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U-10Mo Monolithic Fuel Qualification Plan

The Material Management and Minimization (M3) Program’s primary objective within the U.S. Department of Energy/National Nuclear Security Administration is to achieve permanent threat reduction by minimizing and when possible, eliminating weapon-usable nuclear material around the world. Under M3’s Office of Conversion, the U.S. High Performance Research Reactor (USHPRR) Project, is pursuing a fuel qualification and licensing effort focused on converting high-performance research reactors in the United States from using highly enriched uranium (HEU) fuel to using low-enriched uranium (LEU) fuel. The body of this document is focused on defining the activities required for generic qualification of high density, LEU fuel that then allows reactor conversions to proceed for the four high-performance research reactors and the critical assembly that will operate using the U-10Mo monolithic fuel design (see Subsection 1.3): MITR, MURR, NBSR, ATR, and ATRC. Fuel qualification in this report means generic fuel acceptance of the U-10Mo monolithic fuel form by the NRC for use in reactor conversions in the United States, which allows the fuel to be used in subsequent reactor specific licensing requests. The U 10Mo Monolithic Fuel Research, Development, and Qualification Plan utilizes the functions and requirements of the USHPRR Project that was established in the Functions and Requirements Document (F&RD) [1] and expands on these requirements to ensure that planned tests have traceable results that will ensure the requirement has been met. The methods by which data will be collected to show that these requirements have been met are described in this document.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Enhanced Accident Tolerant LWR Fuels: Metrics Development

The Department of Energy (DOE) Fuel Cycle Research and Development (FCRD) Advanced Fuels Campaign (AFC) is conducting research and development on enhanced Accident Tolerant Fuels (ATF) for light water reactors (LWRs). This mission emphasizes the development of novel fuel and cladding concepts to replace the current zirconium alloy-uranium dioxide (UO2) fuel system. The overall mission of the ATF research is to develop advanced fuels/cladding with improved performance, reliability and safety characteristics during normal operations and accident conditions, while minimizing waste generation. The initial effort will focus on implementation in operating reactors or reactors with design certifications. To initiate the development of quantitative metrics for ATR, a LWR Enhanced Accident Tolerant Fuels Metrics Development Workshop was held in October 2012 in Germantown, MD. This paper summarizes the outcome of that workshop and the current status of metrics development for LWR ATF.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Reactor Physics Methods and Preconceptual Core Design Analyses for Conversion of the Advanced Test Reactor to Low-Enriched Uranium Fuel Annual Report for Fiscal Year 2012

Under the current long-term DOE policy and planning scenario, both the ATR and the ATRC will be reconfigured at an appropriate time within the next several years to operate with low-enriched uranium (LEU) fuel. This will be accomplished under the auspices of the Reduced Enrichment Research and Test Reactor (RERTR) Program, administered by the DOE National Nuclear Security Administration (NNSA). At a minimum, the internal design and composition of the fuel element plates and support structure will change, to accommodate the need for low enrichment in a manner that maintains total core excess reactivity at a suitable level for anticipated operational needs throughout each cycle while respecting all control and shutdown margin requirements and power distribution limits.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Log-N/Period Sensitivity Analysis

The Log-N/Period system utilizes a compensated ion chamber to measure neutron radiation in the reactor core. This analysis focuses on determining a more accurate value for the sensitivity of the installed compensated ion chambers for the Log-N/Period system at the ATR. Using calibration procedures a formula for indirectly calculating the sensitivity of the chambers was derived. Using historical data from approximately ten reactor cycles a new average sensitivity for both channels of the Log-N/Period system was determined.

42 ENGINEERING↗

History of Pu-238 Production Restart Efforts at Idaho National Laboratory and Oak Ridge National Laboratory

In the early 2010s, efforts to restart production in the U.S. of plutonium-238 heat source (HSPu) material for NASA deep space missions were initiated. Processes, procedures, hardware, and chemical separations were developed and implemented to enable the production of heat source material at Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL). Here, this review provides an overview of the timeline and efforts associated with the restart of production, as well as upcoming efforts to increase production.

07 ISOTOPE AND RADIATION SOURCES↗

U.S. HIGH PERFORMANCE RESEARCH REACTOR PRELIMINARY DESIGN MILESTONE FOR CONVERSION TO LOW ENRICHED URANIUM FUEL

The U.S. reactors that regularly refuel with highly enriched uranium (HEU) have undertaken conversion to low-enriched uranium (LEU) using a high-density alloy of uranium-10 wt% molybdenum (U-10Mo) that is under development for the U.S. High Performance Research Reactors (USHPRR). The U.S. National Nuclear Security Administration (NNSA) Material Management and Minimization (M3) Reactor Conversion Program is pursuing USHPRR conversion. The USHPRR consists of nine national laboratories and three universities working with a uranium processing plant and commercial fuel fabricator to convert five reactors and an associated critical assembly. Feasibility designs were completed in 2009 for all USHPRR. Since then, the USHPRR have completed key milestones leading to preliminary designs. Between 2007 and 2011, the Fuel Qualification (FQ) Pillar conducted seven irradiation campaigns consisting of 14 large size plates and over 60 mini plates with U-10Mo fuel with a zirconium interlayer. The Preliminary Report on U-Mo Monolithic Fuel for Research Reactors submitted for review to the U.S. Nuclear Regulatory Commission (NRC) in 2017 summarizes these irradiation tests. The Fuel Fabrication (FF) Pillar has installed and is operating a fabrication pilot line at BWX Technologies, Inc. In tandem, the Reactor Conversion (RC) Pillar, has been working with each USHPRR to mature conversion designs and to include recent data. As of 2018, all five USHPRR have completed LEU designs. This includes three Preliminary Safety Analysis Reports (PSARs) submitted between 2014 and 2017 to the NRC by the National Institute of Standards and Technology, University of Missouri, and Massachusetts Institute of Technology for their reactors NBSR, MURR, and MITR, respectively. In 2018, the two USHPRR reactors regulated by the U.S. Department of Energy (DOE) at Idaho National Laboratory (ATR) and Oak Ridge National Laboratory (HFIR) completed optimized conceptual or preliminary designs, with ATR confirming a ‘base fuel’ design of the same fabrication complexity as required for MURR, MITR and NBSR. Instead of available U-10Mo designs, HFIR is pursuing a longer silicide (U3Si2) fuel design with a fuel meat density of 4.8 gU/cm3. However, HFIR conversion will require additional fuel qualification due to the complex fuel design containing boron and since HFIR exceeds existing silicide qualification limits. These preliminary designs allow for a commercial fabrication demonstration, and subsequent irradiation qualification of these fuel element designs in order to complete final SARs that allow for USHPRR conversion to LEU fuel.

Wilson, E. H.↗

Infrasound and Low-Frequency Acoustics MINOS Briefing

Oral presentation intended for Multi-Informatics for Nuclear Operations Scenarios (MINOS) venture teams describing programmed notification algorithm and ground truth collected at the Advanced Test Reactor.

42 ENGINEERING↗

Preliminary Criticality and Radiation Shielding Analysis for the Storage and Transfer of MARVEL Reactor Spent Nuclear Fuel

This report documents the results of preliminary nuclear criticality and radiation shielding assessments during transfer and dry storage of irradiated Microreactor Applications Research Validation and Evaluation (MARVEL) reactor fuel at Idaho National Laboratory (INL). The assessments focus on transfer casks and storage canisters that are currently in use at INL, which may be compatible with the irradiated MARVEL reactor fuel. The criticality assessments were performed using the radiation transport code MCNP6 with 37 MARVEL reactor fuel elements in various configurations and scenarios. All transfer and storage configurations under dry conditions were below the assumed criticality safety limit of 0.93. Some storage and transfer configurations under wet conditions exceeded the criticality safety limit. This suggests that the appropriate administrative and engineering controls, in addition to reducing the number of MARVEL reactor fuel elements per transfer cask or storage canister, can be expected to ensure criticality safety under all scenarios. The radiation shielding assessments were performed by generating conservative neutron and photon source terms using the ORIGEN module in the SCALE suite of codes. These source spectra were used to estimate the dose equivalent rates using the radiation transport code MCNP6, both on contact and 1 m away from the fuel and transfer casks. The maximum estimated dose equivalent rate of 37 unshielded MARVEL reactor fuel elements on contact is approximately 42000 R/hr. The maximum estimated dose equivalent rates on contact to the ATR transfer cask, HFEF-5 transfer cask, and high load charger were approximately 233 mR/hr, 171 mR/hr, and 201 mR/hr, respectively. This suggests that with the appropriate administrative and engineering controls, all three transfer casks analyzed can be expected to provide sufficient radiation shielding to workers during transfer of irradiated MARVEL reactor fuel. These calculations are performed to support the planning and strategy for the MARVEL project and will demonstrate the technical viability of the different configurations discussed and help identify where engineered or administrative controls may be necessary. A complete criticality safety analysis and radiation shielding analysis, including validation and contingency and accident analysis must be completed by licensed and authorized personnel before any transfer or storage of MARVEL reactor nuclear fuel.

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TEV-3349 "ATF-2 2A Loop Pin Cladding Requirements"

Industry partners, including Westinghouse, Framatome, General Electric, General Atomics, Toshiba, etc. require requirements for fuel pins they insert in the reactor for testing. This document contains those requirements. These requirements represent an agreement between ATR and NS&T, and include the requirements for pins fabricated at the INL. These include inspections such as radiography, helium leak check, etc.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Geophysical measurements of a demolition at NRF

On May 31 st , 2025, at approximately 14:40:00 UTC, the former Submarine First Westinghouse (SW1) structure housing a large crane was demolished at the Naval Reactors Facility (NRF) located within the perimeter of the Idaho National Laboratory (INL). Several targeted explosives were used to facilitate this demolition. The INL Seismic Monitoring Program (SMP) installed four temporary seismic instrument suites around the site of the demolition in order to monitor ground motion including measuring peak ground acceleration (PGA), peak ground velocity (PGV), and to calculate peak ground displacement (PGD). The demolition produced three types of waves: body waves, surface waves, and acoustic waves. The acoustic wave represents the largest signal received. The PGA, measured on the eastern component of the instrument located approximately 95m away from the demolition site, was 0.187g. The PGV measured was 0.0004 m/s, and the PGD was approximately 0.000006m. Rayleigh waves incident on an instrument located at the Advanced Test Reactor, about 7.6km away, were used to estimate a magnitude of 0.3 at the ATR, representing a yield of energy equivalent to approximately 3 grams of TNT.

58 - GEOSCIENCES↗

Design of a first-of-A-kind instrumented advanced test reactor irradiation Capsule experiment for In situ thermal conductivity measurements of metallic fuel

Metallic fuel undergoes dramatic microstructural changes early in life due to fission gas swelling until ~2–3 at% burnup which affects the conductivity of the material, however the evolution of metallic fuel thermal conductivity during this early phase burnup has never been successfully measured in situ. The Irradiated Material Properties Accelerated Characterization Test (IMPACT) experiment will be the first in a series of experiments to irradiate advanced nuclear metallic fuel specimens with novel embedded thermal conductivity probes in ATR. In the current work the IMPACT experiment final design and supporting analysis is reported in detail. Results are evaluated for various reactor operational conditions to meet the functional requirements of the experiment. Finally, the first iteration of this IMPACT experiment will provide data regarding thermal properties evolution in uranium-zirconium (U10Zr) fuel, but this experiment vehicle is envisioned for future advanced fuels and structural materials irradiations in ATR.

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AFIP-6 MKII First Cycle Report

The first fuel plate frame assembly of the AFIP-6 MKII experiment was irradiated as planned from December, 2011 through February, 2012 in the center flux trap of the Advanced Test Reactor during cycle 151A. Following irradiation in this cycle and while reconfiguring the experiment in the ATR canal, a non-fueled component (the bottom plate) of the first fuel plate frame assembly became separated from the rail sides. There is no evidence that the fueled region of the fuel plate frame assembly was compromised by this incident or the irradiation conditions. The separation of this component was determined to have been caused by flow induced vibrations, where vortex shedding frequencies were resonant with a natural frequency of the bottom plate component. This gave way to amplification, fracture, and separation from the assembly. Although parallel flow induced vibrations were analyzed, vortex shedding flow induced vibrations was an unfamiliar failure mode that was difficult to identify. Both the once-irradiated first fuel plate and un-irradiated second fuel plate frame assemblies were planned for irradiation in the subsequent cycle 151B. The AFIP-6 MKII experiment was excluded from irradiation in cycle 151B because non-trivial design modifications would be needed to mitigate this type of incident during the second irradiation cycle. All items of the experiment hardware were accounted for and cycle 151B occurred with a non-fueled AFIP backup assembly in the center flux trap. Options for completion of the AFIP-6 MKII experiment campaign are presented and future preventative actions are recommended.

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Future TRISO fuel irradiations in the Advanced Test Reactor

AGR-5/6/7 was thought to be the last experiment in the AGR series and the last experiment directly sponsored by DOE. Over the last five years three developments have caused a reevaluation of that assumption. First is that interest in TRISO fueled reactors has spiked dramatically. Virtually all of the new reactor designs are for SMRs or micro-reactors . Some of these reactors use new fuel designs with higher concentrations of U235. This results in changes to the particle design and even fuel pellet design. Second, a design flaw in AGR-5/6/7 Capsule 1 produced a large number of particle failures which resulted in the loss of data from Capsule 1. An additional irradiation could fill in this lost data set. Thirdly, many reactor developers have decided to use AGR spec fuel but different irradiation goals have been identified.

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Bench-Scale Monolith Autothermal Reformer Catalyst Screening Evaluations in a Micro-Reactor With Jet-A Fuel

Solid oxide fuel cell systems used in the aerospace or commercial aviation environment require a compact, light-weight and highly durable catalytic fuel processor. The fuel processing method considered here is an autothermal reforming (ATR) step. The ATR converts Jet-A fuel by a reaction with steam and air forming hydrogen (H2) and carbon monoxide (CO) to be used for production of electrical power in the fuel cell. This paper addresses the first phase of an experimental catalyst screening study, looking at the relative effectiveness of several monolith catalyst types when operating with untreated Jet-A fuel. Six monolith catalyst materials were selected for preliminary evaluation and experimental bench-scale screening in a small 0.05 kWe micro-reactor test apparatus. These tests were conducted to assess relative catalyst performance under atmospheric pressure ATR conditions and processing Jet-A fuel at a steam-to-carbon ratio of 3.5, a value higher than anticipated to be run in an optimized system. The average reformer efficiencies for the six catalysts tested ranged from 75 to 83 percent at a constant gas-hourly space velocity of 12,000 hr 1. The corresponding hydrocarbon conversion efficiency varied from 86 to 95 percent during experiments run at reaction temperatures between 750 to 830 C. Based on the results of the short-duration 100 hr tests reported herein, two of the highest performing catalysts were selected for further evaluation in a follow-on 1000 hr life durability study in Phase II.

Tomsik, Thomas M.↗

Ferritic Alloys as Accident Tolerant Fuel Cladding Material for Light Water Reactors

The objective of the GE project is to demonstrate that advanced steels such as iron-chromium-aluminum (FeCrAl) alloys could be used as accident tolerant fuel cladding material in commercial light water reactors. The GE project does not include fuel development. Current findings support the concept that a FeCrAl alloy could be used for the cladding of commercial nuclear fuel. The use of this alloy will benefit the public since it is going to make the power generating light water reactors safer. In the Phase 1A of this cost shared project, GE (GRC + GNF) teamed with the University of Michigan, Los Alamos National Laboratory, Brookhaven National Laboratory, Idaho National Laboratory, and Oak Ridge National Laboratory to study the environmental and mechanical behavior of more than eight candidate cladding materials both under normal operation conditions of commercial nuclear reactors and under accident conditions in superheated steam (loss of coolant condition). The main findings are as follows: (1) Under normal operation conditions the candidate alloys (e.g. APMT, Alloy 33) showed excellent resistance to general corrosion, shadow corrosion and to environmentally assisted cracking. APMT also showed resistance to proton irradiation up to 5 dpa. (2) Under accident conditions the selected candidate materials showed several orders of magnitude improvement in the reaction with superheated steam as compared with the current zirconium based alloys. (3) Tube fabrication feasibility studies of FeCrAl alloys are underway. The aim is to obtain a wall thickness that is below 400 µm. (4) A strategy is outlined for the regulatory path approval and for the insertion of a lead fuel assembly in a commercial reactor by 2022. (5) The GE team worked closely with INL to have four rodlets tested in the ATR. GE provided the raw stock for the alloys, the fuel for the rodlets and the cost for fabrication/welding of the rodlets. INL fabricated the rodlets and the caps and welded them to provide hermetic seal. The replacement of a zirconium alloy using a ferritic material containing chromium and aluminum appears to be the most near term implementation for accident tolerant nuclear fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Accelerating Nuclear-Integrated Data Centers in the USA: SWOT Analysis, Power-Thermal Management Strategies, and Industrial-Scale Demonstration and Potential Deployment

Driven by the growth in digital services, cloud computing, AI, and manufacturing, data centers face rising energy demands that challenge traditional power sources and cooling efficiency. This study explores using nuclear power to meet these demands, focusing on accelerated reactor technology deployment and highlighting needs such as N+1/N+2 power supplies and integrated power-thermal management. A SWOT analysis addresses grid connectivity, reactors, and site selection, particularly DOE sites. Reactor technology demonstration and deployment could be accelerated by leveraging test facilities such as MARVEL, MAGNET, TED, FAS, DOME, LOTUS, ATR, Energy System Proving Grounds, and upcoming Energy Launch Pads, along with modeling and simulation tools such as RELAP5, MOOSE, VERA, RAVEN, and FORCE. The potential power and thermal management options, including various cooling technologies, waste-heat utilization, and an industrial-scale demonstration plan, aim to accelerate the integration of nuclear power and data centers in the USA, while emphasizing community and stakeholder engagement and synergistic efforts.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

As-run thermal-hydraulics analysis of the EPRI-2 experiment

The EPRI-2 experiment was designed to irradiate various types of reactor pressure vessel steels at a temperature of 288°C (PLN-3934). The specimens were irradiated in a non-instrumented test train inside a pressurized water loop in the center lobe of the ATR during PALM cycle 153B. Temperature was indicated by post-irradiation examination of melt wires placed within the test train. The purpose of this analysis is to calculate specimen temperature using measured data on reactor power and as-run calculations of heating rates of the test train. The experiment contains several melt wires spanning the temperature range 239°C to 327°C. The accuracy of the model is assessed by comparing the measured and calculated in-pile tube inlet to outlet temperature difference, and comparing the calculated specimen temperature to the temperature range indicated by examination of the melt wires.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗