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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Visual Examination of Aluminum Containers for Extended Wet Storage of Non-Aluminum-Clad Spent Nuclear Fuel (FY 2021)

The goal of the Augmented Monitoring and Condition Assessment Program (AMCAP) program is to provide a condition assessment of the storage containers for non-aluminum-clad spent nuclear fuel (NASNF) in L Basin and demonstrate continued safe storage of all NASNF pending retrieval for ultimate disposition. The storage configuration of NASNF is vulnerable to inside-out corrosion attack. The approach being used in AMCAP is to develop and deploy examination methods for remote, in-situ inspection of the bundle storage in VTS and for OSC storage in the OSC racks. A method for Visual Examination (VE) using video-recording cameras was readied as part of the full-scale mockup development, and was deployed in L Basin for the initial condition assessment work. This report describes the development and the deployment of the VE for inspection of selected bundles in L Basin. The first deployment of the VE system was for visually examining five spent fuel bundles. Bundles were chosen based on their vulnerability in terms of inner fuel contents, history, storage duration, storage configuration, and possibility of inside out corrosion due to galvanic coupling of fuel cladding with the aluminum bundle wall.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Development of Transient Coupled Chemical-Thermal-Fluids Simulation for Unsealed Aluminum-Clad Spent Nuclear Fuel Storage Canister

This study examines a preliminary three-dimensional (3D) multi-physics computational fluid dynamics (CFD) model of the unsealed canisters containing aluminum-clad spent nuclear fuel from INL’s ATR in the irradiated fuel storage facility. This 3D CFD model considers fully resolved fuel plates in an unsealed canister with small mass exchange with surrounding air as time evolves in the simulation and contains a network of chemical reactions to consider due to several of the side reactions occurring in the presence of water vapor, nitrogen, oxygen and carbon dioxide rather than in helium backfilled DOE standard canisters. Prior to the CFD modeling, the full set of chemical reactions under these conditions was analyzed, reduced, and refit to a more manageable number of equations for the computational efficiency of the 3D CFD simulation. To deal with the long time-scale of interest for tracking the possible buildup of trace species such as nitric acid, NOx, and hydrogen, a segregated time stepping algorithm is used, wherein the velocity field is only updated periodically, and assume to be in a pseudo steady state. This study first examines the theory of the model, workflow to establish radiolysis reaction network, and initial simulations of the evolutions of thermal fields, hydrogen gas and nitric acid concentrations within unsealed canisters in conditions relevant to the INL INTEC CPP-603 facility over a long period of time.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Development of Transient Coupled Chemical-Thermal-Fluids Simulation for Unsealed Aluminum-Clad Spent Nuclear Fuel Storage Canister

This study examines a preliminary three-dimensional (3D) multi-physics computational fluid dynamics (CFD) model of the unsealed canisters containing aluminum-clad spent nuclear fuel from INL’s ATR in the irradiated fuel storage facility. This 3D CFD model considers fully resolved fuel plates in an unsealed canister with small mass exchange with surrounding air as time evolves in the simulation and contains a network of chemical reactions to consider due to several of the side reactions occurring in the presence of water vapor, nitrogen, oxygen and carbon dioxide rather than in helium backfilled DOE standard canisters. Prior to the CFD modeling, the full set of chemical reactions under these conditions was analyzed, reduced, and refit to a more manageable number of equations for the computational efficiency of the 3D CFD simulation. To deal with the long time-scale of interest for tracking the possible buildup of trace species such as nitric acid, NOx, and hydrogen, a segregated time stepping algorithm is used, wherein the velocity field is only updated periodically, and assume to be in a pseudo steady state. This study first examines the theory of the model, workflow to establish radiolysis reaction network, and initial simulations of the evolutions of thermal fields, hydrogen gas and nitric acid concentrations within unsealed canisters in conditions relevant to the INL INTEC CPP-603 facility over a long period of time.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Development of Transient Coupled Chemical-Thermal-Fluids Simulation for Unsealed Aluminum-Clad Spent Nuclear Fuel Storage Canister - 19273

This study examines a preliminary three-dimensional (3D) multi-physics computational fluid dynamics (CFD) model of the unsealed canisters containing aluminum-clad spent nuclear fuel from INL's ATR in the irradiated fuel storage facility. This 3D CFD model considers fully resolved fuel plates in an unsealed canister with small mass exchange with surrounding air as time evolves in the simulation and contains a network of chemical reactions to consider due to several of the side reactions occurring in the presence of water vapor, nitrogen, oxygen and carbon dioxide rather than in helium backfilled DOE standard canisters. Prior to the CFD modeling, the full set of chemical reactions under these conditions was analyzed, reduced, and refit to a more manageable number of equations for the computational efficiency of the 3D CFD simulation. To deal with the long time-scale of interest for tracking the possible buildup of trace species such as nitric acid, NOx, and hydrogen, a segregated time stepping algorithm is used, wherein the velocity field is only updated periodically, and assumed to be in a pseudo steady state. This study first examines the theory of the model, workflow to establish radiolysis reaction network, and initial simulations of the evolutions of thermal fields, hydrogen gas and nitric acid concentrations within unsealed canisters in conditions relevant to the INL INTEC CPP-603 facility over a long period of time. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Aluminum-clad Spent Nuclear Fuel Engineering Scale Drying Experiment Design

The purpose of this document is to provide the technical specifications for the Engineering Scale Design for the drying tests of aluminum-clad spent nuclear fuel (ASNF). The engineering scale design is to accommodate both forced helium drying (FHD) as well as vacuum drying. The experiments will employ mock ASNF assemblies with a limited number of chemically treated aluminum plates to simulate the aluminum hydroxides found on ASNF. The goal here is to understand the transformation that may occur in plates including the loss of chemisorbed water and changes in morphology. Physiosorbed and bulk water found in experiments will be dried in the process and the effect on drying operations noted. Decay heat will be simulated in one assembly using a custom designed resistance heating element. A typical radial arrangement of assemblies will be employed using a modified Type 1A Basket design. For the chamber/canister, a single assembly layer with full radial dimension will be employed. Modifications to the standard canister design and configuration include the addition of a siphon tube to enable recirculation of hot gas for forced helium drying. A ring of ports/flanges are added near the top of the chamber to accommodate the feedthroughs for instrumentation and power needed for the experiment and data collection. Four viewports are added to the main section of the chamber with two in line with one of the fuel assembly and siphon tube. The other two viewports are on the opposite side of the chamber. The purpose here is to provide the option of thermal imaging in addition to the nearly four dozen thermocouples available inside the chamber. Modeling of the chamber, basket, and mock ASNF assemblies was conducted to estimate temperature distributions throughout the chamber during forced helium drying and over the anticipated drying period. This modeling was used as input to decisions on the Engineering Scale Design. Work on modeling continues in the period during setup and testing to develop preliminary drying models. Analysis of experimental results will later be used to validate these and subsequent models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Radiolytic evaluation of select sulfur chlorides (S 2 Cl 2 and SOCl 2 ) for advanced low temperature chlorination of zirconium-based used nuclear fuel cladding

New sulfur chloride compounds—sulfur monochloride (S 2 Cl 2 ) and thionyl chloride (SOCl 2 )—have been proposed as alternative chlorinating agents for the chemical decladding of zirconium-based used nuclear fuel cladding materials. However, the radiation stability of these compounds has not been thoroughly evaluated, despite envisioned process conditions involving intense, multi-component radiation fields. Knowledge of the radiation chemistry of these sulfur chlorides is essential for the development and optimization of alternative chlorination technologies. To this end, we present preliminary findings on the gamma radiolysis of neat S 2 Cl 2 and SOCl 2 at ambient temperature up to ~ 34 MGy. In this study, Raman spectroscopy and density functional theory calculations were used to identify the Raman-active degradation products from S 2 Cl 2 and SOCl 2 radiolysis. Both sulfur chloride compounds exhibited significant radiation resistance, with respect to changes in the Raman signatures of the parent compounds and the ingrowth of Raman-active degradation products. For S 2 Cl 2 , molecular chlorine (Cl 2 ) was directly identified as the predominant degradation product, which was completely consumed at higher absorbed doses (> 9 MGy). Similarly, the main degradation product from SOCl 2 radiolysis was also Cl 2 , although in this system it continued to grow in with dose over the entire dose range. Further, an “S=O” containing degradation product(s) was also identified as a compliment to Cl 2 . Overall, the perceived radiation resistance of these sulfur chloride compounds makes them suitable for inclusion in a used nuclear fuel chemical decladding process, especially as radiolytically formed Cl 2 can be used to reform the parent compounds, thereby increasing the longevity of the solvents used.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2016

Assessment of wear coefficients of nuclear zirconium claddings without and with pre-oxidation

In the cores of pressurized water nuclear reactors, water-flow induced vibration is known to cause claddings on the fuel rods to rub against their supporting grids. Such grid-to-rod-fretting (GTRF) may lead to fretting wear-through and the leakage of radioactive species. The surfaces of actual zirconium alloy claddings in a reactor are inevitably oxidized in the high-temperature pressurized water, and some claddings are even pre-oxidized. As a result, the wear process of the surface oxide film is expected to be quite different from the zirconium alloy substrate. In this paper, we attempt to measure the wear coefficients of zirconium claddings without and with pre-oxidation rubbing against grid samples using a bench-scale fretting tribometer. Results suggest that the volumetric wear coefficient of the pre-oxidized cladding is 50 to 200 times lower than that of the untreated cladding. In terms of the linear rate of wear depth, the pre-oxidized alloy wears about 15 times more slowly than the untreated cladding. Finally, fitted with the experimentally-determined wear rates, a stage-wise GTRF engineering wear model demonstrates good agreement with in-reactor experience in predicting the trend of cladding lives.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Technology Development for Aluminum-clad Spent Nuclear Fuel for Extended Dry Storage (Status Report)

A task group under the Spent Nuclear Fuel Working Group of the U.S. Department of Energy (DOE), Offices of Environmental Management (EM) and Nuclear Energy (NE) identified technical challenges (“information gaps"’) to the ability to provide for safe extended (>50 years) dry storage of Aluminum-Clad Spent Nuclear Fuel (ASNF) in a report issued in 2017, An Action Plan was developed, and a task- based program was launched under the sponsorship of DOE-EM, Office of Technology Development (EMTD) in October 2018 to close the gaps and complete the technical information set needed to implement extended dry storage with confidence. This interim status report summarizes the work to date of this EMTD program to complete the technical bases and demonstrate that extended dry storage is safe and viable.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Completion and Testing of a New High-Temperature Cell Holder to Support High Dose Rate Electron Beam Irradiations of Select Sulfur Chlorides (S2Cl2 and SOCl2) for Advanced Low Temperature Chlorination of Zirconium-based Used Nuclear Fuel Cladding

Short communication on the completion and testing of a new high-temperature cell holder to support high dose rate electron beam irradiations of select sulfur chlorides (S2Cl2 and SOCl2) for advanced low temperature chlorination of zirconium-based used nuclear fuel cladding.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2025

Improved damage tolerance of SiC-based nuclear fuel cladding with novel multi-layered SiC coating design at 1200 °C

Continuous SiC fibre reinforced SiC matrix composites (SiC f -SiC m ) with monolithic SiC outer coatings are considered as a damage-tolerant cladding design for loss of coolant accident (LOCA) conditions in light water reactors. However, monolithic SiC coatings are brittle and prone to catastrophic failure. In this study, a SiC f -SiC m cladding with a novel multi-layer SiC outer coating (11 sub-layers, ∼260 µm in total thickness) was investigated under C-ring compression at room temperature and 1200 °C in argon environment. Real-time synchrotron X-ray computed tomography (XCT) was employed to capture crack initiation and propagation processes. Compared to conventional monolithic SiC outer coatings, the multi-layer coating structure facilitated crack deflection and bifurcation enhancing its damage tolerance at both temperatures. Despite pre-existing surface cracks, claddings exhibited stable mechanical-performance at both temperatures. These initial cracks did not critically affect the failure processes as they were not aligned with the maximum stress direction. Furthermore, the microstructure, distribution of residual stresses, and local properties of individual components in the material were thoroughly characterized, and compared with open literature on conventional claddings with monolithic outer coatings. These results provide new insights into the failure mechanisms of multi-layer SiC coatings and offer guidance for the future design of accident-tolerant nuclear fuel claddings.

36 - MATERIALS SCIENCE↗
DOE OSTI2012

Process Development Studies for Zirconium Recovery/Recycle from Used Nuclear Fuel Cladding

Process development studies are being done to recover and reuse zirconium from used nuclear fuel (UNF) zirconium alloy cladding. This has been shown to be economically viable and is a major initiative in waste reduction. The studies have included recovery processes based on dry pyrochemical iodination, chlorination, and hydrochlorination. Chlorination, using either or both chlorine and hydrogen chloride, was shown to provide better performance and is more compatible for interfacing with existing industrial chlorination processes used for fuel rod cladding manufacture from natural zirconium. The chlorination recovery process could be used for chemical decladding of intact UNF assemblies or for treatment of empty cladding segment hulls. Future work is planned to optimize recovery process conditions, equipment design, and scale-up operations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Effect of PVD-coated chromium on the subcooled flow boiling performance of nuclear reactor cladding materials

Here we elucidate the separate effect of a thin Cr coating deposited by physical vapor deposition (PVD) on the subcooled flow boiling performance of zircaloy-4. First, we run flow boiling experiments on prototypical zircaloy-4 surfaces mimicking the scratch pattern and surface roughness of nuclear reactor claddings. Then, we PVD-coat a 0.3 µm thick chromium layer on the same exact surface and repeat the same flow boiling investigations. All experiments are run using deionized water at atmospheric pressure, flowing on a 1 × 3 cm 2 rectangular cross section channel at a rate of 1000 kg/m 2 /s and a subcooling of 10 K. We measure the average temperature of the boiling surface at increasing surface heat fluxes, covering a wide range of heat transfer regimes, from single-phase forced convection to the boiling crisis. We also record high-speed videos of the boiling process, which we postprocess to measure bubble nucleation site density, growth time, departure diameter and frequency. The surface analysis reveals that, while the chromium coating does not seem change the surface roughness and morphology, it improves surface wettability. However, it decreases the critical heat flux. The chromium coating causes an increase of nucleation temperature, bubble departure diameter and growth time, and a reduction of the nucleation site density. The concurrence of these observations indicates that a size reduction of the nucleation sites, conformally covered by the chromium coating, may be the cause of the boiling performance deterioration. We confirm this hypothesis repeating the same analysis on a FeCrAl sample prepared and tested using the same protocol as the zircaloy-4 sample, but with a different initial surface texture.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2013

SiC-CMC-Zircaloy-4 Nuclear Fuel Cladding Performance during 4-Point Tubular Bend Testing

The U.S. Department of Energy Office of Nuclear Energy (DOE NE) established the Light Water Reactor Sustainability (LWRS) program to develop technologies and other solutions to improve the reliability, sustain the safety, and extend the life of current reactors. The Advanced LWR Nuclear Fuel Development Pathway in the LWRS program encompasses strategic research focused on improving reactor core economics and safety margins through the development of an advanced fuel cladding system. Recent investigations of potential options for “accident tolerant” nuclear fuel systems point to the potential benefits of silicon carbide (SiC) cladding. One of the proposed SiC-based fuel cladding designs being investigated incorporates a SiC ceramic matrix composite (CMC) as a structural material supplementing an internal Zircaloy-4 (Zr-4) liner tube, referred to as the hybrid clad design. Characterization of the advanced cladding designs will include a number of out-of-pile (nonnuclear) tests, followed by in-pile irradiation testing of the most promising designs. One of the out-of-pile characterization tests provides measurement of the mechanical properties of the cladding tube using four point bend testing. Although the material properties of the different subsystems (materials) will be determined separately, in this paper we present results of 4-point bending tests performed on fully assembled hybrid cladding tube mock-ups, an assembled Zr-4 cladding tube mock-up as a standard and initial testing results on bare SiC-CMC sleeves to assist in defining design parameters. The hybrid mock-up samples incorporated SiC-CMC sleeves fabricated with 7 polymer impregnation and pyrolysis (PIP) cycles. To provide comparative information; both 1- and 2-ply braided SiC-CMC sleeves were used in this development study. Preliminary stress simulations were performed using the BISON nuclear fuel performance code to show the stress distribution differences for varying lengths between loading points and clad configurations. The 2-ply sleeve samples show a higher bend momentum compared to those of the 1-ply sleeve samples. This is applicable to both the hybrid mock-up and bare SiC-CMC sleeve samples. Comparatively both the 1- and 2-ply hybrid mock-up samples showed a higher bend stiffness and strength compared with the standard Zr-4 mock-up sample. The characterization of the hybrid mock-up samples showed signs of distress and preliminary signs of fraying at the protective Zr-4 sleeve areas for the 1-ply SiC-CMC sleeve. In addition, the microstructure of the SiC matrix near the cracks at the region of highest compressive bending strain shows significant cracking and flaking. The 2-ply SiC-CMC sleeve samples showed a more bonded, cohesive SiC matrix structure. This cracking and fraying causes concern for increased fretting during the actual use of the design. Tomography was proven as a successful tool to identify open porosity during pre-test characterization. Although there is currently insufficient data to make conclusive statements regarding the overall merit of the hybrid cladding design, preliminary characterization of this novel design has been demonstrated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

A survey on fabrication practice of cladded components from nuclear and non-nuclear industry

Integral claddings are used to provide corrosion protection for pressure vessels in nuclear and non-nuclear applications. In this work, a survey was carried out on the fabrication practice of cladded components from nuclear and non-nuclear industry, to provide the baseline reference point for the development of design and fabrication practices of cladding MSR coolant boundary components and core support structures. Gap analysis on applying these fabrication procedures to MSR applications was carried out, with emphasis on fabrication procedures that can lead to desired quality and metallurgical properties and also be applied commercially.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Ceramic reinforced zirconium alloy nuclear fuel cladding with intermediate oxidation resistant layer

The invention relates to compositions and methods for coating a zirconium alloy (e.g., ceramic-containing) cladding tube for use with fuel rods in a nuclear water reactor. The coating includes an intermediate oxidation resistant layer and a SiC containing layer at least partially deposited on the intermediate oxidation resistant layer. The SiC containing layer can include a plurality of fibers. The SiC containing layer may also be on the outer surface of end plugs. The invention provides improved capability for the zirconium alloy cladding to withstand normal and accident conditions in the nuclear water reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Transition of Spent Nuclear Fuel to Dry Storage: Modeling activities concerning aluminum spent nuclear fuel cladding integrity

In 2017, a report was prepared by the Spent Nuclear Fuel Working Group in 2017 and titled “Technical Considerations and Challenges for Extended (>50 Years) Dry Storage” [1-2]. In this report several key scientific issues were identified pertaining to the problem of aluminum spent nuclear fuel (ASNF) and its safe removal from wet storage with subsequent drying and transfer to dry storage at the Department of Energy (DOE) Idaho National Laboratory (INL). This report outlines two modeling analyses performed for aluminum and aluminum oxides. The first analysis examined the solubility of aluminum oxides as a function of temperature and pH. This report presents existing literature produced as far back as the 1950’s and including significant analysis and reporting performed at Alcoa in the 1980’s. The primary technical gap was the lack of solubility data beyond that reported at standard temperature (25°C). The analysis examined these solubility curves as a function of temperature as well as phase type. The pH value of minimum solubility shifted with temperature but was insensitive to the oxide phase type. The solubility increases with temperature as would be expected, where an order of magnitude increase was observed from 25°C and 90°C. This data provides greater information to understand the various conditions experiences by ASNF including in dry storage in cases where water filming may occur. A second thermodynamic analysis was performed to examine the aluminum phase behavior as a function of temperature. This was performed to understand limitations and possible problems with fuel drying at elevated temperatures. Based on what has been established in previous reports, water remains chemically entrained within boehmite until temperatures exceeding 400°C. Analysis showed that significant phase changes occurred with highly alloyed AA6061 and AA5052 while the more pure aluminum (AA1100) showed nearly ideal behavior (i.e. limited phase changes). In the case of the more alloyed AA5052 and AA6061, the phase changes could take place at relatively low temperatures (100°C to 250°C), and thus may have already experienced some of these phase changes in service. As results are thermodynamic in nature, assessment of kinetics will be examined to determine if the phase changes are a concern for the relatively short fuel drying step.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Investigating grid-to-rod fretting wear of nuclear fuel claddings using a unique autoclave fretting rig

Fuel rods in a pressurized water nuclear reactor (PWR) experience coolant flow-induced relative motion against the grid support features, a phenomenon called grid-to-rod fretting (GTRF), which may cause progressive fretting wear damage. Wear-through of the cladding on fuel rods will leak the radioactive fuel into the coolant loop to significantly increase the radiation level in PWR primary loop and often trigger expensive Post Irradiation Examination. In this work, a unique autoclave fretting test rig was designed and fabricated to allow studying GTRF using actual cladding and grid materials. Water temperature was up to 220 °C, which was designed to mimic the environment in an industry full-assembly reactor core simulator. The contact load (0.1–1 N), oscillation frequency (20–30 Hz) and stroke (50–150 µm), and work rate (1–3 mW) were defined based on simulations of GTRF in an actual reactor. Using this autoclave GTRF rig, tests were conducted to learn the effect of water temperature and to investigate the wear behavior of different cladding-grid material combinations currently used in actual PWRs, including Zr alloy claddings without and with pre-oxidation against Zr alloy and Inconel grids. Higher water temperature evidently increased the cladding wear, and pre-oxidation of the Zr alloy and/or using the Inconel grid effectively reduced the wear rate. In conclusion, results were correlated with the data of a full-size industry reactor core simulator in terms of both wear rate and wear scar morphology.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗