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DOE OSTI2021

RX-PSA

This code is built on top of the ML-PSA utility and implements the ability to implement a multi-fidelity parallel simulated annealing optimization for a range of engineering problems. RX-PSA provides specializations to interact with modern nuclear reactor codes such as VERA to perform assembly and core optimization in a robust way. RX-PSA also provides LWR specific objective functions and constraints to provide a straightforward user interface that reactor designers are familiar with.

Collins, BenjaminS.↗

DOE OSTI2022

The fast neutron source at UTK: a project with Massimo Salvatores

This article is dedicated to the memory of Massimo Salvatores and offers an overview of the history of the design of the Fast Neutron Source (FNS) flexible experiment system at the University of Tennessee. Our collaboration with Massimo set much of the over-arching design goals and inspired the concept that we have today. The decision to design the FNS as a subcritical assembly rather than a critical one stems back to discussions with Massimo Salvatores and his advocacy for subcritical Accelerator Driven Systems (ADS) which coincides with lower licensing time, costs and greater safety for a university-operated nuclear experimental facility. The second contribution of Massimo to the design concept of the FNS was the direct instruction to design the FNS as an extremely flexible facility. This article provides an update on the current design concept and discusses the future innovations in design optimization of flexible, re-configurable nuclear experiments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

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↗

DOE OSTI2021

Machine learning application to single channel design of molten salt reactor

This study proposes a robust approach to quickly design a nuclear reactor core and explores the best performing machine learning (ML) technique for predicting feature parameters of the core. Here we implemented the approach into a hypothetical channel of molten salt reactors to demonstrate the applicability of the method. We prepared a Python tool, named Plankton, which couples to a reactor physics code and an optimization tool, and imports ML methods. The tool performs three consecutive phases: reactor database generation, machine learning application, and design optimization. We identified the extra trees method as the best performing estimator. With the estimator, we found nine optimum designs in total, one for each fuel-salt pair, and estimated all the performance metrics of the designs with a <5% prediction error compared to their actual values. U-Pu-NaCl fuel-salt gave promising results with the highest conversion ratio, the most negative feedback coefficient, and the lowest fast flux.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Conceptual Spacer Design for the ATR GEN I Target for Pu-238 Production in the Advanced Test Reactor at Idaho National Laboratory

The initial target design used for Pu-238 production at Idaho National Laboratory was designed by Oak Ridge National Laboratory to optimize the production of Pu-238 in the High Flux Isotope Reactor (HFIR) and are referred to as HFIR GEN II targets. To take advantage of the Advanced Test Reactor’s (ATR) taller active core region a redesign of the HFIR GEN II targets was needed. It was proposed to stack two HFIR GEN II targets nose to nose about the core center line; however, this resulted in excessive neutron and photon heating in the pellets located in the center. This peak heating was not desirable so three alternative designs were investigated for the ATR GEN I targets. The python-based code, MCNP to ORIGEN2 in Python (MOPY), was used to calculate the heating rates after 40 days of irradiation to capture the effects of each configuration. The purpose of this paper is to document the details of these conceptual design calculations and comparisons for the ATR GEN I targets.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2024

Conceptual Spacer Design for the ATR GEN I Target for Pu-238 Production in the Advanced Test Reactor at Idaho National Laboratory

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2024

Sensitivity analysis, surrogate modeling, and optimization of pebble-bed reactors considering normal and accident conditions

This research provides a valuable tool that streamlines the optimization process while significantly increasing its accuracy. This study creates a robust framework for reactor design optimization by incorporating comprehensive modeling using the Comprehensive Reactor Analysis Bundle, or BlueCRAB, within the Multiphysics Object-Oriented Simulation Environment (MOOSE). BlueCRAB is the United States Nuclear Regulatory Commission's code suite for non-light water reactor analysis and includes the Griffin, Pronghorn, and Bison applications. This not only improves the efficiency of the optimization process but also enhances the reliability of the results. Such a tool is essential for advancing the state-of-the-art in pebble-bed reactor technology and is critical for achieving the goals of Generation IV reactors, which aim for safe, sustainable, and economically viable nuclear energy solutions. This work presents and applies this workflow on pebble-bed reactors while considering both normal and off-normal conditions. A representative gas-cooled pebble-bed reactor at equilibrium core conditions serves as the nominal design specification for normal operation and is based on previous research. The depressurized loss-of-forced-cooling accident is deployed for off-normal conditions in this work. After defining design-related parameters and quantities of interest regarding reactor safety and performance, this multiphysics model is sampled using the MOOSE stochastic tools module. The result is a comprehensive dataset of configurations, enabling sensitivity analysis and the generation of surrogate models. Subsequently, the dataset and surrogate models are employed in two optimization studies aimed at maximizing fuel utilization and economic profit while adhering to safety and operational constraints. Performing the optimization process with fuel utilization as the metric leads to an improvement of approximately 10%, compared to engineering-judgment-based nominal conditions. The optimization on economic profit leads to an estimated increase of ~300 million USD over the lifetime of the reactor.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Application of Proliferation Resistance Optimization (PRO-X) Methodology to a Generic Research Reactor

The Proliferation Resistance Optimization Program (PRO-X) has been established by the NNSA to provide a framework for evaluating and integrating proliferation resistance into nuclear reactor system (core, fuel, and auxiliary facilities) designs that also maintain the safety and peaceful use missions of those systems. The research reactor (PRO-RR) area is the component of PRO-X that supports the program objectives by applying state-of-the-art analysis methods to research reactor systems. This report details the results of using a defined set of analytical tools to evaluate the neutronics, thermal hydraulics and proliferation risk characteristics of a set of parametric cores based on a generic 10 MW materials test reactor that uses a plate-type low enriched uranium (LEU) fuel. The analysis shows that by suitable adjustment of the core size, reflector configuration and power level, mission performance and safety margins can be maintained or improved while reducing the potential for production of special nuclear material.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Reactor physics characterization of triply periodic minimal surface-based nuclear fuel lattices

Triply periodic minimal surface (TPMS) lattices are receiving substantial attention in numerous engineering fields due to their impressive topology-driven physical characteristics. TPMS lattices are periodic structures of two distinct intertwined volume domains separated by an area-minimizing surface or wall. TPMS lattices have been observed in nature, such as biological membranes, skeletons, block copolymers, sea urchins, butterfly wings, and equipotential surfaces in crystals. Intriguingly, the topology of TPMS lattices can be easily parametrized via level-set equations and thus are heavily numerically and experimentally studied. Here, a significant research effort is currently applying TPMS lattices for heat exchangers and sinks. This paper extends TPMS lattice applications to nuclear reactor fuel designs, with a focus on identifying relevant TPMS geometric parameters controlling neutronics characteristics, such as reactivity, neutron spectrum, and heat removal properties. We found that fuel surface-area-to-volume ratios for TPMS lattices can be two orders of magnitude larger than current cylindrical fuel rods. Further, the selected TPMS lattice and its implicit equation, the unit cell pitch, wall thickness, and structure porosity are design parameters enabling neutronics optimization for both thermal and fast spectrum configurations, paving the way for exceptionally compact and dense nuclear core concepts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Employing MACS/ViBRANT as a Surrogate MARVEL Reactor for Startup Reactivity Tuning and Supervisory Control Processes

Advanced nuclear reactors are a key part of the future of nuclear energy both in the United States and globally. They offer unique benefits for various energy-demanding applications, including use in remote locations, compact size, modular manufacturing, remote monitoring, low and/or variable power rating operation, and reliance on novel technologies to enhance operational safety. To achieve economic feasibility, advanced reactors must significantly reduce their workforces in comparison with the current fleet. Achieving this reduction will occur through reducing staff workloads using technology to achieve autonomous or semi-autonomous operations, demonstrated by comprehensive testing and validation activities. These operations will require both software and hardware platforms during the design and testing phases. While simulations are useful during the design phase, their performance can significantly deviate during actual deployment on hardware. This report presents the outcomes of a collaborative technical initiative between the U.S. Department of Energy (DOE) Microreactor Program (MRP) and Advanced Sensors and Instrumentation (ASI) Program. The collaboration utilized the Microreactor Automated Control System (MACS) hardware platform to bridge the gap between theoretical reactor design and actual startup and control operations. Two key use cases were investigated: facilitating the startup testing period and demonstrating supervisory control. The first use case details the key Microreactor Applications Research Validation and Evaluation (MARVEL) reactor startup physics testing activities conducted using the MACS platform. These activities included drum worth measurements, shutdown margin assessment, temperature feedback analysis, and scram time evaluation, as well as unique testing that would apply to the MARVEL reactor to demonstrate the testing methodologies in a low-risk environment. The MACS platform, serving as a surrogate representation of the MARVEL reactor, proved instrumental in performing these tests. The exercise revealed aspects that led to optimized processes, refined hardware design, and enhanced base software capabilities. By maturing methods and technologies in this manner, the initiative promises to reduce wasted time in the actual on-site reactor deployment effort, thereby saving significant time and resources. The second use case focuses on the development and implementation of supervisory control methods aimed at managing core tilt, which can result from asymmetrical operations or manufacturing imperfections in fuel rods or reactivity control devices. A key objective was to assess and compare the use of artificial intelligence (AI) for supervisory control. The effort aimed to define the role of supervisory control to enhance performance without risking control instability. This effort explored three distinct approaches: rules-based (RB) methods, optimization techniques, and reinforcement learning (RL) algorithms. Each approach was evaluated for its ease of implementation, its usability, and its effectiveness in responding to asymmetries in neutron flux. Comparative analysis of these approaches provided valuable insights into their applicability and effectiveness, offering a robust framework for advanced reactor operations. Together, these two use cases highlight the potential of hardware test beds to help streamline the design, operation, and control of advanced nuclear reactors. This collaborative effort underscores the importance of continued innovation and experimentation in achieving the next generation of safe, reliable, and economically viable nuclear energy solutions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Transition Core Modeling for Extended Enrichment & Accident-Tolerant Fuels Using Polaris/PARCS

Commercial light water reactor (LWR) operators and fuel vendors are currently interested in increasing the low-enriched uranium (LEU) fuel enrichments from the current limit of 5.0 $^w/_o$ $^{235}U$ up to 10 $^ w/_o$ $^{235}U$ (referred to as "LEU+") in their current fleets; they are also interested in using accident-tolerant fuel (ATF) with both LEU and LEU+ fuel. This report aims to identify modeling challenges and accuracy concerns in transition core analysis using the SCALE Polaris lattice physics code and U.S. Nuclear Regulatory Commission core simulator PARCS. At the time this study was started, no publicly available LEU+ core designs existed for boiling water reactor (BWR) or pressurized water reactor (PWR) systems. Therefore, fuel lattices were shuffled within a multi-assembly model to mimic neutronically challenging lattice combinations seen in transition cores, such as a fresh LEU+ lattice next to depleted LEU lattices. In addition to multi-assembly models, whole-core BWR transition core calculations were performed for ATF and LEU+ fuel using an existing Hatch-1 Cycle 3 core model. A whole-core BWR model was chosen due to the more heterogeneous core designs compared to those for a PWR core. Since the original core is an old checkerboard core design and no core or fuel design optimization was performed for the modeled fuel types, these core calculations were intended only to provide: (1) Comparisons of core characteristics of interest, such as the pin power distributions and peaking factors, Doppler temperature coefficients (DTCs), and control blade worths (CBWs) under challenging core designs, (2) Identification of reactor physics challenges in modeling LEU+ and ATF cores, and (3) A stress test for the Polaris/PARCS two-step modeling approach, including characterization of the relative accuracy for predicting characteristics of interest such as pin power distributions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Design and full core fuel performance assessment of high burnup cores for 4-loop PWRs

Increasing the fuel discharge burnup of current light water reactors (LWRs) promises reductions in fuel cycle and/or operations costs. By assuming a constant core power density, the economic gain is enabled by better fuel utilization and/or an increased capacity factor. In this effort to investigate greater than 62 MWd/kgU maximum rod average burnup for 110+ kW/l core power density, two core designs have been developed for a standard 17x17, 193 fuel assemblies pressurized water reactor (PWR). The levelized unit cost methodology is employed to evaluate fuel cycle, operation and maintenance, and capital cost impacts and to examine the economic viability of both core design pathways. Core design and optimization are performed using the commercial STUDSVIK code package. Fuel performance analysis is realized in full core configuration via auditing FRAPCON4.1, FAST1.2, and the high-fidelity code BISON. To provide a realistic assessment, the core design process takes into consideration best practices in current PWR core design. It features acceptable performance in terms of various core design constraints on maximum allowable peaking and boron concentration. Gadolinia (Gd2O3) is used as a burnable poison with a maximum of 9 wt% concentration while feeding 89 or 77 fuel assemblies in a 3-batch refueling scheme. Full core fuel performance simulation, which allows for characterization of relevant fuel temperatures, plenum pressures, stresses, and strains, is performed with respect to two bounding burnup levels. Such performance is potentially licensable for the 18-month high burnup core (<68 MWd/kgU peak pin), while it is more challenging for the 24-month high burnup core design pathway (<75 MWd/kgU peak pin). Maximum rod plenum pressure is identified as the most limiting fuel performance parameter. Here, while the scope of the present study focuses on the steady-state plus overpower conditions, the acceptability of the new discharge burnup has to be further assessed by considering uncertainties and impacts under accident scenarios in the future.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

NREL's Capabilities in Organism Development and Fermentation Sciences Research and Development (R&D)

NREL is developing robust microbial strains and scalable fermentation technologies for converting biomass sugars to fuels and biochemicals, and one-carbon (C1) gaseous substrates (e.g., CO2, CO, CH4) to high-value products. Core capabilities include: (1) Fermentation optimization of aerobic, microaerophilic, and anaerobic cultivation processes of gas and traditional liquid fermentation R&D; (2) Gas mass transfer R&D and CFD modeling for improved reactor design and gas mixing (3) Metabolic engineering in CRISPR editing tools to improve titer, rates, and yields; (4) Probing and optimizing carbon, redox, and energy flux using transcriptomics and fluxomic techniques; and (5) Consolidated bioprocessing (CBP) using cellulose and hemicellulose directly to minimize pretreatment.

BASIC BIOLOGICAL SCIENCES,BIOMASS FUELS,SYNTHETIC ↗

DOE OSTI2022

Simulating self-powered neutron detector responses to infer burnup-induced power distribution perturbations in next-generation light water reactors

Understanding how 3D power distribution will be monitored throughout reactor core volumetric space in next-generation nuclear power reactors is crucial to the design, deployment, and licensing of these reactors. Although numerous techniques exist for 3D power distribution monitoring based on the response of both in situ and ex situ sensors currently implemented or proposed for use in the US reactor fleet, crucial details about these techniques are often unclear. The publicly available documentation does not include information such as how well these techniques are characterized and optimized in their implementations and the levels of uncertainty in the inferred 3D power distribution. The work described herein investigated a recently developed 3D power distribution inferencing method as applied to two next-generation reactor simulations: (1) the NuScale small modular reactor design and (2) the Westinghouse AP1000 design, both of which contain in-core strings of vanadium self-powered neutron detectors (SPNDs). This investigation considered a range of SPND string sensor densities, as well as a range of 3D power distribution axial segment sizes. In this work, SPND response simulation is informed by neutron flux calculations in representative homogenized cores. For the different sensor densities and power distribution axial segment sizes in these simulations, the average solution error, solver iterations, and run time were tracked to parameterize the sensor-core configuration.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Transformational Challenge Reactor – On the Application of Design for Additive Manufacturing (DfAM) Techniques to the Conception of Nuclear Core

Additive manufacturing (AM) technologies are radically changing the way objects are designed and manufactured. They allow building by deposition and solidification of material layer by layer, enabling the possibility to create simple and complex features alike, almost seamlessly. Generally, the design optimization process requires to define objectives, design variables and constraints. Additive manufacturing does not challenge this process per se but does allow designers to completely redefine the constraints space as the ones originating from fabrication can be considerably relaxed compared to more “traditional” manufacturing. Thus, design optimization becomes naturally far more responsive to the actual physics being solved and considerably less influenced by fabrication limitations, leading to dramatically different designs. To take advantage of these new opportunities, so-called Designing for Additive Manufacturing (DfAM) techniques are emerging. Development of design techniques specifically tailored for additive manufacturing is warranted because, considering AM, the design space is typically considerably larger than with traditional manufacturing. The ability to explore the design space efficiently is of paramount importance for designers. This study proposes to investigate and apply some of these DfAM techniques to the conception of nuclear core. The goal being to assess if these new methods can be applied to core design and if core design could benefits from additive manufacturing technologies. After a brief investigation on the pertinence of some DfAM techniques for core design, algorithms are proposed and a workflow is established to carry neutronics and steady-state thermal-hydraulics analyses. To diminish the work load, the workflow has been automated using python modules. These modules allow the rapid creation of input files, post-treatment of output files and visualization. To test the pertinence of the proposed workflow, three test cases have been investigated: a research and test reactor, a micro-reactor and a space propulsion reactor. These test cases offered a variety of objectives, constraints and operating conditions. It is observed that the proposed workflow is capable of converging quickly and efficiently to valid design solutions. It is then concluded that DfAM techniques can be applied to core design.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

MEITNER Resource Team Modeling and Simulation Support to Holos-Quad Reactor Development (Final CRADA Report)

The main objective of this CRADA is to provide Argonne National Laboratory (ANL)’s modeling and simulation capabilities via ARPA-E's MEITNER (Modeling-Enhanced Innovations Trailblazing Nuclear Energy Reinvigoration) Resource Team (RT) arrangement to support the demonstration of the viability of HolosGen’s Holos-Quad reactor design. The Holos-Quad reactor design is an advanced reactor concept that incorporates many new design features, such as the neutron-coupled Subcritical Power Modules (SPMs) in its core design, elimination of balance of plant (BOP) by direct integration of a helium Brayton cycle power conversion system with each SPM, among many other innovative features. The demonstration of the viability of such an innovative reactor design warrants iterations of modeling and simulation and testing. The purpose of this project is to utilize ANL’s modeling and simulation capabilities in nuclear reactor analysis and power conversion system analysis to inform HolosGen and the Design Team (DT) in the design and optimization of the Holos-Quad concept. The major work scopes of this project include: to investigate conceptual designs and materials for radiation shielding to protect personnel and internal components such as turbomachinery; Assess the the helium Brayton cycle power conversion system performance in both nominal and load following conditions; Investigate power conversion components and overall system performance; Identify control strategies to enable load following; Perform simulations of HolosGen’s subscale simulator and using available test data for code validation/benchmark purpose; Perform core thermal-hydraulics, safety analysis, and structural analysis.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Demonstration and Verification of Thermo-Mechanical Bowing in a Limited Free-Bow SFR Concept Using MOOSE

Core bowing due to thermal gradients and irradiation induced swelling and creep introduces significant reactivity feedback effects in liquid metal-cooled fast spectrum reactors. During startup, normal operations, and transient events, differential thermal and flux gradients cause expansion, creep, and swelling, which results in bowing in preferential directions depending on local material properties and load-pad and restraint-ring design. The bowing phenomenon produces negative reactivity during accident conditions provided the restraint system has been properly designed to optimally guide the deformation outwards in the active core region. Under the Department of Energy Nuclear Energy Advanced Modeling and Simulation program, a Multiphysics Object Oriented Simulation Environment (MOOSE)-based multiphysics approach to model core bowing is being developed. The present work expands on previous modeling of simpler International Atomic Energy Agency (IAEA) verification problems with these tools by modeling IAEA Verification Problem 4, which involves a symmetric sector of a reactor core with ducted assemblies undergoing differential thermal expansion due to thermal gradients bowing outward with duct-to-duct contact. This model is available on the National Reactor Innovation Center Virtual Test Bed repository. This example was verified against benchmark participant results, which includes bowing deformation evaluation and duct-to-duct interactions at load pads with mechanical contact.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Review of the Technical Basis for Properties and Fuel Performance Data Used in HEU to LEU Conversion Analysis for U-10Mo Monolithic Alloy Fuel

This report provides the technical basis for properties and fuel performance data used in conversion analysis for U.S. High Performance Research Reactors (USHPRR) that will convert from highly enriched uranium (HEU) to low-enriched uranium (LEU) using a new U-10Mo monolithic alloy fuel that is being qualified. The conditions that the fuel experiences changes between an HEU and LEU fuel element design due to many causes, including the density of the fuel, the presence of U-238 resonant absorber, changes to the plate and coolant channel dimensions, and changes in fuel management due to reactivity or optimization. These types of changes have been documented in operational and safety analyses conducted for conversions over decades for over 70 reactors. These conversions have all, or almost all, required recalculation of safety-related values as well as establishing operational characteristics of the core, including power distribution, reactor core power level, and cycle length between required fuel management. An overall objective of conversion is to change the reactor core design as little as possible while maintaining the reactors’ scientific, isotope production, medical, and engineering missions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗