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At least 73 records · Page 4

Development and demonstration of a methodology to evaluate high burnup fuel susceptibility to pulverization under a loss of coolant transient

For economic reasons, the US nuclear industry is renewing efforts to build a technical basis to extend rod average burnup limits above the current regulatory burnup limit of 62 GWd/MTU. The primary driver is to increase pressurized water reactor cycle lengths to 24 months, reducing the number of fresh fuel assemblies and core design constraints, thereby making core energy utilization more efficient. However, fuel pellet fragmentation and pulverization, termed high burnup fuel fragmentation (HBFF), has been observed in the high burnup (>90 GWd/MTU) Halden loss-of-coolant-accident (LOCA) integral test series. The issue gained attention when fuel fragmentation and pulverization were also observed closer to the current US regulatory limit during the US Nuclear Regulatory Commission (NRC) sponsored out-of-core integral test at Studsvik Nuclear in early 2011. This led to NRC concerns with potential changes to fuel and core designs relative to fuel pellet pulverization. In a letter to the NRC Commissioners, the staff specifically identified a need to “…define the boundary of safe operation for key fuel design and operating parameters,” stating that “the staff is challenged to evaluate the acceptability of future fuel design advancements and fuel utilization changes.” As such, it can be concluded that HBFF and potential dispersal into the reactor coolant system introduces additional complications in light-water reactor (LWR) fuel safety evaluations. However, it is not clear how much fuel will be susceptible to HBFF; nor has there been a methodology developed to evaluate fuel susceptibility to HBFF. To that end, this paper proposes an analysis methodology to assess fuel susceptibility to HBFF during LOCA scenarios. The work presented here uses the BISON fuel performance code to evaluate a representative pressurized water reactor fuel rod exposed to a rod average burnup of 75 GWd/MTU. Sensitivity studies investigated the impact of the peak cladding temperature, transient fission gas released, and pre-transient fission gas release on cladding ballooning and burst timing. Subsequently, a methodology to assess fuel susceptibility to HBFF will be developed based on experimental data published in the open literature. The methodology will then be demonstrated by calculating the mass of fuel susceptibility to HBFF. The BISON results conclude that increasing peak cladding temperature drastically decreased time to failure, and decreased balloon size both of which have been confirmed experimentally. Additionally, the effect of pre-transient and transient fission gas release affected cladding balloon size and burst timing. Finally, fuel susceptibility to HBFF significantly decreased as a function of peak cladding temperature.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Accelerating nuclear fuel development and qualification: Modeling and simulation integrated with separate-effects testing

In this work, an approach to transform and accelerate nuclear fuel development and qualification is outlined. The approach exploits advanced modeling and simulation at the outset to inform constituent and system selection and to enable integral fuel performance analyses. Analyses using these tools identify and prioritize the most important fuel performance parameters and phenomena for subsequent targeted characterization with separate-effects tests. Separate-effects testing spans out-of-pile and in-pile tests and is meant to iterate with and inform engineering-scale integral fuel performance analyses throughout the development process. Exercising this cycle in an agile fashion will increase confidence in the integral fuel performance predictions while reducing uncertainties. This process sets the stage for executing a much more limited set of well-defined integral irradiation tests designed to validate engineering-scale fuel performance codes and to confirm the performance and safety of the fuel system under prototypic conditions. This approach will reduce the time for development and qualification of a new fuel system, and it will also reduce associated costs.

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Development and application of sorption mass transfer models for fission product transport in TRISO fuel systems using BISON

Fission product mass transfer within and between TRISO particle and compact layers is an important phenomenon. It directly impacts fission product release predictions, which are used as source terms for safety and licensing calculations. Modeling fission product transport within layers and across bonded interfaces is relatively straightforward under the assumptions of isotropic Fickian diffusion, concentration continuity, and flux continuity. Modeling fission product transport across gaps and debonded layers is more difficult. Gaps are known to form between the buffer and inner PyC (IPyC), and debonding may occur between the IPyC and silicon carbide (SiC). A new mass transfer model was developed to provide a more accurate and robust fission product release calculation by accounting for interlayer sorptivity. One importance of the new model is to account for temperature and material changes across the gap based on sorption isotherm. This work presents the development of the sorption behavioral model and a fission product trapping model, and analyses the subsequent fission product diffusion behavior, specifically cesium, through TRISO particles and compact materials using the BISON fuel performance code.

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Multiscale, mechanistic calculation of the effective silver diffusion coefficient in polycrystalline silicon carbide: application to silver release in AGR-1 TRISO particles

The silicon carbide (SiC) layer in tristructural isotropic (TRISO) fuel particles serves as a barrier to prevent the escape of fission from the fuel kernel. The release of silver (Ag) is a concern due to the long half-life of the 110mAg isotope. In this study, the effective diffusion coefficient of the fission product Ag through the grain boundary (GB) network is calculated using a combination of atomistic and phase-field methods. Atomistic calculations of Ag diffusivity in SiC bulk and GBs are leveraged to develop a mesoscale effective Ag diffusion coefficient (Deff) in SiC. Since GBs serve as pathways for Ag diffusion, Deff is defined as a function of temperature, microstructure variables, and fluence. Deff is implemented in the fuel performance code Bison to predict Ag release from AGR-1 TRISO fuel particles. We hereby quantify the impact of SiC grain size and irradiation on Ag release and improve Bison's predictions.

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BISON Capability, Validation and Demonstration for Reactivity-Initiated Accidents

Reactivity Initiated Accidents (RIA) are design basis accidents that could have adverse impacts on the core coolability. In the unlikely event that sufficient reactivity is inserted into the reactor core by the ejected/dropped control rod, prompt energy deposition into the fuel can occur, which when sufficiently high can lead to fuel rod failure or, at large energy deposition levels, expulsion of UO2 fragments or molten UO2 material from the fuel rod. This results in a release of fission product and fuel into the coolant and has the potential to compromise core coolability and threatening the pressure boundary of the primary coolant system. The design basis RIA is one of the industry challenging problems that the CASL aimed to address; the CASL RIA Challenge Problem Charter [1] states, ?The Pressurized Water Reactor (PWR) Rod Ejection Accident (REA) and Boiling Water Reactor (BWR) Control Rod Drop Accident (CRDA) are postulated accidents with consequences that are important to nuclear safety (fuel rod integrity and core coolability). Currently each reload core design must be analyzed to meet regulatory acceptance criteria. The goal of CASLs ModSim capability for RIA is to model the event at a higher fidelity, with validation to existing tests, to better model the transient neutronics and the progression of the fuel and cladding thermal-mechanical behavior. These improved analytical capabilities can be used to better inform reload core design, limits on fuel assembly discharge burnup, restrictions on placement of fuel in the reactor, control rod insertion limits, operating margin, and performance sensitivities.? In support of that charter, BISON, the fuel performance code has been used to demonstrate the simulation of thermal-mechanical behavior of LWR fuels during a reactivity-initiated accident. The combination of mechanical, thermal, and thermal-hydraulic phenomena all present during an RIA makes a multi-physics code such as BISON a valuable tool for modeling these scenarios. This paper will highlight many of the activities associated with BISON relevant to reactivity-initiated accident capability development and validation efforts. These efforts have been performed under both CASL and the Nuclear Energy Advanced Modeling and Simulation (NEAMS) programs.

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BISON BWR Fuel Modeling Capability: Material Models (FY2020)

Until this year the BISON fuel performance code has been developed primarily for pressurized water reactor (PWR), accident tolerant fuel (ATF), and advanced reactor (e.g., tri-structural isotropic (TRISO), metallic) analyses. The main focus of this work is to develop and document required material models that would aid predicting cladding failure with a specific hydride distribution to be investigated for boiling water reactor (BWR) applications in the next fiscal year. In terms of materials, the primary differences between a BWR and PWR is the use of gadolinia doping of the UO 2 fuel, the use of Zircaloy-2 for the cladding, and the addition of a liner on the inner surface of the cladding for improved pellet-clad mechanical interaction (PCMI)performance. The liner is typically made of pure zirconium or a lower tin content zirconium alloy (e.g. Zr-0.3%Sn). This work details the development and documentation of material and behavioral models for BWR analysis such as the addition of material and behavior models for gadolinia doped UO 2 , pure zirconium, Zr-0.3%Sn, and Zircaloy-2 as well as the ease-of-use additions to allow internal meshing capabilities to include liners. Another important aspect affecting cladding performance is hydrogen diffusion and hydride precipitation in the cladding. A model was added previously for non-lined, homogeneous claddings. In this work, instructions are provided on how to apply the model to BWR liner cladding. Representative experimental values are provided for the hydrogen diffusion parameters and precipitation-dissolution kinetics for typical liner materials of interest.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Versatile TRISO fuel particle modeling in Bison

Tri-structural isotropic (TRISO) fuel particles are a key component in several previous and current reactors as well as in a variety of novel nuclear reactor designs. Interest in TRISO fuel is on the rise, necessitating considerable computer modeling of TRISO fuel behavior in order to support related design and licensing activities. The Bison nuclear fuel performance code, which offers a full set of capabilities for modeling TRISO fuels, makes it easier to explore the various important aspects of TRISO fuel behavior. One key advantage of Bison is its ability to create meshes in 1D, 2D, and 3D. Users can customize these meshes for specific geometries, mesh densities, and use cases. This enables a wide variety of analyses, including thermal, structural, mass diffusion, homogenization, and statistical failure analyses. Furthermore, the meshing capability simplifies analysts’ workflows. The inherent mesh generation capability eliminates the need for separate mesh-generating software and mesh file management. Also, the fact that the meshes are customizable makes it straightforward to automate an investigation over a range of geometric parameters or mesh densities. Here, the present paper highlights the ease with which Bison may be used to create meshes for both simple and relatively complex TRISO fuel particles, and it explores the types of analyses enabled by these meshes.

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Initial development of an RIA envelope for dispersed nuclear fuel

A reactivity insertion accident (RIA) is a design basis accident in which reactivity is rapidly injected as a result of a control rod ejection or blade drop scenario. The resultant power increase can result in fuel rod failure and subsequent release of radioactive material into the reactor’s primary system. For light water reactors, failure under RIAs is typically a result of fuel melt, pellet-cladding interaction, or rod over-pressurization. Fuel melt occurs when the fuel system is unable to transport heat out of the fuel system. Pellet-cladding interaction occurs when an aggressive fuel pellet expansion pushes on an embrittled cladding beyond its strain limit. Rod over-pressurization occurs when a fuel rod exceeds the critical heat flux and departs from nucleate boiling, causing the rod internal pressure to rapidly increase, exceeding the systems pressure, and balloon until it bursts. To prevent failure, regulators have developed safety requirements that limit the injected enthalpy based on the state of the fuel system. However, dispersed fuel could enable the removal or relaxation of regulator-imposed safety criteria. Dispersed fuel embeds fuel particles in a highly conductive metal. Dispersed particles can have a particle radius of 1 µm to greater than 100 µm. Traditional fuel systems are plagued by poor thermal conductivity, especially at higher burnups, thus reducing the ability of the fuel system to respond to an RIA. However, dispersed fuel could improve the ability of the fuel system to transport injected energy away from the fissile material and into the coolant more efficiently. Furthermore, dispersing the fuel particles mitigates hard contact that typically occurs in the traditional zirconium-uranium dioxide fuel system, thus removing pellet-cladding mechanical interaction as a potential failure mechanism. This paper evaluates fuel particles dispersed in a metal matrix using the BISON fuel performance code to develop an initial failure threshold based on melt temperature of the fuel particle and/or cladding material as a function of fission density for beginning-of-life and end-of-life conditions. BISON results show that (1) reducing the size of the particles allows fission density to increase as a function of time, (2) particle-to-particle proximity must be considered to evaluate the limiting conditions, and (3) improving the fuel particle thermal conductivity improves thermal performance.

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TRU BISON Simulation Overview [Slides]

The BISON fuel performance code has been used to model minor actinide (MA) bearing metallic ternary fuel. This presentation gives an overview on the progress made so far on this effort, focusing on the modeling of EBR-II experiment X501-G591. Comparisons with PIE have also been made.

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Impact of LWR Assembly Structural Features on Cladding Burst Behavior under LOCA Conditions

This report builds on the previous work by assessing the impact of assembly structural features on cladding balloon and burst behavior. The BISON fuel performance code was used to generate two dimensional RZ meshes containing structural features commonly used in nuclear fuel assemblies. The results were then compared to the cladding burst temperature and balloon strain results from the previous work. A mesh sensitivity study was performed to ensure spacer grid effects were appropriately considered, resulting in a more refined mesh than the previous study. The balloon deformation and burst times of the cladding were compared. Consideration was also given to the effect of rod initial pressure. Overall, the BISON simulations indicated the spacer grids can locally influence cladding performance, however, the impact on the cladding performance was minor.

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Unpacking model inadequacy: The quantification of silver release from TRISO fuel by considering empirical and mechanistic approaches

Increasing adoption of the proposed tristructural isotropic (TRISO) particle fuel for both advanced and existing reactors makes it critical to assess and address any uncertainties and inadequacies of TRISO fission product release models. Model inadequacy stems from simplifications made to the computational model when compared to the experiments. The modeling and simulation efforts conducted using the BISON fuel performance code, along with the experimental campaigns carried out under the Advanced Gas Reactor Fuel Development and Qualification Program, afford a unique opportunity to conduct a rigorous modeling inadequacy assessment within the Bayesian uncertainty quantification (UQ) framework. Here, this study compares the standard Bayesian framework against the Kennedy-O'Hagan (KOH) framework, which explicitly represents modeling inadequacy, in regard to UQ for TRISO silver release models. For this purpose, both the traditional Arrhenius equation fitted to experimental data and the more advanced lower-length-scale (LLS)-informed model, which considers microstructure information, are independently considered. Applying the inverse UQ process on the AGR-2 and -3/4 datasets revealed modeling inadequacy to be the most dominant source of uncertainty. Experimental noise uncertainty is also significant; however, model parameter uncertainty can be considered negligible. Interestingly, both the Arrhenius equation and the LLS-informed model demonstrated similar levels of modeling inadequacy. For the forward predictive UQ, the KOH framework improved both the accuracy and quality of quantified uncertainties in comparison to the standard Bayesian framework. This is true for both the Arrhenius equation and the LLS-informed model. In comparing these modeling approaches, both demonstrated similar performance at the engineering scale, while the LLS-informed model expectedly outperformed the Arrhenius equation at the mesoscale. These conclusions highlight the importance of explicitly accounting for modeling inadequacy in the UQ process, and reinforce the need for continuous refinement of physics-based models in order to address the modeling inadequacy.

Advanced reactors↗

Evaluation of BISON metallic fuel performance modeling against experimental measurements within FIPD and IMIS databases

Simulations were conducted using the BISON fuel performance code on an automated process to read initial and operating conditions from two databases—the Fuels Irradiation and Physics Database (FIPD) and Integral Fast Reactor Materials Information System (IMIS) database. These databases contain metallic fuel data from the Experimental Breeder Reactor-II (EBR-II) and the Fast Flux Test Facility (FFTF). The work demonstrates use of an integrated framework to access EBR-II fuel pin data for evaluating fuel performance models contained within BISON to predict fuel performance of next-generation metallic fuel systems. Between IMIS and FIPD, there is enough information to conduct 1,977 unique EBR-II metallic fuel pin histories from 29 different experiments, and 338 pins from FFTF MFF-3 and MFF-5 with varying levels of details between the two databases. Each of these fuel performance histories includes a high-resolution power history, flux history, coolant channel flow rates, and coolant channel temperatures, and new model developments in BISON since the initial demonstration of this integrated framework. Fission gas release (FGR), cumulative damage fraction, fuel axial swelling, FCCI wastage thickness, cladding profilometry, and burnup were all simulated in BISON and compared to post-irradiation examination (PIE) results to evaluate BISON fuel performance modeling. Implementation of new fuel performance models into a generic BISON input file coupled with IMIS and FIPD yielded results with a better representation of physics than the initial evaluation of the integrated framework. Cladding profilometry, FGR, and fuel axial swelling were found to be in good agreement with PIE measurements for most of the pins simulated. The chosen mechanical contact solver was found to significantly impact the axial fuel swelling and cladding strain predictions when used in conjunction with the U-Pu-Zr hot-pressing model since it bound the fuel to prevent further swelling and increased hydrostatic stresses. This work suggests that fuel performance modeling in BISON under steady-state conditions represents the PIE data well and should be reassessed when new PIE data become available in IMIS and FIPD databases and when improved physical models to better capture fuel performance are added to BISON.

Paaren, Kyle M.↗

Impact of LWR assembly structural features on cladding burst behavior under LOCA conditions

This provides an initial scoping study on clad balloon and burst behavior for burnup extension of reactor fuel. The associated issues with burnup extension are fuel fragmentation, relocation, and dispersal in the event of cladding failure. The general finding of this work is that the structural features, spacer grids and mixing vanes, locally suppress cladding deformation but have little impact on the overall clad performance during loss-of-coolant accidents. The work detailed in a previous report by Capps et al. focused on core optimization via neutronics, thermal hydraulics and thermomechanical analysis for burnups beyond 62 GWD/tU and enrichments above 5%. Uncertainty of fuel fragmentation relocation and dispersal in high-burnup rods during accident conditions was also investigated. The dispersal aspect of fuel fragmentation depends on cladding rupture. Thus, assessing uncertainties in the rupture behavior is helpful in estimating the dispersal of high-burnup fuel. This study builds on the previous work by assessing the impact of assembly structural features on cladding balloon and burst behavior in a full-length fuel rod. In this work, the BISON fuel performance code was used to generate 2D radial and height meshes containing structural features commonly used in nuclear fuel assemblies. First, meshes were generated with spacer grids. Results were then compared to the cladding burst temperature and balloon strain results from the previous work. A mesh sensitivity study was performed to ensure that mixing vanes and spacer grid effects were appropriately considered, resulting in a more refined mesh than the previous study. The balloon deformation and burst times of the cladding were compared to the original case. Consideration was also given to the effect of rod initial pressure. In conclusion, 3D quarter rod simulations were also performed and found good agreement with the 2D simulations in clad deformation and reasonable agreement in burst times.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Understanding the effect of irradiation and silicon carbide microstructure on silver diffusion in TRISO particles

The silicon carbide (SiC) layer in tristructural isotropic (TRISO) fuel particles serves as a barrier to prevent the escape of fission from the fuel kernel. The release of silver (Ag) is a concern due to the long half-life of the 110mAg isotope. In this study, a combination of atomistic and phase-field methods focuses on quantifying the effect of irradiation and SiC microstructure on Ag diffusion. Atomistic calculations provide the Ag diffusivity in SiC bulk and GBs, also providing an estimate of the effect of irradiation defects on Ag diffusivity in bulk SiC. These lower length scale efforts are leveraged to develop a mesoscale effective Ag diffusion coefficient (Deff) in SiC. Deff is defined as a function of temperature, microstructure variables, and fluence. Deff is implemented in the fuel performance code Bison to predict Ag release from AGR-1 and AGR-2 TRISO fuel particles. We hereby quantify the impact of SiC grain size and irradiation on Ag release and improve Bison's predictions.

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Hydride Reprecipitation in Prototypical 17x17 PWR Fuel Rods after Simulated Vacuum Drying Conditions

Light water reactor (LWR) fuel rod cladding picks up hydrogen as it oxidizes in reactor. Once the hydrogen concentration exceeds the solubility limit, zirconium hydride platelets precipitate, generally in the circumferential direction. In preparation for dry storage, elevated temperatures can dissolve some of the circumferential hydrides, which during cooling can then reprecipitate in a direction perpendicular to the hoop stress (radially). From 2019 to 2024, ORNL published a series of reports that included metallographic observations of cladding after a thermal transient to 400°C followed by slow cooling. The simulated dry storage process was performed on three full-length 17x17 PWR fuel rods at their as-discharged rod internal pressure. There were two important observations from the metallographic examinations of these heat-treated rods: (1) the propensity for hydride reorientation is strongly influenced by nearby as-discharged precipitated hydrides, (2) the radial hydrides observed near the cladding inner diameter were often associated with cracks in the pellet. Subsequent modeling using the BISON fuel performance code that considered the effects of pellet cracks and pellet-cladding bonding observed in high-burnup fuel support the conclusion that pellet cracks enhance the local hoop stress in the cladding creating preferential sites for hydride reorientation, and that the influence of the pellet cannot be ignored in accurate fuel rod performance predictions.

Montgomery, Rose [ORNL] (ORCID:0000000286038936)↗

Mechanistic calculation of the effective silver diffusion coefficient in polycrystalline silicon carbide: Application to silver release in AGR-1 TRISO particles

The silicon carbide (SiC) layer in tristructural isotropic (TRISO) fuel particles serves as a barrier to prevent the escape of fission products produced and not retained in the fuel kernel. The release of silver (Ag) is a concern due to the long half-life of the 110m Ag isotope. However, accurately determining the fission gas release rate requires knowing the diffusion coefficient through the SiC layer. In this study, we leverage atomistic calculations of Ag diffusivity in SiC bulk and grain boundaries (GBs) to develop a mesoscale effective Ag diffusion coefficient (D eff ) in SiC. Since GBs serve as pathways for Ag diffusion, D eff is defined as a function of temperature and microstructure variables. In particular, the size of SiC grains in the direction perpendicular to diffusion is shown to significantly affect Ag diffusion. The prediction of the mechanistic, mesoscale approach falls within one order of magnitude of empirical values. The temperature and microstructure-dependent effective Ag diffusivity in SiC is implemented in the fuel performance code Bison with a correction factor to predict Ag release from AGR-1 TRISO fuel particles. We hereby quantify the impact of SiC grain size on Ag release and improve Bison’s predictions.

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Selection and Ranking of Experiments from the Halden Database in support of Multiscale Model Validation

Validating fuel performance codes, such as BISON, requires an extensive amount of experiments covering a wide range of operating conditions and fuel types. Within the light-water reactor (LWR) space, there have been several international experimental programs that have contributed to the wealth of available experimental data available for use. One of those international programs, the Halden Reactor Project (HRP), began in 1958 and utilized the Halden Boiling Water Reactor to conduct many highly instrumented experiments until the reactor closed in 2018. Idaho National Laboratory, through the U.S. Department of Energy, has utilized several Halden experiments to perform the initial validation of the BISON code based upon their inclusion in international modeling and simulation benchmarks. Recently, the HRP has provided member organizations a complete copy of all available data, reports, and presentations since the HRP began. This report provides an initial exploration of the data available in the database for use in validating the multiscale models under development in the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program for LWR applications. Ranking tables that identify potential validation cases are provided for the high priority models of interest. It was found that some of the recommended high priority experiments correspond to additional rods in existing assemblies already available in the BISON validation suite. It is expected that several of these cases will be incorporated into future NEAMS milestones in the fuels technical area for increased validation of BISON.

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Report on DIC Cyclic Dryout Testing of ATF Cladding Materials

Boiling water reactors can experience anticipated operational occurrences, where an expected deviation from normal operating conditions is witnessed for short time scales. One example of such transients arises from cladding dryout, where stable boiling becomes unstable, resulting in cladding heat up before re-wetting occurs. To understand the impact of such transients on fuel cladding lifetime and performance, cyclic dryout conditions were imposed upon fresh fuel cladding in the absence of irradiation. Pressurized cladding tube segments were exposed to rapid temperature increases to intermediate temperatures below a cladding rupture threshold and deformation was monitored in situ via 3-D digital image correlation. The impact of cycle frequency on cladding deformation was assessed. A clear understanding of elastic and plastic strain responses were developed for Zr alloy deformation under temperature transients, and these results can be used to support material model development and validate fuel performance codes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗