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DOE OSTI2023

Thermo-Hydro-Mechanical Modeling of Brine Migration in a Heated Borehole Test in Bedded Salt

Abstract This research paper focuses on the thermo-hydro-mechanical (THM) modeling of brine migration in a heated borehole test conducted as part of the ongoing Brine Availability Test in Salt (BATS) at the Waste Isolation Pilot Plant (WIPP) in New Mexico. It is a component of the international collaboration project DECOVALEX-2023 (DEvelopment of COupled models and their VALidation against EXperiments), which aims to understand the THM processes governing brine flow in heated rock salt repositories through collaborative analysis by multiple research teams. Using the TOUGH–FLAC simulator, THM simulations were performed and compared with data from the BATS phase 1a. This experiment involved two identical horizontal-borehole arrays, one heated and one serving as a control, both equipped with sensor arrays. Analysis of measurements revealed water flow rate surges during heater power transitions, with the highest jump observed during cooling. Acoustic emission activity exhibited distinct patterns in response to heater power changes, suggesting that damage to rock salt is particularly pronounced during the cooling phase. The THM simulations successfully captured these phenomena, highlighting the significance of thermal effects, brine migration, and mechanical behavior in predicting brine availability in heated and damaged rock salt. Our modeling also revealed the critical interplay between heating and cooling-induced damage and its influence on flow properties, particularly affecting brine inflow estimation. Notably, we found that cooling-induced brine inflow spikes result from increased permeability due to tensile dilatancy. These findings have important implications for the development of robust containment strategies and enhance our understanding of the complex processes involved in repository performance.

58 GEOSCIENCES↗

DOE OSTI2021

Characterization of Tank 9H Dissolution Batches in Support of Tank Closure Cesium Removal (TCCR) 1A Batch 1 Preparations

Savannah River Remediation (SRR) is currently preparing the first batch of material to be processed through the Tank Closure Cesium Removal (TCCR) 1A system. The feed for TCCR 1A will consist of dissolved saltcake from Tank 9H. Two batches of salt (Batch 1A and Batch 1B) have been dissolved in Tank 9H and subsequently transferred to Tank 10H to prepare Batch 1 for TCCR 1A. Savannah River National Laboratory (SRNL) received samples from each batch of dissolved salt prior to transfer for characterization. SRNL received both a surface and a variable depth sample from Batches 1A and 1B. In both cases no solids were observed in the surface sample, but were observed in the depth sample. For Batch 1A the variable depth sample was only slightly cloudy, while for Batch 1B the variable depth sample contained a significant amount (10.14 wt%) of solids. The solids were determined to be primarily aluminum containing phases, with only a small fraction (0.22 wt%) being sludge solids. In general, the samples from Batch 1A were more concentrated salt solutions than Batch 1B, with sodium concentrations of 8.53 and 8.57 M for the surface and filtered depth samples in Batch 1A, respectively. The sodium concentrations in Batch 1B samples ranged from 4.27 M for the surface sample to 7.57 M for the depth sample filtrate, indicating some stratification within the tank. The 137 Cs activity as well as the total Cs concentration in the filtered Batch 1A depth sample were approximately double the activity and concentration measured in the filtrate from the Batch 1B depth sample. The total Cs concentration in the Batch 1A depth sample filtrate was 22.4 mg/L, while for the Batch 1B depth sample filtrate the total Cs concentration was calculated to be 12.0 mg/L. These Cs concentrations are significantly higher than was measured in Batches 1-3 from Tank 10H dissolved saltcake which was previously processed through the original TCCR unit.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRSDate not supplied

Integrated Bosch Process System Models for In-Situ Oxygen and Carbon Production

In-Situ Resource Utilization (ISRU) technology is a vital component to NASA’s mission of a sustainable presence on the Moon and Mars. Local resources can be leveraged to reduce resupply frequency and mass. Elements of the Bosch process, combined with the carbothermal reduction process, can produce oxygen on the lunar surface with minimal consumables. The Bosch process can also produce oxygen on the Martian surface by using the CO 2 -rich environment. Between both systems, adsorption pump, solar thermal energy, carbon formation reactor, and water recovery subsystems are modeled and integrated to create a functional model in MATLAB software. The model is used to simulate performance of the system and reduce mass, power, and volume requirements. This integrated system model provides a tool to scale ISRU technologies for oxygen and carbon production. The MATLAB model is created by developing a system of independent subsystem models that are solved for their quasi-steady state values which can be integrated with respect to time to determine the change in current states. A flexible time stepping method is used to ensure a high level of accuracy during periods of rapid change while still making use of a simple explicit integration method. The flexible time step is calculated for each independent subsystem and the minimum value from those is used as the overall time step. A flexible time step is calculated by dividing a resolution value, or the maximum change per time step, by the variables current rate of change. The maximum value from all points in space is used for subsystem models that contain multiple values. The process is done for every variable that is being monitored in each subsystem and the global minimum is used as that iteration’s timestep. Several assumptions used in the MATLAB model for fluid flow dynamics, such as 1-D gas flow through the sorption pump, are supported by modeling in Ansys Fluent software. The Lunar oxygen production system is outlined in Fig. 1. The carbothermal reduction subsystem uses solar energy to heat a mixture of lunar regolith and carbon powder to produce carbon monoxide. To begin, the carbon monoxide feeds to the modified Bosch subsystem along with hydrogen gas. The reactants then enter the carbon formation reactor where water and carbon powder are produced. Solar thermal energy is used to add energy to the reactor, but waste heat from the carbothermal process is another potential heat source. The water is collected and electrolyzed to produce hydrogen which reenters the Bosch subsystem, and the oxygen is stored for downstream use. The carbon powder is collected and feeds back into the carbothermal subsystem. The Martian oxygen production system uses the full Bosch process and is outlined in Fig 2. A CO 2 adsorption pump thermally cycles to scrub and pressurize CO 2 from the environment. Along with an initial supply of hydrogen, the reactants enter the Reverse Water Gas Shift Reactor (RWGSR) which produces carbon monoxide and water. Carbon monoxide and unreacted hydrogen enter the carbon formation reactor to produce water and carbon powder. The water is collected from both reactors and electrolyzed to reintroduce hydrogen and store oxygen for propellant production or life support. Carbon is removed from the carbon formation reactor and stored. The adsorption pump utilizes rapid cycle temperature swings within a stack of zeolite coated surfaces. The subsystem model solves 1-D quasi-steady conservation laws of the quasi-steady form, shown in Eq. 1, for the gas stream and heat exchange liquid to predict performance parameters such as breakthrough capacity and optimum cycle time. The source term S is used to capture interactions between the fluid flows and the sorbent. A quasi-steady-state scheme is used where no time derivatives appear in the governing equations, except for those in the source terms. This results in an autonomous system, where ∂F/∂x = ƒ(F). The fluxes F are provided at the inlet, and an explicit method is used to solve for the spatial distribution of F. The heat and mass flows to the sorbent are then extracted from the source terms. These flows are numerically integrated to produce a 1-D solution for the system’s state as a function of both time and space. The body of the adsorption pump is separated into two semi-independent models: the heat exchanger fluid flow and gas flow through the zeolite coated surfaces. Both models are solved using the above-described method to find a 1-D solution as a function of space and interact only once a timestep is taken. The interaction point is the sorbent through which all heat transfer between the two models must occur. Sorbent mass adsorption is calculated using the Lagergren model, shown in Eq. 2, where the transfer coefficient, λ D , is found by solving a system of nondimensionalized equations derived by using the heat and mass transfer analogy for transport phenomena. Using Grade 544 Type 13X zeolite as the sorbent material, the equilibrium concentration, θ eq , is calculated using the k-site Langmuir isotherm and fit parameters. Additionally, the enthalpy of adsorption used in the model is computed by interpolation of available data [1]. The subsystem model was validated using the Rapid Cycle Temperature Swing Adsorption (RC-TSA) pump. The solar thermal energy subsystem focuses on a solar concentrator concept with a heat exchanger to heat the reactants before entering the carbon formation reactor. The subsystem model assumes a fixed solar flux and reflector efficiency to calculate the reactant temperature given the incoming temperature, pressure, and exchanger geometry. The receiver is a custom manufactured series of copper blocks with serpentine channels to increase its surface area and the residence time of the reactants to heat up to 550 °C. The subsystem model was validated using a heat exchanger developed at NASA Glenn Research Center (GRC). The solar thermal energy subsystem focuses on a solar concentrator concept with a heat exchanger to heat the reactants before entering the carbon formation reactor. The subsystem model assumes a fixed solar flux and reflector efficiency to calculate the reactant temperature given the incoming temperature, pressure, and exchanger geometry. The receiver is a custom manufactured series of copper blocks with serpentine channels to increase its surface area and the residence time of the reactants to heat up to 550 °C. The subsystem model was validated using a heat exchanger developed at NASA Glenn Research Center (GRC).

In situ Resource Utilization↗

DOE OSTI2016

Microbial Oxidation of Hg(0) - Its Effect on Hg Stable Isotope Fractionation and Methylmercury Production

Mercury (Hg) associated with mixed waste generated by nuclear weapons manufacturing has contaminated vast areas of the Oak Ridge Reservation (ORR). Neurotoxic methylmercury (MeHg) has been formed from the inorganic Hg wastes discharged into headwaters of East Fork Poplar Creek (EFPC). Thus, understanding the processes and mechanisms that lead to Hg methylation along the flow path of EFPC is critical to predicting the impacts of the contamination and the design of remedial action at the ORR. In part I of our project, we investigated Hg(0) oxidation and methylation by anaerobic bacteria. We discovered that the anaerobic bacterium Desulfovibrio desulfuricans ND132 can oxidize elemental mercury [Hg(0)]. When provided with dissolved elemental mercury, D. desulfuricans ND132 converts Hg(0) to Hg(II) and neurotoxic methylmercury [MeHg]. We also demonstrated that diverse species of subsurface bacteria oxidizes dissolved elemental mercury under anoxic conditions. The obligate anaerobic bacterium Geothrix fermentans H5, and the facultative anaerobic bacteria Shewanella oneidensis MR-1 and Cupriavidus metallidurans AE104 can oxidize Hg(0) to Hg(II) under anaerobic conditions. In part II of our project, we established anaerobic enrichment cultures and obtained new bacterial strains from the DOE Oak Ridge site. We isolated three new bacterial strains from subsurface sediments collected from Oak Ridge. These isolates are Bradyrhizobium sp. strain FRC01, Clostridium sp. strain FGH, and a novel Negativicutes strain RU4. Strain RU4 is a completely new genus and species of bacteria. We also demonstrated that syntrophic interactions between fermentative bacteria and sulfate-reducing bacteria in Oak Ridge saprolite mediate iron reduction via multiple mechanisms. Finally, we tested the impact of Hg on denitrification in nitrate reducing enrichment cultures derived from subsurface sediments from the Oak Ridge site, where nitrate is a major contaminant. We showed that there is an inverse relationship between Hg concentrations and rates of denitrification in enrichment cultures. In part III of our project, we examined in more detail the effects of microbial interactions on Hg transformations. We discovered that both sulfate reducing and iron reducing bacteria coexist in freshwater sediments and both microbial groups contribute to mercury methylation. We showed that mercury methylation by sulfate reducing and iron reducing bacteria are temporally and spatially separated processes. We also discovered that methanogens can methylate mercury. We showed that Methanospirillum hungatei JF-1 methylated Hg at comparable rates, but with higher yields, than those observed for sulfate-reducing bacteria and iron-reducing bacteria. Finally, we demonstrated that syntrophic interactions between different microbial groups increase mercury methylation rates. We showed that Hg methylation rates are stimulated via inter-species hydrogen and acetate transfer (i) from sulfate-reducing bacteria to methanogens and (ii) from fermenters to the sulfate-reducing bacteria. In part IV of the project, we studied Hg bioavailability and Hg isotope fractionation. We demonstrated that thiol-bound Hg is bioavailable to mercury resistant bacteria. We found that uptake of Hg from Hg-glutathione and Hg-cysteine complexes does not require functioning glutathione and cystine/cysteine transport systems. We demonstrated that a wide range of methylmercury complexes (e.g. MeHgOH, MeHg-cysteine, and MeHg-glutathione) are bioavailable to mercury resistant bacteria. The rate of MeHg demethylation varies more between different species of mercury resistant bacteria than among MeHg complexes. We showed that microbial demethylation of MeHg depends more on the species of microorganism than on the types and relative concentrations of thiols or other MeHg ligands present. Finally, we demonstrated that Hg methylation by Geobacter sulfurreducens PCA and Desulfovibrio desulfuricans ND132 imparts mass-dependent discrimination against 202Hg relative to 198Hg. G. sulfurreducens PCA and D. desulfuricans ND132 have similar kinetic reactant/product Hg fractionation factors. Using the Hg isotope data, we showed that there are multiple intra- and/or extracellular pools provide substrate inorganic Hg for methylation.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2019

Corrosion Monitoring in an Irradiated/Used Fuel Dry Storage Container - 19193

A corrosion monitoring system was developed to monitor the corrosion behaviour of steel components embedded in the high density concrete of a Dry Storage Container (DSC). The DSC is a free-standing reinforced concrete container, with an inner carbon-steel liner and an outer carbon-steel shell, for the storage, on-site transfer and off-site transportation of irradiated Candu fuel. Normally, uncontaminated concrete is benign with regards to embedded steel components because high alkalinity in the concrete leads to formation of a passive film on the steel surface, which prevents excessive metal loss. However, corrosion of steel in concrete may be promoted by one or more of local concentration of chloride ions or local loss of alkalinity. For the DSC, it is recognized that the above mechanism(s) are unlikely, however, if any did exist, the corrosion mechanisms that could then occur would include corrosion of carbon steel components and stress corrosion cracking of 304L stainless steel components. In order to confirm that these unlikely events are not occurring, Ontario Power Generation has undertaken a project to investigate the corrosion behaviour of metallic components embedded in the DSC's high density concrete. A corrosion monitoring system that can be installed within the concrete space of a DSC was designed and installed to monitor changes in temperature, corrosion potential, corrosion rate, and electrochemical noise. The corrosion monitoring system was commissioned in July 2012, followed by the commencement of monitoring and measurements. The corrosion data, collected for the three years from year 2012 to 2015, were analyzed. It was concluded that the corrosion rates of both carbon steel and stainless steel within the DSC are very low and consistent with the intended minimum operational life of the DSC. The monitoring system as a whole has allowed a systematic and long term judgement regarding the conditions within the DSCs. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Computational Safeguards Analysis of PWR Spent Nuclear Fuel in Dry Storage - 17435

The master plan for spent nuclear fuel (SNF) management in Korea recently adopted by Korean atomic energy promotion council. According to the master plan, the detailed practical and R and D strategies for SNF transferring, storage and disposal should be determined in the near future. Besides, it is also necessary to make plan how to secure SNF at each step in terms of nuclear safeguards, safety, security and nonproliferation. Several nondestructive analysis (NDA) techniques have been studied for assuring the safety of SNF in PWR methods. Obviously, gamma-ray is most dominant radiation emitted by SNF so several gamma-ray measurement methods have been developed and applied for the purpose of SNF monitoring. Those methods, however, suffer from a lack of nuclear data and interfering background radiation. To date, several neutron measurement methods have been developed as a solution to the problem of gamma-ray methods. Korea Institute of Nuclear Nonproliferation and Control (KINAC) currently develops a new novel technique of fast neutron detection for spent fuel monitoring at dry spent fuel storage facilities. As the first step, a computational program has been developed in order to evaluate neutron flux on the surface of PWR dry storage cask and study for some potential sabotage events. Typically, neutron flux on the surface of dry storage cask can be evaluated via two steps. The source term, based on burn-up rate of SNF, its cooling time and others related to operation condition at nuclear power plants, can be firstly defined by ORIGEN code. The surface flux can be then evaluated via MCNP code. These two separated steps are complicated and time consuming so KINAC developed a new algorithm and user-interface, coupled ORIGEN and MCNP. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

additive manufacturing↗

DOE OSTI2020

Comparison of Extended and Accelerated VOG Tests

The reprocessing of used nuclear fuel would release volatile radionuclides into the off-gas streams of a processing plant, including ¹²⁹I. The dissolver off-gas and more dilute vessel off-gas streams (VOG) must both be targeted when mitigating ¹²⁹I environmental release because each contains some amount of iodine. Iodine-129 will likely be found as elemental iodine (I₂) and methyl iodide (CH₃I) in these off-gas streams. Reduced silver-exchanged mordenite (AgZ or Ag⁰Z) has been investigated as a potential sorbent for iodine abatement and is studied here under prototypic VOG conditions. Because of the relatively low iodine abundance and high flow rates of the VOG, total iodine concentrations are expected to be in the parts per billion range. Thus, VOG experiments need to run for extended durations at low concentrations to reach sorbent saturation. Because the sorbent will be exposed to oxidizing gas streams for extended periods of time, aging effects and sorbent degradation need to be considered when designing a sorbent-based abatement system. Three sets of experiments were performed with the aim of determining how the adsorption of iodine by AgZ is affected by differing test durations and gas compositions. The first tested the capacity of sorbent aged for 8 months under a humid air stream. The second tested differences in sorbent capacity and mass transfer zone (MTZ) length during high-concentration (1200 ppb v ) CH₃I loading in a humid nitrogen gas (N₂) stream and a humid air gas stream over 28 days. The third tested sorbent capacity and MTZ length during low concentration (< 200 ppb v ) CH₃I and I₂ loading in a humid air stream over 9 months. The results of these tests suggest that AgZ capacity drops by ~50% after 1 month of aging, by ~60% after 2 months of aging, and then does not continue to decrease significantly at up to 8 months of aging. One-month aging tests that compared N₂ and air as the gas stream diluent resulted in similar maximum loading capacities and overall loading curves, indicating that the effects of aging cannot be mitigated by avoiding air as the balance gas. The 9-month extended VOG tests did not result in clear sorbent saturation at the inlet, but it can be inferred using an assumption of a maximum capacity of 45 mg I/g AgZ. Applying this assumption, then the MTZ of CH₃I is 12.8 cm, and the MTZ of I₂ is 12.4 cm. These results are similar to previous tests. Comparisons to tests completed at Idaho National Laboratory suggest that the CH₃I MTZ may be dependent on concentration. Future work should re-evaluate the design of the VOG iodine capture system with this updated data and should seek to understand fundamental characteristics of CH₃I adsorption by AgZ, such as the effect of concentration, gas velocity, and gas composition.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

A Comprehensive Review of Working Fluids for High-Temperature Heat Pumps: History, Selection, and Evaluation

High-temperature heat pumps (HTHPs) are essential for enhancing energy efficiency across various industrial applications, especially in terms of integrating with renewable energy sources and recovering waste heat. This article thoroughly investigates suitable working fluids for HTHPs, highlighting the evolution from traditional refrigerants to contemporary alternatives with low global warming potential (GWP). It proposes comprehensive selection criteria for these working fluids, pre-selects low-GWP working fluids, and outlines a screening methodology. The pre-selected low-GWP working fluids are evaluated for applications in three typical industrial scenarios involving HTHPs. Furthermore, this study demonstrates that regulatory compliance and environmental impacts significantly influence the development of next-generation refrigerants. The choice of working fluids is closely linked to the types of vapor compression cycles, tailored to the specific industrial applications for HTHPs. This study emphasizes areas for future research, including the development of innovative working fluids; integrated strategies that account for performance, safety, and regulatory standards; alignment of HTHP components; exploration of natural working fluids; and broadening the applications of existing working fluids.

Compression↗

DOE OSTI2019

Iodine Capture and Mechanical Stability of Modified Silver-Functionalized Silica Aerogel

Silver-functionalized silica aerogel (AgAero) is a material proposed for use in the removal of iodine from the off-gas streams arising from nuclear fuel reprocessing. This material was developed by Pacific Northwest National Laboratory and has been shown to adsorb up to 300 mg of iodine per gram of AgAero. One of the challenges noted for AgAero as an iodine sorbent is its mechanical stability. Its initial particle size is >0.85 mm, but previous testing has shown that extended exposure to heated gas streams results in the degradation of the material such that the sorbent bed is compacted with a substantial amount of fines produced. The observed mechanical degradation prompted an effort to reengineer the silica aerogel to improve the mechanical stability of the material without compromising its iodine capture characteristics. Pacific Northwest National Laboratory has modified the material with the intention of strengthening the aerogel backbone and improving mechanical durability. This reengineered material was transferred to Oak Ridge National Laboratory for extended testing to assess its mechanical durability. Modified AgAero was continuously exposed to a CH 3 I-bearing humid gas stream for 84 days. Testing was performed at 150°C with a superficial gas velocity of 10 m/min., a CH 3 I concentration of 554 ppb, and an inlet dew point of 10°C. The density of the AgAero increased by 16% during testing, and the height of the column was observed to decrease by 11%. The fines produced by the material were comparable to that of previously supplied material. Additionally, iodine loading of a thin bed of modified AgAero was performed at 150°C with a superficial gas velocity of 10 m/min. and a CH 3 I concentration of 50 ppm (balance dry air) with a total test duration of 1 week. The CH 3 I capture capacity of the reengineered material was 225 mg iodine per gram AgAero, as compared to a CH 3 I capacity of 250 mg iodine per gram AgAero for the original material. The primary data collected were visual observations, density measurements before and after testing, and the extent of column compaction during testing. Additionally, the material was tested to ensure that the iodine capacity of the material was not adversely impacted by the alternative methods used in the production of the reengineered material. Based on these criteria, no distinguishable improvements were observed between the material produced in fiscal years 2017 and 2019 and the mechanical stability of the aerogel in prototypic off-gas conditions remains a challenge to large-scale deployment.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Agro-waste shaped porous Al2O3/Ni composites: Corrosion resistance performance and artificial neural network modelling

Highlights: • Porous Al{sub 2}O{sub 3}/Ni composites were developed with agro-waste pore-forming agents. • The RH and SCB graded composites showed Ni{sub 3}Al{sub 2}SiO{sub 8} and NiAl{sub 2}O{sub 4} spinels respectively. • Superior chemical stability was demonstrated by the Al{sub 2}O{sub 3}-2Ni-RH composite. • The ANN model demonstrated a good performance with R{sup 2} value of approx. 0.99. - Abstract: In the present study, an analysis on the combined effect of nickel (Ni) reinforcement and pore former type in characterizing the corrosion behavior of composite porous alumina ceramics was performed. In order to showcase the potential of the new porous ceramics, pore-forming agents (PFAs) from rice husk (RH) and sugarcane bagasse (SCB) were used in shaping the plain and composite porous alumina samples having sample formulation of Al{sub 2}O{sub 3}-xNi-PFA; x = 0, 2, 4, 6 and 8 wt%. Results showed that the emergence of a highly stable Ni{sub 3}Al{sub 2}SiO{sub 8} spinelloid phase in the RH-graded composites enhanced their chemical stability in the corrosive mediums (10 wt% NaOH and 20 wt% H{sub 2}SO{sub 4}) relative to the plain and the corresponding SCB-graded counterparts. An artificial neural network (ANN) model has been developed for predicting the corrosion behavior of the plain and composite porous alumina ceramics based on the experimental data. The developed ANN model satisfactorily predicted the percent mass losses of the porous ceramics in strong alkali and strong acid solutions with coefficient of determination (R{sup 2}) of approximately 0.99.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Incorporation of Fines and Noble Metals into HLW Borosilicate Glass: Industrial Responses to a Challenging Issue - 13056

During the early stages of spent fuel reprocessing, the fuel rods are cut and dissolved to separate the solid metallic parts of the rods (cladding and end pieces) from the radioactive nitric acid solution containing uranium, plutonium, minor actinides and fission products (FP). This solution contains small, solid particles produced during the shearing process. These small particles, known as 'fines', are then separated from the liquid by centrifugation. At the La Hague plant in France, the fines solution is transferred to the vitrification facilities to be incorporated into borosilicate glass along with the highly radioactive FP solution. These fines are also composed of Zr, Mo and other noble metals (i.e. Ru, Pd, Rh, etc.) that are added before vitrification to the the FP solution that already contained noble metals. As noble metals has the potential to modify the glass properties (including viscosity, electrical conductivity, etc.) and to be affected by sedimentation inside the melter, their behavior in borosilicate glass has been studied in depth over the years by the AREVA and CEA teams which are now working together in the Joint Vitrification Laboratory (LCV). At La Hague, the R7 vitrification facility started operation in 1989 using induction-heated metallic melter technology and was quickly followed by the T7 vitrification facility in 1992. Incorporating the fines into glass has been a challenge since operation began, and has given rise to several R and D studies resulting in a number of technological enhancements to improve the mixing capability of the melters (multiple bubbling technology and mechanical stirring in the mid-90's). Nowadays, the incorporation of fines into R7T7 glass is well understood and process adaptations are deployed in the La Hague facilities to increase the operating flexibility of the melters. The paper will briefly describe the fines production mechanisms, give details of the resulting fines characteristics, explain how the metallic particles can influence the glass properties and challenge vitrification technologies and finally, give a rundown of the R and D efforts which have produced innovative solutions contributing to the operational excellence of AREVA's vitrification facilities in the La Hague reprocessing plant. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

2021 Report - SRNL Aging and Lifetimes program tritium aging studies on structural alloys

This report documents work performed in fiscal year 2021 at SRNL in support of the Aging and Lifetimes program. This work is part of an on-going collaboration between SRNL and SNL to understand tritium embrittlement of structural metals used in Gas Transfer System reservoirs, thereby informing lifetime assessments and predictions. In this effort, test coupons are pre-charged with tritium and allowed to age in a freezer to minimize tritium diffusion and off-gassing while allowing for born-in helium levels to systematically increase. Coupons are then removed periodically and tested to develop an understanding of how mechanical properties degrade as helium levels increase. This report summarizes test results from coupons which are in various stages of aging as they were tritium pre-charged in previous years. Tests were performed on 304L that was previously tritium pre-charged and allowed to age to nominally 300 appm helium. Specimens from this study were previously tested at 100 appm nominal helium content, and this new test point expands that study. Tensile testing of these heat treated 304L tubes (and welded tubes) aged to 100 appm helium were completed which provided a unique study of a diverse set of microstructures and yield strengths ranging from 200-800 MPa. Additionally, 304L notched and smooth tensile specimens aged to 300 appm helium were tensile tested to predetermined strains to provide for a systematic microscopy investigation of aging effects on microstructural damage in partnership with SNL. Testing was performed on 304L electron beam (EB) weld coupons as well as 21-6-9 annealed coupons that were thermally pre-charged in 2020. Tests on the EB welds were completed at 100 appm helium contents, and tests on the annealed 21-6-9 material were completed at 100, 200, and 300 appm helium. Table 0-1 provides the status of the ongoing tritium coupon aging studies. The table includes the year tritium pre-charging took place, the material, and the targeted helium concentrations (appm) for testing.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Innovative Strategies for Long-Term Monitoring of Complex Groundwater Plumes at DOE’s Legacy Sites (Workshop Report)

Most remaining Department of Energy (DOE) sites will require extended periods of institutional control, especially at complex groundwater sites where attenuation-based strategies have been implemented to facilitate closure. The current practice of monitoring—obtaining and analyzing contaminant concentration in groundwater samples at numerous wells—will account for a large portion of the projected life-cycle at these DOE sites unless a new approach is adopted. State-of-the-art technologies are being developed, including in situ sensors, geophysics, radiation mapping, numerical modeling and AI/ML. These technologies can optimize monitoring strategies in space and time, provide spatially extensive information at vulnerable regions and/or provide more continuous monitoring at lower cost. As part of DOE’s Office of Environmental Management (DOE-EM’s) efforts to advance long-term monitoring systems, an in-person/virtual hybrid workshop was hosted by Savannah River National Laboratory (SRNL) on January 24 and 25, 2023, in Augusta, Georgia. Because DOE-EM’s complex sites will eventually be transferred to DOE’s Office of Legacy Management (DOE-LM), representatives of DOE-LM were important participants in the workshop. The purpose of the workshop was to identify challenges and opportunities for deploying advanced technologies for long-term monitoring at DOE sites. The key questions during the workshop were: 1) the regulatory acceptance of replacing a process that traditionally has used laboratory sampling and analysis of groundwater samples, and 2) the application of this strategy to the southwestern arid sites that include many of the remaining DOE-EM and DOE-LM complex groundwater plumes. Characteristics common to most arid sites present both limitations and opportunities for advanced technologies. DOE-EM has funded a National Laboratory team from SRNL, Lawrence Berkeley National Laboratory (LBNL), and Pacific Northwest National Laboratory (PNNL) to establish the overarching framework of long-term monitoring by systematically combining advanced hardware and software technologies. This project is titled “Advanced Long-Term Environmental Monitoring Systems (ALTEMIS)” and is sponsored by the DOE-EM Technology Development Program. The multi-laboratory team is currently developing and testing innovative monitoring strategies, including the use of in situ groundwater sensors, geophysics, drone/satellite-based remote sensing, reactive transport modeling, and artificial intelligence/machine learning (AI/ML). The project’s demonstration testbed is at the Savannah River Site (SRS) F-Area Seepage Basins, where a well-characterized complex groundwater plume composed of uranium and other radionuclides is in the latter stages of remediation. The workshop included more than 70 participants, presentations, a field visit to F-Area, breakout working groups, and large group discussion. Participants developed recommendations on five topics: in situ sensors, spatially integrative tools, challenges to regulatory acceptance, AI/ML strategies, and transitioning sites to DOE-LM.

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DOE OSTI2013

Sensor Network Demonstration for In Situ Decommissioning - 13332

Florida International University's (FIU's) Applied Research Center is currently supporting the Department of Energy's (DOE) Environmental Management Office of D and D and Facility Engineering program. FIU is supporting DOE's initiative to improve safety, reduce technical risks, and limit uncertainty within D and D operations by identifying technologies suitable to meet specific facility D and D requirements, assessing the readiness of those technologies for field deployment, and conducting feasibility studies and large scale demonstrations of promising technologies. During FY11, FIU collaborated with Savannah River National Laboratory in the development of an experimental test site for the demonstration of multiple sensor systems for potential use in the in situ decommissioning process. In situ decommissioning is a process in which the above ground portion of a facility is dismantled and removed, and the underground portion is filled with a cementious material such as grout. In such a scenario, the question remains on how to effectively monitor the structural health of the grout (cracking, flexing, and sinking), as well as track possible migration of contaminants within and out of the grouted monolith. The right types of sensors can aid personnel in better understanding the conditions within the entombed structure. Without sensors embedded in and around the monolith, it will be very difficult to estimate structural integrity and contaminant transport. Yet, to fully utilize the appropriate sensors and the provided data, their performance and reliability must be evaluated outside a laboratory setting. To this end, a large scale experimental setup and demonstration was conducted at FIU. In order to evaluate a large suite of sensor systems, FIU personnel designed and purchased a pre-cast concrete open-top cube, which served as a mock-up of an in situ DOE decommissioned facility. The inside of the cube measures 10 ft x 10 ft x 8 ft. In order to ensure that the individual sensors would be immobilized during the grout pouring activities, a set of nine sensor racks were designed. The 270 sensors provided by Idaho National Laboratory (INL), Mississippi State University (MSU), University of Houston (UH), and University of South Carolina (USC) were secured to these racks based on predetermined locations. Once sensor racks were installed inside the test cube, connected and debugged, approximately 32 cubic yards of special grout material was used to entomb the sensors. MSU provided and demonstrated four types of fiber loop ring-down (FLR) sensors for detection of water, temperature, cracks, and movement of fluids. INL provided and demonstrated time differenced 3D electrical resistivity tomography (ERT), advanced tensiometers for moisture content, and thermocouples for temperature measurements. University of Houston provided smart aggregate (SA) sensors, which detect crack severity and water presence. An additional UH sensor system demonstrated was a Fiber Bragg Grating (FBG) fiber optic system measuring strain, presence of water, and temperature. USC provided a system which measured acoustic emissions during cracking, as well as temperature and pH sensors. All systems were connected to a Sensor Remote Access System (SRAS) data networking and collection system designed, developed and provided by FIU. The purpose of SRAS was to collect and allow download of the raw sensor data from all the sensor system, as well as allow upload of the processed data and any analysis reports and graphs. All this information was made available to the research teams via the Deactivation and Decommissioning Knowledge Management and Information Tool (D and D KM-IT). As a current research effort, FIU is performing an energy analysis, and transferring several sensor systems to a Photovoltaic (PV) System to continuously monitor energy consumption parameters and overall power demands. Also, One final component of this research is focusing on developing an integrated data network to capture, log and analyze sensor system data in near real time from a single interface. FIU personnel and DOE Fellows monitored the progress and condition of the sensors for a period of six months. During this time, the sensors recorded data pertaining to strain, compression, temperature, crack detection, moisture presence, fluid mobility, shock resistance, monolith movement, and electrical resistivity. In addition, FIU regularly observed the curing process of the grout and documented the cube condition via the nine racks of sensors. The sensors held up throughout the curing process, withstood the natural elements for six months, and monitored the integrity of the grout. The large scale experiment and demonstration conducted at FIU was the first of its kind to demonstrate the feasibility of state of the art sensors for in situ decommissioning applications. These efforts successfully measured the durability, performance, and precision of the sensors in question as well as monitored and recorded the curing process of the selected grout material under natural environmental conditions. The current energy analysis work is resulting in data on the constraints placed by some of the sensor systems on a power network that requires high reliability and low losses. In addition, a sensor system demonstration has determined that it is feasible to develop an integrated data network where data can be accessed in near real-time from all systems, thereby allowing for larger-scale integrated system testing to be performed. Information collected during the execution of this research project will aid decision makers in the identification of sensors to be used in nuclear facilities selected for in situ decommissioning. (authors)

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DOE OSTI2019

Dry Cask Shipments of ATR Spent Nuclear Fuel at INL - 19600

The High Load Charger (HLC) cask will be replacing the Advanced Test Reactor (ATR) spent fuel transfer cask that has been used at Idaho National Laboratory (INL) to wet-transfer spent ATR fuel elements from ATR to Idaho Nuclear Technology and Engineering Center (INTEC) in order to support future plans at both facilities. INTEC intends to discontinue use of the CPP-666 storage pools in compliance with the Idaho Settlement Agreement and the basins will no longer be available to store spent ATR fuel elements. In order to support the core-internals change out in 2021 for ATR, spent ATR fuel elements must be removed from the canal and shipped to INTEC. INL contractors will use the HLC cask for safe, dry transfer of spent Advanced Test Reactor (ATR) fuel elements between the ATR Complex managed by Battelle Energy Alliance, LLC and the Idaho Nuclear Technology and Engineering Center (INTEC) managed by Fluor Idaho, LLC. The HLC cask (also known as the High Load Charging Cask or High Load Charger) is a lead-shielded, stainless steel transfer container originally designed in 1954 by the Idaho Nuclear Corporation to meet the radiation and contamination controls requirements of the time for shipment of spent nuclear fuel. The cask has been modified over the years and is currently used for wet-to-dry transfers at INTEC. It is approved only for out-of-commerce transfers. The cask will arrive at the ATR where eight spent ATR fuel elements will be loaded into two, newly-designed buckets. Each bucket is a quarter section, right-cylinder shape that has four compartments. The cask will be lifted out of the ATR canal allowing most of the water to drain from the cask. Processing the 12,500 kg cask will be completed in ATR and then transported on a tractor trailer to INTEC where the loaded buckets will be removed from the cask. The loaded buckets will undergo a drying process before placing the four buckets into a canister for long-term storage in the Irradiated Fuel Storage Facility (IFSF) at INTEC. A new transportation plan that was submitted to, and approved by, the U.S. Department of Energy to provide the cask safety basis, which describes the hazard analysis and accident analysis for the cask during transport. Supporting accident analysis include criticality, thermal, dose, and drop analyses. Of particular interest for this cask was the drop analysis from which was derived the speed limit for the transport. The drop analysis addressed drops in air onto an unyielding surface and in water onto an energy-absorbing pad for the cask in the ATR facility. These analyses are typically applied as the bounding drop scenarios during transport; however, this resulted in a safety basis speed limit of 12.9 kph. In order to more accurately represent the in-transit accident scenario, LS-DYNA software was procured and the model was updated to more closely represent the potential drop heights and impact surfaces of asphalt and soil for the cask while in transit. This analysis resulted in a safety basis speed limit of 48 kph. This safety basis speed limit is more practical to implement and control. (authors)

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DOE OSTI2012

Diffusive parameters of tritiated water and uranium in chalk

The Cretaceous Chalk of North-western Europe exhibits a double porosity (matrix and fracture) providing pathways for both slow and rapid flow of water. The present study aims at understanding and predicting the contaminant transfer properties through a significant section of this formation, with a particular emphasis on diffusion. This requires to study the nature of porosity and to perform diffusion experiments in representative samples using uranium and tritiated water (HTO), respectively taken as a reactive tracer and an inert one. The diffusive parameters, i.e. the accessible porosity and the effective diffusion coefficient were determined. Additional information was obtained with mercury porosimetry, gravimetric water content, textural and mineralogical characterization. The diffusion tests performed with HTO appear to be the best method to measure the total accessible porosity in any type of porous media, especially those having large pore size distributions. Our study demonstrates that classical gravimetric water content measurements are not sensitive to the reduction in pore size as opposed to HTO diffusion tests because capillary water is not extracted by conventional gravimetric method but can still be probed by diffusion experiments. We found effective diffusion coefficients D{sub e}(U(VI)) near 4 x 10{sup -10} m{sup 2}s{sup -1}). The slower migration of U(VI) compared to HTO indicates sorption, with R{sub d}(U(VI)) from 100 to 360 mL g{sup -1}. These values are one order of magnitude larger than other determinations of the U(VI) sorption coefficient because only the matrix porosity is concerned here. The migration of U(VI) in chalk is only limited by sorption on ancillary Fe-Pb-bearing minerals. Transport of HTO and U(VI) is independent of the porosity distribution. Uranium diffusion in the chalk matrix porosity is fast enough to allow the total invasion of the pore space within characteristic time scales of the order of 1000 years. This results in a partitioning of uranium velocities in fracture flow and matrix flow proportionally to the respective fracture and matrix porosities. (authors)

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