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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

THE USA’S ADVANCED REACTOR TECHNOLOGIES (ART) GRAPHITE R&D PROGRAM

The USA DOE Advanced Reactor Technologies (ART) graphite R&D program supporting HTR design is one of the longest running nuclear graphite R&D programs. Significant progress has been made in several areas of research within this extensive program including unirraidated and irradiated testing of nuclear graphite, oxidation results and modeling, fracture behavior, irradiation damage studies, and several international collaboration studies. The latest results in these research areas as well as a discussion of a new direction in nuclear graphite irradiation for the USA program will be presented. Recently, the USA made a decision to support moderate to high dose irradiation of nuclear graphite (0.5 to 15 dpa). This will provide irradiation data for graphite HTR core components up to 15 dpa for numerous nuclear graphite grades. The irradiation plan and a tentative schedule for this new irradiation direction will be presented in detail.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Modular fabrication and characterization of complex silicon carbide composite structures Advanced Reactor Technologies (ART) Research Final Report (Feb 2015 – May 2017)

Advanced ceramic materials exhibit properties that enable safety and fuel cycle efficiency improvements in advanced nuclear reactors. In order to fully exploit these desirable properties, new processing techniques are required to produce the complex geometries inherent to nuclear fuel assemblies and support structures. Through this project, the state of complex SiC-SiC composite fabrication for nuclear components has advanced significantly. New methods to produce complex SiC-SiC composite structures have been demonstrated in the form factors needed for in-core structural components in advanced high temperature nuclear reactors. Advanced characterization techniques have been employed to demonstrate that these complex SiC-SiC composite structures provide the strength, toughness and hermeticity required for service in harsh reactor conditions. The complex structures produced in this project represent a significant step forward in leveraging the excellent high temperature strength, resistance to neutron induced damage, and low neutron cross section of silicon carbide in nuclear applications.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

AGR-5/6/7 Fuel Fabrication Report

The U.S. Department of Energy Office of Nuclear Energy (DOE NE) and the Idaho National Laboratory (INL) Advanced Reactor Technologies (ART) Advanced Gas Reactor (AGR) Fuel Development and Qualification program (referred to as AGR Fuel program hereafter) are pursuing qualification of tristructural isotropic (TRISO) coated particle fuel for use in high temperature gas cooled reactors (HTGRs). The AGR Fuel program was established to provide a fuel qualification data set in support of the licensing and operation of an HTGR. BWX Technologies Nuclear Operations Group (BWXT-NOG) was subcontracted to fabricate the fuel for the AGR program. Several investments and innovations were realized in preparation to fabricate fuel for the AGR-5/6/7 irradiation experiments that brought fuel fabrication fully out of the laboratory and into engineering-scale operations. These included: • Increased the kernel fabrication line capacity and uniformity • Upgraded ancillary support equipment and processes for the tristructural isotropic (TRISO) coating furnace • Demonstrated efficient production of the matrix precursor powder by dry jet milling of co mingled components • Demonstrated an engineering-scale method for quick and efficient overcoating TRISO particles with the matrix precursor • Demonstrated an automated, multi cavity compacting system with a volumetric feed system • Demonstrated a combined-cycle thermal treatment furnace These changes increased production rates of some of these processes by an order of magnitude or more while eliminating the use of flammable solvents, multiple grinding and sorting operations, and the weighing out of individual die charges. Three fuel kernel lots were fabricated for production of the fuel for AGR-5/6/7. The initial lot (J52R-16-39316) was certified to fuel specifications but was not used because the kernels had a high fraction of internal fissures that caused an unacceptable fraction of the kernels to fragment when charged to the coating furnace where the TRISO coating would be deposited. Fragmented kernels increased the dispersed uranium in the particles and produced a worrisome fraction of dimpled particles with an elevated probability of in-pile failure. After some efforts to identify the cause of the fissure formation, two additional lots were produced with much lower fissure fractions, J52R-16-69317 and 69318. The latter kernel lot was a backup to the first and was not needed. Multiple kernel batches were composited to form each of the lots so as to simulate a commercial-scale operation where kernel batches would also be composited. Multiple TRISO coating runs were performed and the product characterized so that several could be composited into a TRISO lot. TRISO lot J52R-16-98005 conformed to all fuel specifications except the mean outer pyrocarbon (OPyC) layer thickness was thinner than specified. Furthermore, it was determined that the TRISO lot had a dispersed uranium fraction (DUF) that might result in the compacts not meeting the DUF specification. A review of the role of the OPyC layer and consequences of the DUF by the Technical Coordination Team and INL concluded that the fuel was acceptable for use in the AGR-5/6/7 irradiation experiment. The TRISO particles were overcoated with the matrix precursor that had been produced in a jet-milling operation. The overcoating was performed in equipment originally designed to coat pharmaceuticals. The overcoating process performed well; producing highly spherical and uniform overcoats requiring little upgrading and no recycle or rework. TRISO particles were overcoated with the matrix precursor to achieve nominal volumetric packing fractions (PFs) of TRISO particles of 25% and 40% for the irradiation experiments. The 40% PF compacts occupy the first and fifth test capsule in the test train while the inner three capsules are loaded with 25% PF compacts. The resinated graphite matrix precursor powder was a derivative of the German A3-27 matrix formulation, which differs from previous AGR irradiation campaigns that used an A3-3 formulation. Jet milling of the matrix powder precursor produced a finer mean graphite particle size than the milling operations used for the A3-3 matrix powder precursor. Changes made in the matrix formula and equipment yielded compacts with significantly higher matrix density than was attained in previous AGR irradiation campaigns. The changes in the matrix formulation and the means of milling the powders also complicated resolution of the three fuel compact defect fractions, DUF, exposed kernel fraction (EKF), and the silicon carbide defect fraction (SDF). Characterization data from BWXT-NOG had some anomalous results, so samples of the fuel compacts and overcoated TRISO particles were also analyzed by Oak Ridge National Laboratory (ORNL) to ensure that the defect fractions were accurately characterized.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

STATUS OF TRISO FUEL IRRADIATIONS IN THE ADVANCED TEST REACTOR SUPPORTING HIGH-TEMPERATURE GAS-COOLED REACTOR DESIGNS

The United States Department of Energy’s Advanced Reactor Technologies (ART) Advanced Gas Reactor (AGR) Fuel Development and Qualification Program is irradiating up to seven low enriched uranium (LEU) tri-isotopic (TRISO) particle fuel (in compact form) experiments in the Advanced Test Reactor (ATR) located at the Idaho National Laboratory (INL). These irradiations and fuel development are being accomplished to support development of the next generation reactors in the United States. The experiments will be irradiated over the next several years to demonstrate and qualify new TRISO coated particle fuel for use in high temperature gas reactors. The goals of the experiments are to provide irradiation performance data to support fuel process development, to qualify fuel for normal operating conditions, to support development and validation of fuel performance and fission product transport models and codes, and to provide irradiated fuel and materials for post irradiation examination (PIE) and safety testing. The experiments, which will each consist of several independent capsules, will be irradiated in an inert sweep gas atmosphere with individual on-line temperature monitoring and control of each capsule. The sweep gas will also have on-line fission product monitoring on its effluent to track performance of the fuel in each individual capsule during irradiation. The first experiment (designated AGR-1) started irradiation in December 2006 and was completed in November 2009. The second experiment (AGR-2) started irradiation in June 2010 and completed in October 2013. The third and fourth experiments have been combined into a single experiment designated (AGR-3/4), which started its irradiation in December 2011 and completed in April 2014. Since the purpose of this experiment was to provide data on fission product migration and retention in the NGNP reactor, the design of this experiment was significantly different from the first two experiments, though the control and monitoring systems are very similar. The final experiment, AGR-5/6/7, is scheduled to begin irradiation in early summer 2017.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Initial Observations from AGR 5/6/7 Capsule 1

The fourth and final irradiation experiment in the Advanced Reactor Technologies (ART) Advanced Gas Reactor (AGR) fuel development and qualification program is designated as AGR-5/6/7. Data collected from the fabrication, irradiation, and post-irradiation examination (PIE) of this tristructural isotropic (TRISO) fuel are intended to serve as the primary data set for the qualification of this fuel for use in high-temperature gas-cooled reactors (INL 2021, Collin 2018b). However, data collected from the three preceding irradiations (i.e., AGR-1, AGR-2, and AGR-3/4) may also be used to supplement data collected from AGR-5/6/7. All components of the AGR-5/6/7 fuel (i.e., UCO kernels, TRISO coatings, and fuel compacts) were produced on an engineering scale at BWXT (Lynchburg, Virginia USA) according to the fuel specification (Marshall 2017). This fuel was irradiated in the northeast flux trap (NEFT) at the Advanced Test Reactor (ATR) at Idaho national Laboratory (INL) from February 16, 2018 to July 22, 2020 (Pham et al. 2021). Measurements in the fission product monitoring system (FPMS) indicated unexpected and significant numbers of failures of TRISO particles in Capsule 1 near the end of the sixth irradiation cycle (ATR Cycle 166A). In the fourth cycle (ATR Cycle 164B) and beyond, the sweep gas flow became very low (presumably from degradation of the capsule gas outlet line via an unidentified mechanism), and the program deliberately isolated Capsule 1 from gas flow periodically. In later cycles, attempts to reestablish any kind of flow in Capsule 1 were unsuccessful. With little or no flow through Capsule 1, FPMS measurements and enumerations of failed particles in Capsule 1 were difficult or impossible as was the ability to control the helium/neon gas mixture used for temperature control. Gas flows and fission gas activity in the effluent gas from the other AGR-5/6/7 capsules were also impacted by the Capsule 1 gas flow issues and the large increase in fission gas released from the Capsule 1.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Advanced Materials Program Summary

Advanced Reactor Technologies (ART) Advanced Materials Program: Provide material solutions to enable design, construction, and operation of licensable advanced reactors Including Gas-cooled Reactors, Fast Reactors, Molten Salt Reactors (solid or liquid fuel) Could be of modular design, and from 350 to 1 Mwe Conduct developmental R&D on structural materials that are best addressed by the national program Integrate program-directed work at national labs & universities and collaboration with international partners to address advanced reactor developer needs Provide qualification data (to NQA-1 or equivalent) on structural materials and develop & validate improved high temperature design methodology Utilize consensus standards organizations when appropriate (e.g., ASME, ASTM, etc.) Target resolution of issues needed for near to mid-term deployment of advanced reactors

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Report on Year-3 of Water NSTF Matrix Testing: Two-Phase Parametric Test Series

The Natural convection Shutdown heat removal Test Facility (NSTF) is large scale test facility constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactor concepts. With support from the Department of Energy (DOE) offices of Advanced Reactor Technologies (ART) and Advanced Reactors Regulatory Development (RD), this facility reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems. Since the facility also retains all aspects common to a fundamental boiling water thermosiphon, the generated experimental data sets are well poised to advance the understanding of fundamental natural circulation boiling and two-phase flow phenomena.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

PRELIMINARY RESULTS OF THE AGC-4 IRRADIATION IN THE ADVANCED TEST REACTOR AND DESIGN OF AGC-5 (HTR16-18469)

The United States Department of Energy’s Advanced Reactor Technologies (ART) Program will irradiate up to six nuclear graphite creep experiments in the Advanced Test Reactor (ATR) located at the Idaho National Laboratory (INL). The graphite experiments are being irradiated over an approximate eight year period to support development of a graphite irradiation performance data base on the new nuclear grade graphites now available for use in high temperature gas reactors. The goals of the irradiation experiments are to obtain irradiation performance data, including irradiation creep, at different temperatures and loading conditions to support design of the Very High Temperature Gas Reactor (VHTR), as well as other future gas reactors. The experiments each consist of a single capsule that contain six stacks of graphite specimens, with half of the graphite specimens in each stack under a compressive load, while the other half of the specimens are not be subjected to a compressive load during irradiation. The six stacks have differing compressive loads applied to the top half of diametrically opposite pairs of specimen stacks. A seventh specimen stack in the center of the capsule does not have a compressive load. The specimens are being irradiated in an inert sweep gas atmosphere with on-line temperature and compressive load monitoring and control. There are also samples taken of the sweep gas effluent to measure any oxidation or off-gassing of the specimens that may occur during initial start-up of the experiment. The first experiment, AGC-1, started its irradiation in September 2009, and the irradiation was completed in January 2011. The second experiment, AGC-2, started its irradiation in April 2011 and completed its irradiation in May 2012. The third experiment, AGC-3, started its irradiation in late November 2012 and completed in the April of 2014. AGC-4 is currently being irradiated in the ATR. This paper will briefly discuss the preliminary irradiation results of the AGC-4 experiment, as well as the design of AGC-5.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

PIE on Safety-Tested Loose Particles from Irradiated Compact 4-4-2

Post-irradiation examination (PIE) is being performed in support of tristructural isotropic (TRISO) coated particle fuel development and qualification for High Temperature Gas-cooled Reactors (HTGRs). This work is sponsored by the Department of Energy Office of Nuclear Energy (DOE-NE) through the Advanced Reactor Technologies (ART) Office under the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program. The AGR-1 experiment was the first in a series of TRISO fuel irradiation tests initiated in 2006. The AGR-1 TRISO particles and fuel compacts were fabricated at Oak Ridge National Laboratory (ORNL) in 2006 using laboratory-scale equipment and irradiated for 3 years in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) to demonstrate and evaluate fuel performance under HTGR irradiation conditions. Post-irradiation examination was performed at INL and ORNL to study how the fuel behaved during irradiation, and to test fuel performance during exposure to elevated temperatures at or above temperatures that could occur during a depressurized conduction cooldown event. This report summarizes safety testing and post-safety testing PIE conducted at ORNL on loose particles extracted from irradiated AGR-1 Compact 4-4-2.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗