately 75 GWd/MTU, posing potential reactor safety and performance concerns. One such concern is that fuel fragmentation, relocation, and dispersal (FFRD) could occur during a severe loss-of coolant accident (LOCA) in which a fuel rod balloons and bursts, and pulverized fuel fragments are dispersed throughout the reactor’s primary coolant system. Previous analyses have identified which reactor operating conditions leave the core more susceptible to FFRD and have shown that FFRD susceptibility is strongly linked to fuel rod burnup and linear heat rate (LHR) history. The work described in this report uses an optimization strategy known as parallel simulated annealing (PSA) and a coarse mesh Purdue Advanced Reactor Core Simulator (PARCS) reactor physics model to develop two core fuel loading patterns, each with a different optimization objective. One core optimization maximized the core’s cycle length while still respecting regulatory limits on the radial peaking factor and soluble boron concentration with a peak rod average burnup of 75 GWd/MTU. The second optimization was aimed at minimizing FFRD susceptibility while still targeting a 24-month cycle length and respecting regulatory limits. PARCS model predictions were verified using the high-fidelity Virtual Environment for Reactor Applications (VERA). The two core designs were compared to highlight core design strategies to minimize FFRD susceptibility and to maximize economic viability.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Updated Reference VTR Core for CD-1

A preliminary reference core design was previously developed for the Versatile Test Reactor. The main features are that it is a 300 MW th sodium-cooled fast reactor using ternary metallic fuel U-20Pu-10Zr and able to achieve peak fast fluxes (E n > 0.1 MeV) in excess of 4.0x10 15 n/cm 2 -s. The plutonium in the fuel was assumed to be “reactor grade”, with a fissile quality of about 72% (i.e., 239 Pu and 241 Pu comprise 72% of the plutonium isotopes), and the uranium was assumed to be low-enriched uranium with 5% 235 U. This preliminary core design has been used through the CD-0 phase of the VTR project. Progression of the work after CD-0 led to revising, updating and refining the reference VTR core design, based on considerations from the various VTR teams: fuel, experiment, safety, and plant design teams. The objective of this report is to summarize the various changes made and details added to the model, to provide a description of the updated reference VTR core design and of its performance characteristics. This includes the traditional reactor physics characteristics, fuel cycle details, reactivity coefficients, temperature distributions, control rod worths and shutdown requirements. All of these define the updated “reference VTR core” intended to be used through CD-1.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Artificial Intelligence for Multiphysics Nuclear Design Optimization with Additive Manufacturing

The geometric flexibility of additively manufactured metals and ceramics generates a very large and open design space that requires advanced modeling and simulation tools for physics simulations and the rigorous definition of design problems. This effort deploys artificial intelligence (AI) and machine learning (ML) algorithms to understand the design space, evaluate potential designs, and more efficiently generate optimized results. The Transformational Challenge Reactor (TCR) program is leveraging advances in several scientific areas—including materials, manufacturing, sensors and control systems, data analytics, and high-fidelity modeling and simulation—to accelerate the design, manufacturing, qualification, and deployment of advanced nuclear energy systems. Through a manufacturing-informed design approach, the TCR program seeks to integrate digital data for rapid nuclear innovation; accelerate the adoption of advances in manufacturing, materials, and computational sciences for nuclear applications; and dramatically reduce deployment costs and timelines for new nuclear reactor technologies. This report documents efforts under the TCR program to leverage advanced modeling and simulation techniques driven by AI/ML algorithms on high-performance computing (HPC) systems to yield more optimized TCR core designs. A multiphysics ML surrogate model was developed to run on the HPC architectures. The surrogate model is trained on high-fidelity simulation data of coupled neutronics and thermofluidics and is used to quickly evaluate thousands of candidate core designs in parallel, which drives the evolution of the cooling channel shapes to minimize temperature peaking and material stress. Outcomes from these activities provide design information and feedback into the core design efforts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Bayesian Optimization for Reactor Design Optimization

This study present a test case in which the Bayesian Optimization method is applied to a simulation-based reactor core design optimization problem. The test case aims to showcase the potential of an automated design optimization algorithm for reactor designs by streamlining the reactor core design workflow, given the high computational cost of simulations. The contributions of this work are threefold. First, the existing HTGR model is converted into a simulation-based design optimization test case by developing a pipeline that enables modification of key design parameters and evaluates design performance based on simulation outputs. Second, Bayesian Optimization is implemented and adapted to demonstrate the feasibility of automatic design optimization for nuclear reactor core. Proposed approach leverages Gaussian Process models to characterize the relationship between design variables and performance metrics, while incorporating novel acquisition functions that balance exploration of the design space with exploitation of promising configurations. This implementation lays the foundation for the future developments of reactor design optimization algorithms.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Designing optimal core–shell MOFs for direct air capture

Metal–organic frameworks (MOFs), along with other novel adsorbents, are frequently proposed as candidate materials to selectively adsorb CO 2 for carbon capture processes. However, adsorbents designed to strongly bind CO 2 nearly always bind H 2 O strongly (sometimes even more so). Given that water is present in significant quantities in the inlet streams of most carbon capture processes, a method that avoids H 2 O competition for the CO 2 binding sites would be technologically valuable. Here, in this paper, we consider a novel core–shell MOF design strategy, where a high-CO 2 -capacity MOF “core” is protected from competitive H 2 O-binding via a MOF “shell” that has very slow water diffusion. We consider a high-frequency adsorption/desorption cycle that regenerates the adsorbents before water can pass through the shell and enter the core. To identify optimal core–shell MOF pairs, we use a combination of experimental measurements, computational modeling, and multiphysics modeling. Our library of MOFs is created from two starting MOFs-UiO-66 and UiO-67-augmented with 30 possible functional group variations, yielding 1740 possible core–shell MOF pairs. After defining a performance score to rank these pairs, we identified 10 core–shell MOF candidates that significantly outperform any of the MOFs functioning alone.

42 ENGINEERING↗
DOE OSTI2022

Transformational challenge reactor design characteristics

The Transformational Challenge Reactor (TCR) program was conceived with the goal to reduce costs and time frames associated with advanced reactor deployment by leveraging developments in advanced manufacturing, advanced materials, data science, and rapid prototyping and testing. The final deliverable of the TCR program was to be an operational test of a novel reactor design. The TCR core design incorporates a dense tri-structural-isotropic/SiC fuel form and volumetrically efficient yttrium hydride moderator, both of which were manufactured and characterized under the TCR program. The TCR is a 3 MW{sub th} He-cooled experimental nuclear reactor designed to reach a total integrated burnup of less than 24 effective full-power hours to keep the radioactive source term to a very low level. TCR design process revealed a positive moderator coefficient; however, the negative doppler coefficients for the fuel and thermal expansion of fuel, moderator, and core support plate yield an overall negative reactivity coefficient. Calculated fuel element temperatures and stresses are well within safety margins. The maximum hypothetical accident (i.e., de-pressurized loss of forced cooling) yields only a modest increase in reactor temperatures that are all within safety margins. This paper summarizes the high-level TCR design characteristics, which were derived from neutronics, thermohydraulics, thermomechanics, and safety analyses.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1979

Reactor design for nuclear electric propulsion

The paper analyzes the consequences of heat pipe failures, that resulted in modifications to the basic design of a heat-pipe cooled, fast spectrum nuclear reactor and led to consideration of an entirely different core design. The new design features an integral laminated core configuration consisting of alternating layers of UO2 and molybdenum sheets that span the diameter of the core. Design characteristics are presented and compared for two reactors. A conceptual design for a heat exchanger between the core and the thermionic converter assembly is described. This heat exchanger would provide design and fabrication decoupling of these two assemblies.

Koenig, D. R.↗
DOE OSTI2024

High-Burnup BWR LOCA Burst Analysis Framework Development and Demonstration

Nuclear power currently contributes approximately 20% of total electricity generation in the United States and more than 10% globally. Given the increasing reliance on nuclear energy to achieve our nation’s goal of reaching net-zero carbon emissions by 2050, there is significant pressure on the existing nuclear industry to extend plant operational licenses and improve efficiency. This is crucial as the existing nuclear fleet serves as a vital bridge until new light water and advanced reactors can be developed and deployed, bolstering the supply of carbon-free energy to meet domestic demands. Operational costs primarily consist of plant operation and maintenance and fuel costs, influenced by materials and reactor core designs. These factors, coupled with heavily subsidized renewable energy markets, create a challenging economic environment for the existing light water reactor fleet, as well as for new build projects. To address these economic challenges, the nuclear industry has developed a strategic blueprint aimed at enhancing nuclear power’s economic sustainability. Past initiatives, such as efforts to eliminate fuel failures by 2010 and reduce operating costs by 30% before 2020, have laid the groundwork. Optimizing core design parameters, including burnup limits and enrichment levels, can lengthen cycles, reduce outages, reduce batch reload batch fractions and spent fuel storage requirements, and lower maintenance and operating expenses, thereby enhancing economic viability. In the United States, boiling water reactors (BWRs) comprise approximately one-third of the fleet, although much of the research and development focus has traditionally been on pressurized water reactors (PWRs). Advances in modeling and simulation, particularly through the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, are crucial to the long-term viability of BWRs, just as they are for PWRs. A key research area of the high burnup/increased enriched fuel initiative is focused on addressing loss-of-coolant-accident (LOCA)-related issues. NEAMS has dedicated significant effort to enhancing tools to better support BWRs, with a current focus on showcasing the BWR framework for high-burnup LOCA analysis. This high-fidelity work will demonstrate a best estimate pin-by-pin high-burnup BWR LOCA analysis to assess full-core cladding rupture behavior. This modeling capability will help with better understanding and realistic evaluation of fuel fragmentation, relocation, and dispersal (FFRD) phenomena at BWRs, which then could be used to prevent FFRD at BWRs without penalizing operational parameters. In addition, the results of this work will help identify strategies to identify additional margins or to potentially limit cladding rupture through core design optimizations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Core Physics Characteristics of Extended Enrichment and High Burnup Boiling Water Reactor Fuel

This paper presents the highlights of boiling water reactor (BWR) core physics studies performed at Oak Ridge National Laboratory as part of a series of studies conducted to compare low-enriched uranium (LEU) with LEU+ fuel. The studies analyzed isotopic fuel content, lattice parameters (Phase 1), and core physics (Phase 2) to identify challenges in operation, storage, and transportation for BWRs and pressurized water reactors (PWRs). Because of a lack of publicly available lattice and core designs for modern BWR fuel assemblies and reactor cores, several optimized lattice designs were generated, and different core loading strategies were investigated. Twelve optimized lattice designs with 235 U enrichments ranging from 1.6% to 9% and gadolinia loadings ranging from 3 to 8 wt% were used to model axial enrichment and geometry variations in fuel assemblies for core designs. Each core shares a common set of approximations in design and analysis to allow for consistent comparisons between LEU and LEU+ fuel. The objective is to highlight anticipated changes in core behavior with respect to the reference LEU core. The results of this study show that the differences in LEU and LEU+ core reactor physics characteristics are less significant than the differences in lattice physics characteristics reported in the Phase 1 studies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Conceptual design of inverted core lead bismuth eutectic fast reactor for marine applications

The development of an inverted core fast reactor aims to generate 60 MWth for about 30 Effective Full Power Years without refueling. The reactor design is a transportable reactor using UO{sub 2} fuel and lead-bismuth-eutectic cooled designed for marine applications and is intended to improve the reactor performances compared to the normal core design: better condition for passive cooling system capability by lower core pressure drop, taking advantage of potential power uprate from the lower maximum fuel temperature. Systematic design processes are presented in this work: fuel pin geometry selection, fuel assembly (FA) design, and core design. A relationship between pressure drops, coolant velocity, maximum fuel temperature, coolant channel diameter, and fuel volume fraction was introduced in a single graph used as a tool to select fuel pin geometry. Fuel fabrication capability also took place in consideration of FA design which led to 7 holes per FA, and two-dimensional temperature distribution studies were also carried out. Core design processes including radial zoning, axial zoning, and core optimization were conducted using Monte Carlo code MCS, which is UNIST CORE laboratory in-house code. The current core design uses 3 fuel enrichment levels and 3 FA types to control the local power distribution and power shift during its lifetime. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1971

Saturation current spikes eliminated in saturable core transformers

Unsaturating composite magnetic core transformer, consisting of two separate parallel cores designed so impending core saturation causes signal generation, terminates high current spike in converter primary circuit. Simplified waveform, demonstrates transformer effectiveness in eliminating current spikes.

Schwarz, F. C.↗
DOE OSTI2026

PWR Core Analysis for Cycle Extension and Uprates with LEU+ Accident Tolerant Fuel and 80 GWd/Tonne Burnup Limit

The U.S. Nuclear Regulatory Commission has recently drafted a rule enabling fuel burnup increase in light water reactors up to 80 GWd/t. In conjunction with use of fuel enrichment up to 10%, and accident tolerant fuel (ATF), this is anticipated to facilitate 24-month cycles in PWRs, along with further power uprates. In this paper, PWR core analysis is performed for 20% increased PWR power output along with cycle extension up to 24 months, in combination with use of chromia-doped fuel and chromium-coated clad, considered to be the most near-term ATF concepts. In combination, these lead to challenging conditions with a core average discharge burnup of up to ~74 GWd/t, challenging even the 80 GWd/t burnup limit. Analysis is performed using the 2-step method with POLARIS (within SCALE) used for the lattice calculations and PARCS for the core calculations. Core designs are first baselined for current operating conditions (LEU, 62 GWd/t discharge burnup limit) and then derived that meet cycle constraints on power distribution and the updated lead pin discharge burnup limit while maintaining at least two batches of fuel in the core. Gadolina loadings in fuel pins of up to 8% are used, with enrichment zoning both within the core and, to a limited extent, within assemblies. Here, doped fuel with coated cladding can utilize the same core designs as the reference UOX cores, exhibiting slightly lower burnup due to higher fuel density, which also offsets the slight reactivity penalty from the doping and coating. For the analysis performed here, doped fuel enabled a core with 24-month cycle and 20% uprate to stay within the 80 GWd/t lead pin discharge burnup limit.

LEU+↗
DOE OSTI2025

Plant Reload Optimization (prlo)

The PRLO framework is built on a modular and extensible architecture that tightly couples advanced evolutionary optimization algorithms with nuclear fuel depletion solvers (i.e., nuclear physics neutronics code). It supports exploring complex, high-dimensional design spaces constrained by user-specified operational, safety, and economic constraints. Objectives such as minimizing fresh fuel enrichment, flattening radial and axial power distributions, and maximizing discharge burnup are evaluated. PRLO’s equilibrium cycle optimization capability enables the identification of core configurations that maintain fuel cycle sustainability over extended planning horizons. Its integration with the RAVEN platform facilitates optimization of loading patterns or fuel shuffling schemes across multiple cycles. The interface with SIMULATE, a licensed industry-standard nodal code developed by Studsvik, ensures accurate neutronic and thermal-hydraulic feedback for reactor core design. PRLO’s automated workflow engine supports iterative design refinement, enabling utilities to streamline core design processes and meet evolving performance and regulatory targets.

Kim, Junyung [Idaho National Laboratory] (00090005↗