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DOE OSTI2012

Bulk nanostructured austenitic stainless steels with enhanced radiation tolerance

The objective of this project is to increase radiation tolerance in austenitic steels through optimization of grain size and grain boundary (GB) characteristics. The focus will be on nanocrystalline austenitic Fe-Cr-Ni alloys with an fcc crystal structure. The long-term goal is to design and develop bulk nanostructured austenitic steels with enhanced void swelling resistance and substantial ductility, and to enhance their creep resistance at elevated temperatures via GB engineering. The combination of grain refinement and grain boundary engineering approaches allows us to tailor the material strength, ductility, and resistance to swelling by 1) changing the sink strength for point defects, 2) by increasing the nucleation barriers for bubble formation at GBs, and 3) by changing the precipitate distributions at boundaries. Compared to ferritic/martensitic steels, austenitic stainless steels (SS) possess good creep and fatigue resistance at elevated temperatures, and better toughness at low temperature. However, a major disadvantage of austenitic SS is that they are vulnerable to significant void swelling in nuclear reactors, especially at the temperatures and doses anticipated in the Advanced Burner Reactor. The lack of resistance to void swelling in austenitic alloys led to the switch to ferritic/martensitic steels as the preferred material for the fast reactor cladding application. Recently a type of austenitic stainless steel, HT-UPS, was developed at ORNL, and is expected to show enhanced void swelling resistance through the trapping of point defects at nanometer-sized carbides. Reducing the grain size and increasing the fraction of low energy grain boundaries should reduce the available radiation-produced point defects (due to the increased sink area of the grain boundaries), should make bubble nucleation at the boundaries less likely (by reducing the fraction of high-energy boundaries), and improve the strength and ductility under radiation by producing a higher density of nanometer sized carbides on the boundaries. This project will focus on void swelling but advances in processing of austenitic steels are likely to also improve the radiation response of the mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Sensitivity study of hydrogen Soret transport in yttrium Hydride-Based nuclear fuel

Yttrium hydride is an excellent solid neutron moderator material for high temperature nuclear reactor applications due to its high hydrogen density and exceptional hydride stability at high temperatures. Despite these attractive characteristics, the details of how hydrogen behaves within yttrium hydride while temperature gradients exist are still not well understood. The evolution of the hydrogen composition profile resulting from a temperature gradient requires knowledge of hydrogen’s heat of transport, a critical parameter that has not yet been measured for this material. In this work, we perform hydride redistribution, hydrogen dissociation, and hydrogen leakage calculations while varying the Soret heat of transport of hydrogen in yttrium hydride to elucidate the sensitivity of hydride stability under temperature gradients to this parameter. This study analyzes hydride stability of a hypothetical uranium-yttrium hydride nuclear fuel design during operation of a high temperature liquid metal-cooled nuclear reactor. Assuming U-YH x could be fabricated in a physically stabilized manner, this fuel system can likely maintain hydride stability while operating at very high power densities and temperatures. We find that even though the hydrogen dissociation pressure in the gas gap does vary by several percent as the heat of transport temperature parameter is varied, the hydrogen content in the U-YH x fuel meat is relatively insensitive to this parameter over the course of a high burnup fuel cycle; this is due to yttrium hydride’s excellent hydrogen retention under the high temperature conditions considered here. Here, this suggests that hydride stability analyses are insensitive to the value of the Soret heat of transport in U-YH x under steady state liquid metal-cooled reactor conditions. However, the susceptibility to internal gas overpressurization-induced stress-rupture of the cladding during a high temperature transient is more sensitive to this parameter due to the non-linear dependence of hydrogen gas dissociation pressure vs. composition and temperature.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2012

10 CFR 830 Major Modification Determination for Advanced Test Reactor LEU Fuel Conversion

The Advanced Test Reactor (ATR), located in the ATR Complex of the Idaho National Laboratory (INL), was constructed in the 1960s for the purpose of irradiating reactor fuels and materials. Other irradiation services, such as radioisotope production, are also performed at ATR. The ATR is fueled with high-enriched uranium (HEU) matrix (UAlx) in an aluminum sandwich plate cladding. The National Nuclear Security Administration Global Threat Reduction Initiative (GTRI) strategic mission includes efforts to reduce and protect vulnerable nuclear and radiological material at civilian sites around the world. Converting research reactors from using HEU to low-enriched uranium (LEU) was originally started in 1978 as the Reduced Enrichment for Research and Test Reactors (RERTR) Program under the U.S. Department of Energy (DOE) Office of Science. Within this strategic mission, GTRI has three goals that provide a comprehensive approach to achieving this mission: The first goal, the driver for the modification that is the subject of this determination, is to convert research reactors from using HEU to LEU. Thus the mission of the ATR LEU Fuel Conversion Project is to convert the ATR and Advanced Test Reactor Critical facility (ATRC) (two of the six U.S. High-Performance Research Reactors [HPRR]) to LEU fuel by 2017. The major modification criteria evaluation of the project pre-conceptual design identified several issues that lead to the conclusion that the project is a major modification.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Technical Feasibility of Direct Disposal of Electrorefiner Salt Waste

The experimental breeder reactor (EBR-II) used fuel with a layer of sodium surrounding the uranium-zirconium fuel to improve heat transfer. Disposing of this EBR-II used fuel in a geologic repository without treatment is not prudent because of the potentially energetic reaction of the sodium with water. In 2000, the US Department of Energy decided to treat the EBR-II sodium-bonded used fuel in an electrorefiner (ER), which produces a metallic waste, mostly from the cladding. The salt remaining in the ER contains most of the actinides and fission products. Two baseline waste forms were proposed for disposal in a mined repository; the metallic waste, which was to be cast into ingots, and the ER salt waste, which was to be further treated to produce a ceramic waste form. However, alternative disposal pathways for metallic and salt waste streams are being investigated that may reduce the complexity. For example, performance assessments show that both mined repositories in salt and deep boreholes in basement crystalline rock can easily accommodate the ER salt waste without treating it to form a ceramic waste form. Hence the focus of a direct disposal option, as described herein, is now on the feasibility of packaging the ER salt waste in the near term such that it can be transported to a repository in the future without repackaging. A vessel for direct disposal of ER salt waste has been previously proposed, designed, and a prototype manufactured based on desirable features for use in the hot cell. The reported analysis focused on the feasibility of transporting this proposed vessel and whether any issues would suggest that a smaller or larger size is more appropriate. Specifically, three issues are addressed (1) shielding necessary to reduce doses to acceptable levels; (2) the criticality potential and the ease which it can be shown to be inconsequential, and (3) temperatures of the containers in relation to acceptable cask limits. The generally positive results demonstrate that direct disposal of ER in the proposed packaging is feasible without the need to secure funding to modify the facility.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2013

Probabilistic Failure Analysis for Wound Composite Ceramic Cladding Assembly

Advanced ceramic matrix composites based on silicon carbide (SiC) are being considered as candidate material systems for nuclear fuel cladding in light water reactors. The SiC composite structure is considered due to its assumed exceptional performance under accident scenarios, where its excellent high-temperature strength and slow reaction kinetics with steam and associated mitigated hydrogen production are desirable. The specific structures of interest consist of a monolithic SiC cylinder surrounded by interphase-coated SiC woven fibers in a tubular form and infiltrated with SiC. Additional SiC coatings on the outermost surface of the assembly are also being considered to prevent hydrothermal corrosion of the fibrous structure. The inner monolithic cylinder is expected to provide a hermetic seal to contain fission products under normal conditions. While this approach offers the promise of higher burn-up rates and safer behavior in the case of LOCA events, the reliability of such structures must be demonstrated in advance. Therefore, a probability failure analysis study was performed of such monolithic-composite hybrid structures to determine the feasibility of these design concepts. This analysis will be used to predict the future performance of candidate systems in an effort to determine the feasibility of these design concepts and to make future recommendations regarding materials selection.

Hemrick, James Gordon↗

DOE OSTI2012

Identification of limiting case between DBA and SBDBA (CL break area sensitivity): A new model for the boron injection system

Atucha-2 is a Siemens-designed PHWR reactor under construction in the Republic of Argentina. Its geometrical complexity and (e.g., oblique Control Rods, Positive Void coefficient) required a developed and validated complex three dimensional (3D) neutron kinetics (NK) coupled thermal hydraulic (TH) model. Reactor shut-down is obtained by oblique CRs and, during accidental conditions, by an emergency shut-down system (JDJ) injecting a highly concentrated boron solution (boron clouds) in the moderator tank, the boron clouds reconstruction is obtained using a CFD (CFX) code calculation. A complete LBLOCA calculation implies the application of the RELAP5-3D{sup C} system code. Within the framework of the third Agreement 'NA-SA - Univ. of Pisa' a new RELAP5-3D control system for the boron injection system was developed and implemented in the validated coupled RELAP5-3D/NESTLE model of the Atucha 2 NPP. The aim of this activity is to find out the limiting case (maximum break area size) for the Peak Cladding Temperature for LOCAs under fixed boundary conditions. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2013

Investigation of the Performance of D 2 O-Cooled High-Conversion Reactors for Fuel Cycle Calculations

This report presents FY13 activities for the analysis of D 2 O cooled tight-pitch High-Conversion PWRs (HCPWRs) with U-Pu and Th-U fueled cores aiming at break-even or near breeder conditions while retaining the negative void reactivity. The analyses are carried out from several aspects which could not be covered in FY12 activities. SCALE 6.1 code system is utilized, and a series of simple 3D fuel pin-cell models are developed in order to perform Monte Carlo based criticality and burnup calculations. The performance of U-Pu fueled cores with axial and internal blankets is analyzed in terms of their impact on the relative fissile Pu mass balance, initial Pu enrichment, and void coefficient. In FY12, Pu conversion performances of D 2 O-cooled HCPWRs fueled with MOX were evaluated with small sized axial/internal DU blankets (approximately 4cm of axial length) in order to ensure the negative void reactivity, which evidently limits the conversion performance of HCPWRs. In this fiscal year report, the axial sizes of DU blankets are extended up to 30 cm in order to evaluate the amount of DU necessary to reach break-even and/or breeding conditions. Several attempts are made in order to attain the milestone of the HCPWR designs (i.e., break-even condition and negative void reactivity) by modeling of HCPWRs under different conditions such as boiling of D 2 O coolant, MOX with different 235 U enrichment, and different target burnups. A similar set of analyses are performed for Th-U fueled cores. Several promising characteristics of 233 U over other fissile like 239 Pu and 235 U, most notably its higher fission neutrons per absorption in thermal and epithermal ranges combined with lower ___ in the fast range than 239 Pu allows Th-U cores to be taller than MOX ones. Such an advantage results in 4% higher relative fissile mass balance than that of U-Pu fueled cores while retaining the negative void reactivity until the target burnup of 51 GWd/t. Several other distinctions between U-Pu and Th-U fueled cores are identified by evaluating the sensitivity coefficients of keff, mass balance, and void coefficient. The effect of advanced iron alloy cladding (i.e., FeCrAl) on the performance of Pu conversion in MOX fueled cores is studied instead of using standard stainless-steel cladding. Variations in clad thickness and coolant-to-fuel volume ratio are also exercised. The use of FeCrAl instead of SS as a cladding alloy reduces the required Pu enrichment and improves the Pu conversion rate primarily due to the absence of nickel in the cladding alloy that results in the reduction of the neutron absorption. Also the difference in void coefficients between SS and FeCrAl alloys is nearly 500 pcm over the entire burnup range. The report also shows sensitivity and uncertainty analyses in order to characterize D 2 O cooled HCPWRs from different aspects. The uncertainties of integral parameters (keff and void coefficient) for selected reactor cores are evaluated at different burnup points in order to find similarities and trends respect to D 2 O-HCPWR.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Post Examination of Candidate NpO 2 Targets for 238 Pu Production

Four targets composed of sintered NpO 2 pellets enclosed in Zircaloy cladding were irradiated in the High Flux Isotope Reactor for 2 to 4 cycles to determine if an oxide pellet and Zircaloy cladding would be usable candidates for 238 Pu production. The pellets were sintered to a high fraction of theoretical density (TD) and melt wires were placed in small holes that had been drilled in the center of selected pellets to determine if the pellet centers exceeded desirable operating temperatures. After irradiation, the targets were punctured to determine the internal target pressure and the fission gas release. None of the targets had excessive pressure, and fission gas release was in the range of 4 to 38%. The targets were then cut into segments for radiochemical analysis, and metallography (MET) mounts were created to examine the pellet microstructure and to search for the melt wires to determine if they had melted. Three of the four targets resulted in successful MET mounts; the two-cycle pellets were too friable to be handled. No signs of pellet melting were noted, and unfortunately, none of the melt wires could be recovered. The results indicate that this pellet/clad design offers a practical option for 238 Pu production.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Specifications of FIPD Fission Gas Release Data

All fission gas release data stored in the Fuels Irradiation & Physics Database (FIPD) was originally measured using the Gas Assay, Sample and Recharge (GASR) System in the Hot Fuel Examination Facility (HFEF). It is therefore called GASR data in FIPD. During the measurement of a sample, such as an irradiated EBR-II fuel element/capsule, a pinhole-sized region near the top of the element plenum was melted by a laser. Plenum gas then expanded into a calibrated volume (note: in this document, “sample” and “capsule/element” are used interchangeably consistent with GASR documents in FIPD). The pressure rise in the volume was recorded. Helium backfilling and expansion was then performed to determine the sample (e.g., fuel element plenum) volume using Boyle’s Law and assuming ideal gas behavior at constant temperature. With the plenum volume and the recorded pressure rise, the sample (e.g., fuel element plenum) pressure was derived with assumption of ideal gas law behavior. The plenum volume and pressure as well as the cladding temperature during the measurement were collected (GASR data in FIPD). Other records associated with the fission gas release data include: raw GASR data records including volumes and post-puncture pressures of seal head/sealing head and manifold, calibration data, backfilling gas pressure data, and the data analysis records. A sample(s) of the fission gas released from the plenum was collected by the GASR system into sample bottles. The chemical and isotopic composition of the gas sample was analyzed separately from GASR data, and will be discussed in a separate specification. The plenum volume, pressure, and cladding temperature during the measurement are typically utilized to determine the number of moles of gas in the plenum. This quantity is often compared to the number of moles of gas generated by fission events. However, calculating these values and their associated uncertainty is beyond the scope of this document, as it necessitates additional assumptions. The most important document to understand the FIPD fission gas data is the GASR operational manual (title: Gas Assay, Sample and Recharge System (GASR) operation and maintenance manual, HFEF/N OMM 4381, DOC. NO. W0018-0032-ES-00). This manual provides: (1) description of the GASR and the functions of each component (laser drilling, welding, seal head/sealing head, manifold, vacuum system, sample system, purge and gas tag system, etc.); (2) step-by-step guidance on calibrations, operations, and measurements; and (3) maintenance procedures and other details relating to the structure and operation of the GASR. Note that the original GASR operated until 2020. A new GASR with the same design and measurement methodology was installed in 2021. The specifications of the GASR presented on the HFEF website at this time are consistent with the ones given in the operational manual. The methods to calculate the plenum volume and pressures were not included in the operational manual, but were recorded in the legacy data analysis files. Details of the methods are given in Chapter 3.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Comparative study of decay heat calculations with FLUKA and MCNP/CINDER2008

In designing a high-power tungsten target, decay heat driven temperature rise in the spallation volume is a safety concern during maintenance and in loss of coolant accidents. As tungsten hydrates and becomes volatile in steam at above 800 ◦C, it is important to keep the target temperature below this threshold when active cooling is unavailable. Decay heat in a target is calculated with particle transport simulation codes combined with transmutation codes. The calculated decay heat usually differs depending on the nuclear cross sections and the decay particle transport models built in the code architecture. In this paper, we calculated decay heat of a water-cooled tungsten target using popular particle transport codes, FLUKA and MCNP6® paired with CINDER2008 and compared the results. The target-moderator-reflector (TMR) system is modeled with a water-cooled solid tungsten target, water premoderators, liquid hydrogen cold moderators and beryllium reflectors. Water-cooled stainless-steel shielding is modeled around the TMR system. The tungsten volume is clad with a thin layer of erosion/corrosion resistant material. This study provides information about the uncertainty range in decay heat prediction of high-power spallation targets for hazard analysis.

Lee, Yong Joong↗

DOE OSTI2020

RELAP-7 Application and Enhancement for FLEX Strategies and ATF Behavior under Extended Loss of AC Power Conditions

This report summarizes the results of a three-year research project sponsored by the U.S. Department of Energy (DOE) Nuclear Energy University Program (NEUP) to enhance and apply the RELAP-7 code by adding and improving several important components (e.g., a mechanistic Reactor Core Isolation Cooling (RCIC) system model) for thermal hydraulic studies of LWRs under ELAP conditions and evaluating the time available for transition to portable FLEX equipment. The project team included University of Massachusetts–Lowell, The Ohio State University, Texas A&M University, Idaho National Laboratory and Oak Ridge National Laboratory. In the Fukushima accident, it was found that the RCIC system played a crucial role in delaying core meltdown by almost three days in Fukushima Daiichi Unit 2, because of self-regulated operation of the steam driven RCIC turbine-pump injection system. Steam flow in the convergent-divergent nozzles of the RCIC Terry turbine is two-phase non-equilibrium transonic flow with homogenous nucleation condensation. To more accurately predict the dynamic process and behavior of the transonic compressible steam flow, a one-dimensional transient two-phase analytical model is presented. A simplified four-fluid model was employed in the present work with the consideration of four separate fluid fields: vapor, liquid film, entrained droplets and condensed droplets. The mass, momentum and energy interactions between the fluids were considered and modeled. An extended seven-equation non-equilibrium critical flow model was developed to obtain the critical pressure and velocities of each phase at the nozzle throat. To predict the wetness in the divergent section, a mechanistic nucleation condensation model was integrated in the nozzle analysis model, considering the generation and consequent growth of droplets. The governing differential equations on a staggered grid were discretized using the second-order Lax-Wendroff scheme with a flux limiter, and the Semi-Implicit Method for Pressure-Linked Equation (SIMPLE) algorithm was employed to solve the discrete linear system. To demonstrate the predictability and reliability of the physical models and the numerical method proposed in the present work, three representative nozzles were modeled and simulated. The results show good agreement with the available experimental data, even for condensation shock. Then, the 1D nozzle model was employed to obtain nozzle flow tables of the Terry turbine nozzle for different working pressures which can cover the operation pressure range of the RCIC system. A mechanistic RCIC turbine-pump system model was developed and implemented in the system code TRACE to simulate dynamic responses of the RCIC system under Beyond Design Basis Accident (BDBA) conditions. The turbine-pump governing equations are based on the control volume approach of the angular momentum balance. The physics based mechanistic RCIC model was developed using the TRACE control system components (i.e., signal variables, control blocks, and tables), and incorporated into a TRACE boiling water reactor (BWR) model. The TRACE model in this report has a detailed nodalization of the reactor pressure vessel (RPV), and all of the major flow paths and system components, including the safety relief valves (SRVs) and the containment suppression pool and drywell. Based on the nozzle flow tables generated from the 1D nozzle model developed, the turbine drive torque can be calculated from table lookup. Since the detailed specifications of the RCIC pump are unavailable, the homologous curves for a Bingham pump were used in the current pump component. A station black-out (SBO) accident test problem was selected to demonstrate the TRACE RCIC model. The short-term SBO simulations were performed for two cladding materials: Zircaloy and FeCrAl, to demonstrate the effect of the accident tolerant fuel cladding on fuel heat-up under BDBA accident conditions. The wetwell plays a vital safety role in SBO and other BWR accident scenarios in that it can reduce containment pressure and supply additional core make-up water. The suppression pool temperature distribution has a very large impact on both RPV and containment pressure. Thus, another novel contribution of the project comes mainly from an improved, systems-level wetwell model which can capture buoyancy-induced thermal stratification effects due to steam injection and condensation. A two-zone stratified wetwell model has been implemented in RELAP-7 and some results from that model are presented. This wetwell model is capable of simulating thermal stratification due to a low steam mass injection rate. With a low mass flow rate, the model assumes that all the steam condenses within the pipe and the resulting plume can be approximated with a purely buoyant, heat-source driven model. The wetwell model developed with these assumptions is adequate to simulate slow transients such as extended SBO transients.

42 ENGINEERING↗

DOE OSTI2016

Large-eddy simulation, fuel rod vibration and grid-to-rod fretting in pressurized water reactors

Grid-to-rod fretting (GTRF) in pressurized water reactors is a flow-induced vibration phenomenon that results in wear and fretting of the cladding material on fuel rods. GTRF is responsible for over 70% of the fuel failures in pressurized water reactors in the United States. Predicting the GTRF wear and concomitant interval between failures is important because of the large costs associated with reactor shutdown and replacement of fuel rod assemblies. The GTRF-induced wear process involves turbulent flow, mechanical vibration, tribology, and time-varying irradiated material properties in complex fuel assembly geometries. This paper presents a new approach for predicting GTRF induced fuel rod wear that uses high-resolution implicit large-eddy simulation to drive nonlinear transient dynamics computations. The GTRF fluid–structure problem is separated into the simulation of the turbulent flow field in the complex-geometry fuel-rod bundles using implicit large-eddy simulation, the calculation of statistics of the resulting fluctuating structural forces, and the nonlinear transient dynamics analysis of the fuel rod. Ultimately, the methods developed here, can be used, in conjunction with operational management, to improve reactor core designs in which fuel rod failures are minimized or potentially eliminated. Furthermore, robustness of the behavior of both the structural forces computed from the turbulent flow simulations and the results from the transient dynamics analyses highlight the progress made towards achieving a predictive simulation capability for the GTRF problem.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Sensitivity Analysis of Transient Critical Heat Flux by RIA Under High-Pressure Flow Boiling Conditions in TRTL

A reactivity-initiated accident (RIA) is a design-basis accident under which critical heat flux (CHF) is likely to be exceeded. The operational margin for RIAs is currently determined using steady-state CHF lookup tables, which provide conservative estimates relative to transient CHF phenomena. The Transient Reactor Test Loop (TRTL) facility at Oregon State University is capable of performing out-of-pile rapid heating experiments representative of a RIA at conditions representative of a pressurized water reactor (PWR). Here, to further our understanding of and ability to predict transient CHF under PWR conditions, we performed a sensitivity analysis on a RELAP5-3D model of the TRTL facility coupled to the RAVEN code framework to define a proposed experimental test matrix to be performed at the TRTL facility. We then implemented a flow boiling CHF correlation into RELAP5-3D and performed a secondary sensitivity analysis inspecting the impact of the built-in RELAP5-3D CHF and heat transfer multipliers on both the prediction of CHF and key safety parameters, such as peak cladding temperature and heat flux. The results show that the multiplier with the highest influence toward the prediction of CHF occurrence and the safety parameters is the transient CHF multiplier. Operational performance envelopes have been developed for each of the test matrix cases and will be used for validation once the experiments are performed. The TRTL facility is currently performing shakedown testing to verify system performance prior to proceeding with the experimental campaign. Restart testing results include pump curve restart testing, pressure tests, and heater rod thermocouple transients.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Aluminum Metal Dissolution for Mark-18A Target Processing

The Mark-18A Program was established to preserve the unique materials found in Mark-18A targets for future research and development activity within the Department of Energy or other U.S. government agencies. The Savannah River Site has 65 Mark-18A targets to be provided for the recovery of high valued isotopes. The majority of the recovery work will be performed in the Savannah River National Laboratory (SRNL) Shielded Cells due to dose concerns. The recovered product will be transported to the Oak Ridge National Laboratory (ORNL) for future research and development tasks. The Mark-18A target material will be removed from their current configuration, dissolved, chemically separated, and calcined to a stable oxide. The baseline flowsheet is patterned after the flowsheet ORNL has previously used to process both Mark-18A and Mark-42 targets. However, it is necessary for SRNL to adapt its facility and the ORNL flowsheet to identify process improvements to successfully recover the actinide materials within the constraints of the SRNL Shielded Cells. These studies evaluated and demonstrated a chemical method for cladding removal using a mixture of sodium nitrate (NaNO 3 ) and sodium hydroxide (NaOH). Experiments provided better insights into dissolution of the Mark-18A aluminum cladding. In particular, these studies measured the effects of temperature on dissolution rate, flammable gas generation, and nitrite formation. Using the lessons learned from batch dissolution testing at SRNL, a continuous dissolution flowsheet was successfully demonstrated using prototypic-shaped materials and chemically-conservative materials. The SRNL target dissolution flowsheet departs from the baseline ORNL flowsheet in small but significant ways as discussed in the following paragraphs. These flowsheet changes facilitate faster initial reaction rates at a given temperature, enable cladding removal at a lower process temperature, and yield a more uniform dissolution rate throughout cladding removal. Multiple tests indicate that the total time at the dissolution temperatures will be about six hours for one fourth of a target. The shorter dissolution time provides the benefit of a single-shift dissolver operation. Off gas sampling determined that the quantities of flammable hydrogen (H 2 ) and ammonia (NH 3 ) expected in the process off gas will meet allowable flammable gas generation rates for the Shielded Cells Facility. The SRNL approach enables NaOH to be added at a constant rate, which simplifies operations in the shielded cells. In all six continuous dissolution tests, the process was easy to control with minimal operator interface. Analyses of process solutions throughout the experiments provide a better understanding of system behavior. The data show consistent behavior across several similar but different test conditions. Between the batch-test and continuous-test data, if future changes to the flowsheet are required, sufficient data exist to adequately predict how the system will respond to those changes. Future work will focus on design, fabrication, and evaluation of a system for dissolution of one-fourth of a Mark-18A target, which will be full-scale operations for SRNL. Based on these results, the process parameters are adequately understood and the system can be operated safely.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Experimental Studies and Energy Modeling for Evaluating Performance of Various Deep Wall Retrofits

The Pacific Northwest National Laboratory, Oak Ridge National Laboratory, and the University of Minnesota conducted a three-year, multipart study on residential retrofit wall assemblies. The project, which was funded by the U.S. Department of Energy’s Building Technology Office, aimed to compare a range of residential wall retrofit systems that prioritized affordability, durability, and energy savings potential. The research team identified, constructed, tested, simulated, and analyzed the feasibility and economics of 16 wall retrofit assemblies (14 test configurations and two baseline configurations) that can be applied to the exterior side of existing walls (either with or without the existing cladding). The 16 wall assemblies were installed in an in-situ laboratory environment, to evaluate the ease of construction and study the thermal and hygrothermal performance of the walls. This paper presents the methodology used to evaluate the thermal performance of the walls and discusses the energy modeling results of the study. The results from the experiments were used to calibrate a THERM model of each wall assembly, which was then applied to a whole building using the EnergyPlus 8.6 simulation engine. A residential prototype building was used to extrapolate whole-building energy savings in each U.S. climate zone. To capture the conditions of the largest number of homes in the United States, the most frequent building characteristics (e.g., attic insulation level, window specifications, foundation insulation, etc.) were extracted from ResStock data and applied to the prototype model. Results from the energy modeling showed that the climate zones with the highest potential for retrofit savings are those which are heating-dominated (i.e., Cold and Very Cold climate designations). In these climate zones, heating and cooling energy savings due to the wall retrofits alone ranged from 21.5% to 38.2%.

Nagda, Harshil↗

DOE OSTI2023

Massively Parallel Bayesian Model Calibration and Uncertainty Quantification with Applications to Nuclear Fuels and Materials

The U.S. Department of Energy (DOE)’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program aims to develop predictive capabilities by applying computational methods to the analysis and design of advanced reactor and fuel cycle systems. This program has been providing engineering-scale support for the development of BISON, a high-fidelity and high-resolution fuel performance tool. Fuel behavior in a nuclear reactor is governed by a complex network of mechanisms interacting with various other physics aspects in the reactor system. Any model developed to represent the fuel behavior will likely be idealized resulting in uncertainties in their predictions compared to the observed data. As such, this report was motivated by the need to identify the sources of uncertainties and quantify and propagate them through the fuel model outputs. Such quantification of uncertainties will establish a level of model trustworthiness, identify approaches to improve the model trustworthiness, and even guide optimal experiment design for maximal information gain. To accomplish the uncertainty quantification for computational models, this report has relied on the Bayesian framework which provides probabilistic treatment of models their inputs and outputs. The current state-of-the-art on performing Bayesian Uncertainty Quantification (UQ) for nuclear engineering models using High Performance Computing (HPC) resources have been reviewed. Implementation of capabilities for massively parallel Bayesian UQ in Multiphysics Object-Oriented Simulation Environment (MOOSE) is discussed. Several verification cases are discussed to verify the accuracy of the quantified uncertainties using the developed computational capabilities in MOOSE. Then, the problem of quantifying the uncertainties in TRI-Structural isOtropic (TRISO) fuel silver release is addressed. For the first time, the uncertainties arising from the TRISO Fission Gas Release (FGR) model due to model inadequacy and experimental noise are quantified. Also, the Bayesian capabilities are applied to the calibration of the MATPRO creep model, a widely used model in several fuel assessment cases. The impact of the prediction uncertainties in the MATPRO model on the fuel cladding behavior as part of the TRIBULATION assessment case (which is an integral effects case) is investigated. This report concludes with a discussion on the future work for the UQ for computational models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Development of a U-19Pu-10Zr fuel performance benchmark case based on the IFR-1 experiment

Metallic nuclear fuels are subject to research and development for use in advanced reactors. Robust, accurate metallic fuel performance models are important for the design, safety analysis, and licensing of these reactors. However, metallic fuel performance models require additional development; they are not as mature as UO 2 fuel performance models. A benchmark case based on the IFR-1 experiment was developed to better gauge the accuracy of existing models, identify models for high-priority development, and potentially quantify any future improvements made by further model development.This work collected publicly available information on the IFR-1 experiment and used it to develop the benchmark case. Fuel behavior during the IFR-1 irradiation was simulated by using the fuel performance code BISON, and the predicted results were compared with postirradiation examination data from the IFR-1 experiment. Furthermore, a sensitivity study and tuning studies were performed as a preliminary investigation into the causes of inaccurate temperature and dimensional change predictions.The benchmark predicted reasonably accurate values for the burnup and fission gas release. There was error in the predicted temperatures, which could be explained by uncertainty in the input parameters and legacy temperatures. BISON over-predicted dimensional changes in the fuel and cladding. The sensitivity study showed that the dimensional changes were most sensitive to the fuel swelling anisotropy and the cladding void swelling model. Future benchmark and model development should focus on cladding swelling behaviors to improve dimensional change predictions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Early detection of critical material degradation by means of electromagnetic multi-parametric NDE

With an increasing number of power plants operated in excess of their original design service life an early recognition of critical material degradation in components will gain importance. Many years of reactor safety research allowed for the identification and development of electromagnetic NDE methods which detect precursors of imminent damage with high sensitivity, at elevated temperatures and in a radiation environment. Regarding low-alloy heat-resistant steel grade WB 36 (1.6368, 15NiCuMoNb5), effects of thermal and thermo-mechanical aging on mechanical-technological properties and several micromagnetic parameters have been thoroughly studied. In particular knowledge regarding the process of copper precipitation and its acceleration under thermo-mechanical load has been enhanced. Whilst the Cu-rich WB 36 steel is an excellent model material to study and understand aging effects related to neutron radiation without the challenge of handling radioactive specimens in a hot cell, actually neutron-irradiated reactor pressure vessel materials were investigated as well. The neutron fluence experienced and the resulting shift of the ductile-brittle transition temperature were determined electromagnetically, and it was shown that weld and base material can be distinguished from the cladded side of the RPV wall. Low-cycle fatigue of the austenitic stainless steel AISI 347 (1.4550, X6CrNiNb18-10) has been characterized with electromagnetic acoustic transducers (EMATs) at temperatures of up to 300 °C. Time-of-flight and amplitude of the transmitted ultrasound signal were evaluated against the number of load cycles applied and observed as an indication of the imminent material failure significantly earlier than monitoring stresses or strains.

36 MATERIALS SCIENCE↗