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At least 19 records

Readiness Review of BWXT for Fabrication of AGR-5/6/7 TRISO Particles

INL readiness review assessment of BWXT readiness to commence fabrication of low-enriched TRISO coated fuel particles for the AGR-5/6/7 irradiation experiments. BWXT self-identified equipment issues preventing operation. INL identified two findings. The first was that disposition codes had not been assigned and documented on BWXT forms to ensure that off-specification materials could not be used in the fabrication of TRISO particles. The second was that chemical purity specifications were not reliably passed on to chemical suppliers, which resulted in the receipt of one acetylene cylinder with suspect impurity levels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Readiness Review of BWXT for Fabrication of AGR 5/6/7 Compacts

In support of preparations for fabricating compacts for the Advanced Gas Reactor (AGR) fuel qualification irradiation experiments (AGR-5/6/7), Idaho National Laboratory (INL) conducted a readiness review of the BWX Technology (BWXT) procedures, processes, and equipment associated with compact fabrication activities at the BWXT Nuclear Operations Group (BWXT-NOG) facility outside Lynchburg, VirginiaVA. The readiness review used quality assurance requirements taken from the American Society of Mechanical Engineers (ASME) Nuclear Quality Assurance Standard (NQA-1-2008/1a-2009) as a basis to assess readiness to start compact fabrication.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Acceptance Test Data for BWXT Coated Particle Batch 93164A Defective IPyC Fraction and Pyrocarbon Anisotropy

Coated particle fuel batch J52O-16-93164 was produced by Babcock and Wilcox Technologies (BWXT) for possible selection as fuel for the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program’s AGR-5/6/7 irradiation test in the Idaho National Laboratory (INL) Advanced Test Reactor (ATR), or may be used as demonstration production-scale coated particle fuel for other experiments. The tristructural-isotropic (TRISO) coatings were deposited in a 150-mm-diameter production-scale fluidizedbed chemical vapor deposition (CVD) furnace onto 425-μm-nominal-diameter spherical kernels from BWXT lot J52L-16-69316. Each kernel contained a mixture of 15.5%-enriched uranium carbide and uranium oxide (UCO) and was coated with four consecutive CVD layers: a ~50% dense carbon buffer layer with 100-μm-nominal thickness, a dense inner pyrolytic carbon (IPyC) layer with 40-μm-nominal thickness, a silicon carbide (SiC) layer with 35-μm-nominal thickness, and a dense outer pyrolytic carbon (OPyC) layer with 40-μm-nominal thickness. The TRISO-coated particle batch was sieved to upgrade the particles by removing over-sized and under-sized material, and the upgraded batch was designated by appending the letter A to the end of the batch number (i.e., 93164A).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Acceptance Test Data for Candidate AGR-5/6/7 TRISO Particle Batches BWXT Coater Batches 93165 93172 Defective IPyC Fraction and Pyrocarbon Anisotropy

Coated particle fuel batches J52O-16-93165, 93166, 93168, 93169, 93170, and 93172 were produced by Babcock and Wilcox Technologies (BWXT) for possible selection as fuel for the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program’s AGR-5/6/7 irradiation test in the Idaho National Laboratory (INL) Advanced Test Reactor (ATR). Some of these batches may alternately be used as demonstration coated particle fuel for other experiments. Each batch was coated in a 150-mm-diameter production-scale fluidized-bed chemical vapor deposition (CVD) furnace. Tristructural isotropic (TRISO) coatings were deposited on 425-μm-nominal-diameter spherical kernels from BWXT lot J52R-16-69317 containing a mixture of 15.5%-enriched uranium carbide and uranium oxide (UCO). The TRISO coatings consisted of four consecutive CVD layers: a ~50% dense carbon buffer layer with 100-μm-nominal thickness, a dense inner pyrolytic carbon (IPyC) layer with 40-μm-nominal thickness, a silicon carbide (SiC) layer with 35-μm-nominal thickness, and a dense outer pyrolytic carbon (OPyC) layer with 40-μmnominal thickness. The TRISO-coated particle batches were sieved to upgrade the particles by removing over-sized and under-sized material, and the upgraded batches were designated by appending the letter A to the end of the batch number (e.g., 93165A).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Acceptance Test Data for BWXT Coated Particle Batches 93172B and 93173B—Defective IPyC and Pyrocarbon Anisotropy

Coated particle batches J52O-16-93172B and J52O-16-93173B were produced by Babcock and Wilcox Technologies (BWXT) as part of the production campaign for the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program’s AGR-5/6/7 irradiation test in the Idaho National Laboratory (INL) Advanced Test Reactor (ATR), but were not used in the final fuel composite. However, these batches may be used as demonstration production-scale coated particle fuel for other experiments. Each batch was coated in a 150-mm-diameter production-scale fluidized-bed chemical vapor deposition (CVD) furnace. Tristructural isotropic (TRISO) coatings were deposited on 425-μm-nominal-diameter spherical kernels from BWXT lot J52R-16-69317 containing a mixture of 15.5%-enriched uranium carbide and uranium oxide (UCO). The TRISO coatings consisted of four consecutive CVD layers: a ~50% dense carbon buffer layer with 100-μm-nominal thickness, a dense inner pyrolytic carbon (IPyC) layer with 40-μm-nominal thickness, a silicon carbide (SiC) layer with 35-μm-nominal thickness, and a dense outer pyrolytic carbon (OPyC) layer with 40-μm-nominal thickness. The TRISO-coated particle batches were sieved to upgrade the particles by removing over-sized and under-sized material, and the upgraded batches were designated by appending the letter A to the end of the batch number (e.g., 93172A). Secondary upgrading by sieving was performed on the A-designated batches to remove particles with missing or very-thin buffer layers that were identified during previous analysis of the individual batches for defective IPyC, as reported in the acceptance test data report for the AGR-5/6/7 production batches [Hunn et al. 2017b]. The additionally-upgraded batches were designated by appending the letter B to the end of the batch number (e.g., 93172B).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Confirmatory LBL Analysis of AGR-5/6/7 Compacts and Over-Coated Particles BWXT Batches 11034, 14154C, 14156C, AND 14156D

Fuel for the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program’s AGR-5/6/7 irradiation test in the Idaho National Laboratory (INL) Advanced Test Reactor (ATR) was produced by BWX Technologies (BWXT) Nuclear Operations Group in Lynchburg, Virginia. Tristructural isotropic (TRISO) coatings were deposited using a 150-mm-diameter production-scale fluidized-bed chemical vapor deposition (CVD) furnace on 425-μm-nominal-diameter spherical kernels from Lot J52R-16-69317 containing a mixture of 15.5% 235U low-enriched uranium carbide and uranium oxide (UCO). The TRISO coatings consisted of four consecutive CVD layers: a ~50% dense carbon buffer layer with 100-μmnominal thickness, a dense inner pyrolytic carbon (IPyC) layer with 40-μm-nominal thickness, a silicon carbide (SiC) layer with 35-μm-nominal thickness, and a dense outer pyrolytic carbon (OPyC) layer with 40-μm-nominal thickness. TRISO-coated particle Lot J52R-16-98005 was over-coated with a graphite/resin blend and these over-coated particles were pressed in half-inch-diameter, one-inch-long cylindrical compacts. Two packing fractions (PF) were produced, 40%PF and 25%PF, where the TRISO particle volume made up approximately 40% and 25% of the total compact volume, respectively. The AGR-5/6/7 Fuel Specification, SPC-1352 [Marshall 2016], provides the requirements necessary for acceptance of the fuel manufactured for the AGR-5/6/7 irradiation test. Quality control (QC) acceptance testing for all AGR-5/6/7 composited lots and single batches was performed by BWXT, with the exception of pyrolytic carbon (PyC) anisotropy and defective IPyC fraction in the TRISO candidate batches and final composite, which were measured at the Oak Ridge National Laboratory (ORNL) and reported in ORNL/TM-2017/036 [Hunn et al. 2017] and ORNL/TM-2017/037 [Helmreich et al. 2017a].

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Oklo and BWXT Short Decks

Two abstracts, one for each deck: Oklo is planning on producing fuel using spent EBR-II material and demonstrating an NRC licensed reactor. This presentation gives a high level overview of Oklo's progress in this work. The BWXT Advanced Nuclear Reactor Experiment 1 (BANR-1) is an irradiation experiment at INL's Advanced Test Reactor (ATR) that will irradiate novel Tristructural Isotropic (TRISO) fuel for potential future use by BWXT. This presentation gives a program overview and progress.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

02-21 BWXT

7-year DOE cost-shared ARDP with $24.3M of INL scope Years 1-3: test train design Years 4-5: irradiation Years 5-7: post-irradiation examination (PIE) Irradiation of uranium nitride (UN) tri-structural isotropic (TRISO) prismatic fuel in ATR PIE will be conducted at MFC and ORNL NRIC overseeing program and ensuring continuity between disciplines/steps

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE Environmental Management and Newport News Nuclear BWXT Briefing - LANL’s Campus Master Plan [Slides]

Triad proposed a robust integrated planning effort during the bidding process and began this effort soon after the LANL contract transition. Within months of Triad commencing this planning process, NA-LA delivered a Contracting Officer (CO) letter requiring: (1) Area Development Plan for the Pajarito Corridor delivered by end of FY19 (completed), and (2) The Campus Master Plan (CMP) to be delivered by end of FY21 (completed).

42 ENGINEERING↗

X-ray Analysis of Defects and Anomalies in AGR-5/6/7 TRISO Particles

Coated particle fuel batches J52O-16-93164, 93165, 93166, 93168, 93169, 93170, and 93172 were produced by Babcock and Wilcox Technologies (BWXT) for possible selection as fuel for the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program’s AGR-5/6/7 irradiation test in the Idaho National Laboratory (INL) Advanced Test Reactor (ATR), or may be used for other tests. Each batch was coated in a 150-mm-diameter production-scale fluidized-bed chemical vapor deposition (CVD) furnace. Tristructural isotropic (TRISO) coatings were deposited on 425-μm-nominal-diameter spherical kernels from BWXT lot J52R-16-69317 containing a mixture of 15.4%-enriched uranium carbide and uranium oxide (UCO), with the exception of Batch 93164, which used similar kernels from BWXT lot J52L-16-69316. The TRISO-coatings consisted of a ~50% dense carbon buffer layer with 100-μmnominal thickness, a dense inner pyrolytic carbon (IPyC) layer with 40-μm-nominal thickness, a silicon carbide (SiC) layer with 35-μm-nominal thickness, and a dense outer pyrolytic carbon (OPyC) layer with 40-μm-nominal thickness. Each coated particle batch was sieved to upgrade the particles by removing over-sized and under-sized material, and the upgraded batch was designated by appending the letter A to the end of the batch number (e.g., 93164A). Secondary upgrading by sieving was performed on the upgraded batches to remove specific anomalies identified during analysis for Defective IPyC, and the upgraded batches were designated by appending the letter B to the end of the batch number (e.g., 93165B). Following this secondary upgrading, coated particle composite J52R-16-98005 was produced by BWXT as fuel for the AGR Program’s AGR-5/6/7 irradiation test in the INL ATR. This composite was comprised of coated particle fuel batches J52O-16-93165B, 93168B, 93169B, and 93170B.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Support for Fuel Fabrication and Characterization

Oak Ridge National Laboratory (ORNL) has participated in the Advanced Gas Reactor (AGR) program for the Next Generation Nuclear Plant (NGNP) and the transition to the Idaho National Laboratory (INL) Advanced Reactor Technologies (ART) Technology Development Office (TDO) since the inception of the program. In this effort, ORNL has fabricated tristructural isotropic (TRISO) fuel and fuel compacts for AGR-1, AGR-2, and AGR-3/4 experiments, provided matrix only components for AGC-2, AGC-4, and AGR 3/4 experiments and for university studies, and provided characterization, coating, and compaction support for INL and BWX Technologies Nuclear Operations Group (BWXT). In fiscal year (FY) 2017, the activities for the INL ART TDO fuel development are focused on preparations for the AGR-5/6/7 experiments and technical support to the Generation-IV International Forum (GIF) pre-irradiation leach-burn-leach (LBL) round robin effort with China and South Korea. With the successful transfer of fuel fabrication technology to BWXT, ORNL’s involvement has shifted toward transferring fuel characterization methods, providing technical support, verification of BWXT laboratory results, and fabricating surrogate fuel materials for university collaborations. ORNL will also provide analytical support to BWXT and INL for uranium dispersion analysis and confirmatory fuel characterization analyses as needed.

Support for Fuel Fabrication and Characterization

Oak Ridge National Laboratory (ORNL) has participated in the Advanced Gas Reactor (AGR) program for the Next Generation Nuclear Plant (NGNP) and the transition to the Idaho National Laboratory (INL) Advanced Reactor Technologies (ART) Technology Development Office (TDO) since the inception of the program. In this effort, ORNL has fabricated tristructural isotropic (TRISO) fuel and fuel compacts for AGR-1, AGR-2, and AGR-3/4 experiments, provided matrix only components for AGC-2, AGC-4, and AGR 3/4 experiments and for university studies, and provided characterization, coating, and compaction support for INL and BWX Technologies Nuclear Operations Group (BWXT). In fiscal year (FY) 2017, the activities for the INL ART TDO fuel development are focused on preparations for the AGR-5/6/7 experiments and technical support to the Generation IV (GenIV) pre-irradiation leach-burn-leach round robin effort with China and South Korea. With the successful transfer of fuel fabrication technology to BWXT, ORNL’s involvement has shifted toward transferring fuel characterization methods, providing technical support, verification of BWXT laboratory results, and fabricating surrogate fuel materials for university collaborations. ORNL will also provide analytical support to BWXT and INL for uranium dispersion analysis and confirmatory fuel characterization analyses as needed.

Commercialization of High-Density High Assay Low Enriched Uranium Fuel Systems

The Office of Reactor Conversion and Uranium Supply (NA 231) at the National Nuclear Security Administration leads the conversion effort for the United States High Performance Research Reactors (USHPRR). These reactors are the final civilian reactors in the US to transition from High Enriched Uranium (HEU) to high assay low enriched uranium (HALEU). Each of these reactors represents unique capabilities and no currently available fuel system meets their needs for conversion. The Fuel Fabrication (FF) Pillar of the USHPRR project is responsible for the fabrication of experimental elements, conversion elements, and establishing a commercial economical production capability. FF is also responsible to share with the domestic and international community the theoretical knowledge gained. Other pillars within the USHPRR project provide the experimental and conversion fuel designs, assist the reactors with licensing activities, and ensure the entire fuel cycle is evaluated. Over the last decade, FF has worked with the production partners at Y-12 National Security Complex (Y-12) and BWXT Nuclear Operations Group, Research and Test Reactors (BWXT). Y-12 has begun processing the alloy feedstock for the conversion elements with a qualified process. BWXT has started the final fabrication of the experimental elements. Once the experimental elements are complete, BWXT will begin conversion element fabrication. The FF Pillar resides at Pacific Northwest National Laboratory (PNNL) and uses PNNL, universities, commercial vendors, and the DOE national laboratory system to evaluate process development activities to improve the process steps. FF supports the fabrication of two high density fuel systems, monolithic U-10Mo (Figure 1) and Uranium Silicide (Figure 2). The U-10Mo fuel system is further along the development process. FF assists in long term planning with the production partners. This includes ramping production of the elements from experimental quantities to annual steady state needs. As part of the ramp up, opportunities to improve yield and product quality are identified to ensure the fuel systems are cost effective.

Catalan, Michael A. [BATTELLE (PACIFIC NW LAB)]↗

Confirmatory Defect Analyses of AGR-5/6/7 Fuel

The Advanced Gas Reactor (AGR) Fuel Development and Qualification Program has executed a series of experiments to test and qualify tristructural isotropic (TRISO) particle fuels for use in high-temperature gas-cooled reactors. The most recent irradiation experiments, AGR-5/6/7, are testing fuel that was fabricated in near production-scale equipment. There are three important defect fractions that must be characterized, using a deconsolidation-leach-burn-leach (DLBL) method, to better predict and understand fuel performance during irradiation. These are the dispersed uranium fraction (DUF), exposed kernel fraction (EKF), and silicon carbide defect fraction (SDF). The DLBL characterization data from analyses of the four compact batches, fabricated and characterized by the BWX Technologies Nuclear Operations Group (BWXT-NOG), showed unexpectedly higher values for all three defect fractions relative to the parent TRISO particle defect fractions. The DUF and SDF should not have changed significantly during compact fabrication and the apparent increase in the EKF, a metric for particle damage, was higher than anticipated for the compacts with 40% volumetric packing fraction (PF). Analytical results showed no net increase in the EKF for the 25% PF compacts. Compacts from one compact batch of each packing fraction were sent to Oak Ridge National Laboratory (ORNL), along with uncompacted tristructural isotropic (TRISO) particles, overcoated to a thickness targeting a 40% PF, for confirmatory analyses of the defect fractions and determination of the source(s) of damage. The ORNL results did not confirm the BWXT-NOG results for either the DUF or the SDF; the ORNL results showed no significant change in these defect fractions relative to the parent TRISO particle lot. The ORNL results did, however, confirm that a large increase in the exposed kernel fraction was found in the 40% PF compacts and that the 25% PF compacts sustained little if any damage. Data suggest that a large majority of the mechanical damage to the TRISO particles occurred in the overcoater when targeting the 40% PF. The analytical laboratories at both BWXT-NOG and ORNL had inconsistent outcomes on analyses of individual batches. Although the ORNL data is more consistent with the parent TRISO lot and expectations, the data set is too limited in size to justifiably reject suspect data from either laboratory at this time. It is recommended that an additional analysis be done to provide sufficient data for estimating the true defect fractions for interpreting the radionuclide release data during the AGR-5/6/7 irradiation experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Disposition Plan for AGR-Related Equipment and Materials

The Advanced Gas Reactor (AGR) program has purchased equipment, chemicals, and acquired uranium feedstocks for the purpose of developing fuel fabrication processes, fabricating fuel for irradiation experiments, and growing domestic expertise. During the process of fuel development and qualification activities, various quantities of unused chemicals, uranium feedstocks, intermediate materials, scrap, and waste have accumulated at BWX Technologies Nuclear Operations Group (BWXT-NOG) and Oak Ridge National Laboratory (ORNL) that must be properly dispositioned. More expensive standalone equipment will be shipped to and repurposed at the Idaho National Laboratory(INL) and ORNL. Less expensive standalone equipment will be either abandoned in place for use by BWXT-NOG or discarded. Embedded equipment, that effects the functionality of BWXT-NOG systems, will be either abandoned in place or dismantled for disposal. Residual chemicals and non-fuel materials used for fuel fabrication and characterization will be repurposed when economically viable or discarded. High-purity uranium oxides, crystals, and metal will be repurposed for fuel fabrication. The majority of the high-enriched uranium will be included in an upcoming Central Scrap Management Office down blending operation. Archival materials will be collected of low-enriched uranium fuel kernels, tristructural isotropic (TRISO) fuel particles, and fuel compact that are residues of AGR fuel fabrication activities. Archival materials will be stored at either INL or ORNL. Some quality, unenriched uranium materials, that may be of interest to other parties investigating TRISO fuels, will also be archived. Uranium materials that are not archived and which cannot be readily repurposed will be discarded.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Acceptance Test Data for the AGR-5/6/7 Irradiation Test Fuel Composite Defective IPyC Fraction and Pyrocarbon Anisotropy

Coated particle composite J52R-16-98005 was produced by Babcock and Wilcox Technologies (BWXT) as fuel for the Advanced Gas Reactor Fuel Development and Qualification (AGR) Program’s AGR-5/6/7 irradiation test in the Idaho National Laboratory (INL) Advanced Test Reactor (ATR). This composite was comprised of four coated particle fuel batches J52O-16-93165B (26%), 93168B (26%), 93169B (24%), and 93170B (24%), chosen based on the Quality Control (QC) data acquired for each individual candidate AGR-5/6/7 batch. Each batch was coated in a 150-mm-diameter production-scale fluidized-bed chemical vapor deposition (CVD) furnace. Tristructural isotropic (TRISO) coatings were deposited on 425-μm-nominal-diameter spherical kernels from BWXT Lot J52R-16-69317 containing a mixture of 15.5%-enriched uranium carbide and uranium oxide (UCO). The TRISO coatings consisted of four consecutive CVD layers: a ~50% dense carbon buffer layer with 100-μm-nominal thickness, a dense inner pyrolytic carbon (IPyC) layer with 40-μm-nominal thickness, a silicon carbide (SiC) layer with 35-μm-nominal thickness, and a dense outer pyrolytic carbon (OPyC) layer with 40-μm-nominal thickness. The TRISO-coated particle batches were sieved to upgrade the particles by removing over-sized and under-sized material, and the upgraded batches were designated by appending the letter A to the end of the batch number (e.g., 93165A). Secondary upgrading by sieving was performed on the A-designated batches to remove particles with missing or very-thin buffer layers that were identified during previous analysis of the individual batches for defective IPyC, as reported in the acceptance test data report for the AGR-5/6/7 production batches [Hunn et al. 2017]. The additionally-upgraded batches were designated by appending the letter B to the end of the batch number (e.g., 93165B).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

USHPRR MP-1 Irradiation Test: Assessment of Edge Pitting and Bond Line Corrosion in Vendor Produced Fuel Plates

This report summarizes an effort to identify the source of anomalous localized edge pitting and bond line corrosive attack of experimental mini fuel plates manufactured at the commercial fuel vendor BWXT and tested in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) as part of the Miniplate 1 (MP-1) irradiation test. The MP-1 test was conducted by the US High Performance Research Reactor Project (USHPRR) and overseen by the Fuel Qualification Pillar (FQ). The test involved evaluation of a mix of 62 “vendor” fuel plates fabricated at BWXT and 12 “laboratory” fuel plates fabricated at Idaho National Laboratory using commercial-scale and labscale fabrication processes respectively. The MP-1 test was the first in a series of tests to generate data to support qualification of a new plate-type low-enriched uranium (LEU) U-10Mo monolithic fuel system. The major objective of the MP-1 experiment was to test, for the first time, miniplates fabricated by a commercial fuel vendor over the range of irradiation conditions relevant to conversion of NRC regulated High Performance Research Reactors (HPRRs) from high-enriched uranium to LEU. The focus of the efforts described in this report are the vendor fuel plates to inform changes in the fabrication process prior to fabrication of the next miniplate experiment MP2.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

AGR Equipment and Materials Disposition

Fabrication of low-enriched experimental nuclear reactor fuel for the Advanced Gas Reactor (AGR) Fuel Development and Qualification program has concluded after several years of effort. Residual chemicals, uranium compounds, fuel intermediates and fuel compacts need to be dispositioned in an economically and environmentally sound manner that maximizes, within reason, the preservation and repurposing of valuable materials. Government Furnished Equipment (GFE), procured with AGR program funds, are also to be dispositioned as economically as reasonably possible while seeking to maintain the functionality of BWXT equipment and repurposing of stand-alone GFE. Any stand-alone equipment that cannot be repurposed will either be abandoned in place, with BWXT consent, or discarded to an appropriate waste repository.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗