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ARC Software Validation Work for the FFTF Reactor

Extensive efforts have been carried out at ANL for the verification and validation of the Argonne Reactor Codes (ARC) software package currently used for the design of Versatile Test Reactor (VTR). The ARC software package consists of steady state neutronics and thermal hydraulics modeling capabilities which are being used by the VTR program to develop most of the VTR reactor design details which will be part of the licensing application. It is anticipated that this software will continue to be used for the design work and for initial operations although additional software may be introduced at a later time. The validation work was focused primarily on obtaining validation data consistent with VTR and usable for the ARC software. Because no critical facilities or operating fast spectrum reactors are available to do experiments for the VTR, the next best option is to identify historical experimental data that can be used as validation data. Early on in VTR, the ZPPR-15 set of experiments was identified as good validation data because of 1) the availability and quality of the data, 2) existing staff that are already familiar with the experimental machine and measurements, 3) most of the ZPPR-15 loadings of interest have already been processed into ARC models, and 4) a full uncertainty quantification has already been done for several loadings of ZPPR-15. The FFTF startup and operations data was identified as the most consistent reactor type that has validation data usable for VTR. Finally, the EBR-II fuel depletion measurements were identified as the best available validation data for VTR. It is important to note that both the FFTF and EBR-II reactors typically come with higher uncertainties than the ZPPR. In the frame of the discussed verification and validation efforts, the present document discusses the analysis of selected FFTF measurements included in the benchmark specifications of the International Reactor Physics Experiment (IRPhE) handbook. The FFTF reactor core configurations from the benchmark specification are presented in Section 2. The analysis is performed with the use of the ARC code suite available at ANL for fast reactor studies and is discussed in Section 3. The reactor parameters from the benchmark include criticality, neutron spectra, effective delayed neutron spectra, control rod worth, isothermal temperature coefficient and low energy gamma-ray spectra. The calculated values and the comparison with the experimental data is discussed in Sections 4 to 9 for each considered reactor parameter. Finally, conclusions are presented in Section 10.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Lessons Learned about Liquid Metal Reactors from FFTF Experience

The Fast Flux Test Facility (FFTF) is the most recent liquid-metal reactor (LMR) to operate in the United States, from 1982 to 1992. FFTF is located on the DOE Hanford Site near Richland, Washington. The 400-MWt sodium-cooled, low-pressure, high-temperature, fast-neutron flux, nuclear fission test reactor was designed specifically to irradiate Liquid Metal Fast Breeder Reactor (LMFBR) fuel and components in prototypical temperature and flux conditions. FFTF played a key role in LMFBR development and testing activities. The reactor provided extensive capability for in-core irradiation testing, including eight core positions that could be used with independent instrumentation for the test specimens. In addition to irradiation testing capabilities, FFTF provided long-term testing and evaluation of plant components and systems for LMFBRs. The FFTF was highly successful and demonstrated outstanding performance during its nearly 10 years of operation. The technology employed in designing and constructing this reactor, as well as information obtained from tests conducted during its operation, can significantly influence the development of new advanced reactor designs in the areas of plant system and component design, component fabrication, fuel design and performance, prototype testing, site construction, and reactor operations. The FFTF complex included the reactor, as well as equipment and structures for heat removal, containment, core component handling and examination, instrumentation and control, and for supplying utilities and other essential services. The FFTF Plant was designed using a “system” concept. All drawings, specifications and other engineering documentation were organized by these systems. Efforts have been made to preserve important lessons learned during the nearly 10 years of reactor operation. A brief summary of Lessons Learned in the following areas will be discussed: Acceptance and Startup Testing of FFTF FFTF Cycle Reports

Wootan, David W.↗

Core materials development for the fuel cycle R&D program

The Fuel Cycle Research and Development program is investigating methods of burning minor actinides in a transmutation fuel. One of the challenges of achieving this goal is to develop fuels capable of reaching extreme burnup levels (e.g. 40%). To achieve such high burnup levels’ fast reactor core materials (cladding and duct) must be able to withstand very high doses (>300 dpa design goal) while in contact with the coolant and the fuel. Thus, these materials must withstand radiation effects that promote low temperature embrittlement, radiation induced segregation, high temperature helium embrittlement, swelling, accelerated creep, corrosion with the coolant, and chemical interaction with the fuel (FCCI). To develop and qualify materials to a total fluence greater than 200 dpa requires development of advanced alloys and irradiations in fast reactors to test these alloys. Test specimens of ferritic/martensitic alloys (T91/HT-9) previously irradiated in the FFTF reactor up to 210 dpa at a temperature range of 350– 750 °C are presently being tested. This includes analysis of a duct made of HT-9 after irradiation to a total dose of 155 dpa at temperatures from 370 to 510 °C. Compact tension, charpy and tensile specimens have been machined from this duct and mechanical testing as well as SANS and Mossbauer spectroscopy are currently being performed. Initial results from compression testing and Charpy testing reveal a strong increase in yield stress (~400 MPa) and a large increase in DBTT (up to 230 °C) for specimens irradiated at 383 °C to a dose of 28 dpa. Less hardening and a smaller increase in DBTT was observed for specimens irradiated at higher temperatures up to 500 °C. Advanced radiation tolerant materials are also being developed to enable the desired extreme fuel burnup levels. Specifically, coatings are being developed to minimize FCCI, and research is underway to fabricate large heats of radiation tolerant oxide dispersion steels with homogeneous oxide dispersions.

Maloy, S. A.↗

Core materials development for the fuel cycle R&D program

The Fuel Cycle Research and Development program is investigating methods of burning minor actinides in a transmutation fuel. One of the challenges of achieving this goal is to develop fuels capable of reaching extreme burnup levels (e.g. 40%). To achieve such high burnup levels fast reactor core materials (cladding and duct) must be able to withstand very high doses (>300 dpa design goal) while in contact with the coolant and the fuel. Thus, these materials must withstand radiation effects that promote low temperature embrittlement, radiation induced segregation, high temperature helium embrittlement, swelling, accelerated creep, corrosion with the coolant, and chemical interaction with the fuel (FCCI). To develop and qualify materials to a total fluence greater than 200 dpa requires development of advanced alloys and irradiations in fast reactors to test these alloys. Test specimens of ferritic/martensitic alloys (T91/HT-9) previously irradiated in the FFTF reactor up to 210 dpa at a temperature range of 350 750 C are presently being tested. This includes analysis of a duct made of HT-9 after irradiation to a total dose of 155 dpa at temperatures from 370 to 510 C. Compact tension, charpy and tensile specimens have been machined from this duct and mechanical testing as well as SANS and Mossbauer spectroscopy are currently being performed. Initial results from compression testing and Charpy testing reveal a strong increase in yield stress (400 MPa) and a large increase in DBTT (up to 230 C) for specimens irradiated at 383 C to a dose of 28 dpa. Less hardening and a smaller increase in DBTT was observed for specimens irradiated at higher temperatures up to 500 C. Advanced radiation tolerant materials are also being developed to enable the desired extreme fuel burnup levels. Specifically, coatings are being developed to minimize FCCI, and research is underway to fabricate large heats of radiation tolerant oxide dispersion steels with homogeneous oxide dispersions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Temperature and Burnup Correlated FCCI in U-10Zr Metallic Fuel

Metallic fuels are proposed for use in advanced sodium cooled fast reactors. The experience basis for metallic fuels is extensive and includes development and qualification of fuels for the Experimental Breeder Reactor I, the Experimental Breeder Reactor II, FERMI-I, and the Fast Flux Test Facility (FFTF) reactors. Metallic fuels provide a number of advantages over other fuel types in terms of fabricability, performance, recyclability, and safety. Key to the performance of all nuclear fuel systems is the resistance to “breach” and subsequent release of fission products and fuel constituents to the primary coolant system of the nuclear power plant. In metallic fuel, the experience is that significant fuel-cladding chemical (FCCI) interaction occurs and becomes prevalent at high power-high temperature operation and ultimately leads to fuel pin breach and failure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Full-length U-xPu-10Zr (x=0, 8, 19 wt%) Fast Reactor Fuel Test in FFTF

The Integral Fast Reactor-1 (IFR-1) experiment performed in the Fast Flux Test Facility (FFTF) was the only U-Pu-10Zr (Pu-0, 8 and 19 wt%) metallic fast reactor test with commercial-length (91.4 cm active fuel column length) conducted to date. With few remaining test reactors there is little opportunity for performing another test with a long active fuel column. The assembly was irradiated to the goal burnup of 10 at.%. The beginning of life (BOL) peak cladding temperature of the hottest pin was 608?C, cooling to 522?C at end of life (EOL). Selected fuel pins were examined non destructively using neutron radiography, precision axial gamma scanning, and both laser and spiral contact cladding profilometry. Destructive exams included plenum gas pressure, volume, and gas composition determinations on a number of pins followed by optical metallography, electron probe microanalysis (EPMA), and alpha and beta gamma autoradiography on a single U-19Pu-10Zr pin. The post-irradiation examinations (PIEs) showed very few differences compared to the short-pin (34.3 cm fuel column) testing performed on fuels of similar composition in Experimental Breeder Reactor-II (EBR-II). The fuel column grew axially slightly less than observed in the short pins, but with the same pattern of decreasing growth with increasing Pu content. There was a difference in the fuel-cladding chemical interaction (FCCI) in that the maximum cladding penetration by interdiffusion with fuel/fission products did not occur at the top of the fuel column where the cladding temperature is highest, as observed in EBR-II tests. Instead, the more exaggerated fission-rate profile of the FFTF pins resulted in a peak FCCI at ~0.7 X/L axial location along the fuel column. This resulted from a lower production of rare earth fission products higher in the fuel column as well as a much smaller delta-T between fuel center and cladding, and therefore less FCCI, despite the higher cladding temperature. This behavior could actually help extend the life of a fuel pin in a “long pin” reactor design to a higher peak fuel burnup.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Zero Power Reactor Database (ZPRD) Development Plan

Past sodium-cooled fast reactors (SFR) were built with an active experimental program in place to support the design and development work. Most of the experimental facilities in the United States that were important for SFR design were shutdown in the 1980s and 1990s. Reactor licensing and construction requires any reactor design to be verified against existing reactor facilities or experimental measurements. With the absence of those experimental facilities, modern SFR projects must rely on historical measurements to demonstrate that the engineering modeling software and data being used for the new reactor design work are reliable. There has been a considerable push in the last 6 years by both DOE and commercial companies to obtain historical experimental measurements that are relevant for SFRs, in particular those with features that are important for the new reactor designs of interest. The zero power reactor experiments carried out at Argonne National Laboratory’s critical facilities (ZPR-3, ZPR-6, ZPR-9, and ZPPR) from the 1950s to the 1980s are some of the best reactor physics experiments on SFR technology that are available today. Of particular interest today are the ZPPR-15 measurements done at the ZPPR facility for the Integral Fast Reactor project in the 1980s as they are in line with most commercial and DOE interests today. In the past 10 years, the measurements done on ZPPR-15 have been processed into both Monte Carlo (MCNP) and deterministic models (MC2-3 and DIF3D) useable for validating the engineering modeling software for key parts of the SFR design work. To achieve this, a detailed model description must be created for the experiment and the experimental measurement that the engineering modeling software is to reproduce. Then, an assessment of the uncertainty on the measured quantity which considers all of the sources of uncertainty in defining the model must be obtained and documented. The models created for ZPPR-15 provide the best validation basis available today for neutronics modeling software. Reference 2 is a good resource to understand how these models were built and how the uncertainties on the measured quantities were derived. The intention of the Zero Power Reactor Database (ZPRD), hosted at frdb.ne.anl.gov, is to make available the experimental measurements and models that have been constructed to-date. Though ZPPR-15 measurements are the primary data requested for validation needs, other measurements on ZPPR, ZPR-6, and ZPR-9 in support of the Clinch River Breeder Reactor (CRBR) and Fast Test Reactor (FFTF) should also be considered important for future software validation needs. In this manuscript, the details of available measurements on ZPR-3, ZPR-6, ZPR-9, and ZPPR facilities are summarized, and a general organization of the web interface is displayed. Many of the documents associated with the measurements are export controlled information so access to the database will also have to be controlled.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Irradiation performance of fast reactor MOX fuel pins with ferritic/martensitic cladding irradiated to high burnups

The ACO-3 irradiation test, which attained extremely high burnups of about 232 GWd/t and resisted a high neutron fluence (E > 0.1 MeV) of about 39E26 n/m2 as one of the lead tests of the Core Demonstration Experiment in the Fast Flux Test Facility, demonstrated that the fuel pin cladding made of ferritic/martensitic HT-9 alloy had superior void swelling resistance. The measured diameter profiles of the irradiated ACO-3 fuel pins showed axially extensive incremental strain in the MOX fuel column region and localized incremental strain near the interfaces between the MOX fuel and upper blanket columns. These incremental strains were as low as 1.5% despite the extremely high level of the fast neutron fluence. Evaluation of the pin diametral strain indicated that the incremental strain in the MOX fuel column region was substantially due to cladding void swelling and irradiation creep caused by internal fission gas pressure, while the localized strain near the MOX fuel/upper blanket interface was likely the result of the pellet/cladding mechanical interaction (PCMI) caused by cesium/fuel reactions. The evaluation also suggested that the PCMI was effectively mitigated by a large gap size between the cladding and blanket column.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Guideline for Performing Systematic Approach to Evaluate and Qualify Legacy Documents that Support Advanced Reactor Technology Activity

The establishment of a systematic process for the evaluation of historic technology information for use in advanced reactor licensing is described. Efforts are underway to recover and preserve Experimental Breeder Reactor II and Fast Flux Test Facility historical data. These efforts have generally emphasized preserving information from data-acquisition systems and hard-copy reports and entering it into modern electronic formats suitable for data retrieval and examination. The guidance contained in this document has been developed to facilitate consistent and systematic evaluation processes relating to quality attributes of historic technical information (with focus on sodium-cooled fast reactor (SFR) technology) that will be used to eventually support licensing of advanced reactor designs. The historical information may include, but is not limited to, design documents for SFRs, research-and-development (R&D) data and associated documents, test plans and associated protocols, operations and test data, international research data, technical reports, and information associated with past U.S. Nuclear Regulatory Commission (NRC) reviews of SFR designs. The evaluation process is prescribed in terms of SFR technology, but the process can be used to evaluate historical information for any type of advanced reactor technology. An appendix provides a discussion of typical issues that should be considered when evaluating and qualifying historical information for advanced reactor technology fuel and source terms, based on current light water reactor (LWR) requirements and recent experience gained from Next Generation Nuclear Plant (NGNP).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Multi-scale modeling of wastage layer formation in metallic fuel cladding

Fuel-cladding chemical interaction (FCCI) is a major concern for U-Zr metallic fuels' performance, primarily due to the formation of a brittle layer (wastage) in the cladding. This brittle layer, resulting from intermetallic compounds between cladding constituents Fe, Cr, and lanthanide fission products, significantly impacts the cladding's mechanical integrity. Recent efforts focus on developing a mechanistic modeling framework to understand lanthanide production, transport to the fuel-cladding interface, and phase transformation to intermetallic phases. A multi-scale computational approach has been used to calculate lanthanide transport rates, with atomistic calculations determining Nd diffusivities through the solid fuel matrix and along pore surfaces. These diffusivities inform a mesoscale model to determine an effective diffusion coefficient, accounting for porosity and infiltration with bond sodium. This effective diffusivity is used in engineering-scale simulations via the BISON fuel performance code, which has been validated against EBR-II and FFTF reactor experiments.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Tensile Testing on FFTF Irradiated Fast Reactor Cladding

This report covers the first tensile tests on samples oriented perpendicular to the extrusion direction on the FFTF irradiated ACO3 duct, and comparison to similar dose samples oriented in the extrusion direction. Control tests were performed to test the same orientation dependency in control lots of HT9 material. This report also presents data from a recently obtained a cold FFTF HT9 duct and compares its tensile properties to a previously used ACO3 archive control lot. Finally, comparison studies of different thicknesses of SSJ type tensile samples were performed.

36 MATERIALS SCIENCE↗

Corrosion performance of advanced structural materials in sodium.

This report gives a description of the activities in design, fabrication, construction, and assembling of a pumped sodium loop for the sodium compatibility studies on advanced structural materials. The work is the Argonne National Laboratory (ANL) portion of the effort on the work project entitled, 'Sodium Compatibility of Advanced Fast Reactor Materials,' and is a part of Advanced Materials Development within the Reactor Campaign. The objective of this project is to develop information on sodium corrosion compatibility of advanced materials being considered for sodium reactor applications. This report gives the status of the sodium pumped loop at Argonne National Laboratory, the specimen details, and the technical approach to evaluate the sodium compatibility of advanced structural alloys. This report is a deliverable from ANL in FY2010 (M2GAN10SF050302) under the work package G-AN10SF0503 'Sodium Compatibility of Advanced Fast Reactor Materials.'

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Containment margins in FFTF for postulated failure of in-vessel post-accident heat removal

This study was performed to complete the assessment of potential melt-through consequences for the postulated failure of post-accident heat removal following a hypothetical core disruptive accident (HCDA) in the FFTF. The SPRAY, SOFIRE, CACECO, HAA-3B, and COMRADEX codes were used to determine potential site boundary radiation doses. Parametric comparisons were made to evaluate the effects of natural hydrogen-oxygen recombination, reactor cavity liner failures and containment coolers. Containment pressure relief, vent/purge options, and the effects of exhaust filtration were also included in the study. The potential site boundary radiation exposures for all options considered were within 10 CFR 100 guideline values.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Guidelines for locating supports for nuclear power plant piping

Rules and guidelines are given for the location of pipe hangers and snubbers for straight piping, spans with concentrated loads, and crossovers. Recommended minimum support stiffnesses and limitations are given. Evaluations of construction considerations and system operability are also presented.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

FFTF Acceptance and Startup Testing for GAIN

The Fast Flux Test Facility (FFTF) is the most recent liquid metal reactor (LMR) to be designed, constructed, and operated by the U.S. Department of Energy (DOE). The 400-MWt sodium-cooled, fast-neutron flux reactor plant was designed for irradiation testing of nuclear reactor fuels and materials for liquid metal fast breeder reactors. Following the demise of the breeder reactor program in the United States, FFTF continued to play a key role in providing a test bed for demonstrating performance of advanced fuel designs and demonstrating operation, maintenance, and safety of advanced liquid metal reactors. FFTF operations ceased in April 1992 after a determination by DOE that no combination of proposed missions was financially feasible over a ten-year period. The reactor is currently deactivated and in a long-term surveillance and maintenance (S&M) mode. This report provides information on the extensive and rigorous process that was used to conduct turnover from construction followed by acceptance and startup testing of the FFTF. This paper is in support of the Gateway for Accelerated Innovation in Nuclear (GAIN), which provides the nuclear energy community with access to the technical, regulatory, and financial support necessary to move new or advanced nuclear reactor designs toward commercialization while ensuring the continued safe, reliable, and economic operation of the existing nuclear fleet. The information obtained from the design, startup, and operation of the FFTF provides valuable insight for follow-on reactor projects, such as the Versatile Test Reactor (VTR), in the areas of plant system and component design, component fabrication, fuel design and performance, prototype testing, site construction, reactor startup and operations, and reactor deactivation and decommissioning (D&D). The focus of this report is on the process used to startup the FFTF and to ensure that operations could be conducted efficiently and safely. A reference section is provided of documents detailing the successful turnover and testing process implemented for startup of the reactor and its supporting systems. The documents listed can be retrieved upon request and are believed useful for future reactor startup endeavors.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Safe and Effective Deactivation of Metallic Sodium Filled Scrap and Cold Traps From Sodium-cooled Nuclear Reactor D and D - 12176

As part of the Plateau Remediation Project at US Department of Energy's Hanford, Washington site, CH2M Hill Plateau Remediation Company (CHPRC) contracted with IMPACT Services, LLC to receive and deactivate approximately 28 cubic meters of sodium metal contaminated debris from two sodium-cooled research reactors (Enrico Fermi Unit 1 and the Fast Flux Test Facility) which had been stored at Hanford for over 25 years. CHPRC found an off-site team composed of IMPACT Services and Commodore Advanced Sciences, Inc., with the facilities and technological capabilities to safely and effectively perform deactivation of this sodium metal contaminated debris. IMPACT Services provided the licensed fixed facility and the logistical support required to receive, store, and manage the waste materials before treatment, and the characterization, manifesting, and return shipping of the cleaned material after treatment. They also provided a recycle outlet for the liquid sodium hydroxide byproduct resulting from removal of the sodium from reactor parts. Commodore Advanced Sciences, Inc. mobilized their patented AMANDA unit to the IMPACT Services site and operated the unit to perform the sodium removal process. Approximately 816 Kg of metallic sodium were removed and converted to sodium hydroxide, and the project was accomplished in 107 days, from receipt of the first shipment at the IMPACT Services facility to the last outgoing shipment of deactivated scrap metal. There were no safety incidents of any kind during the performance of this project. The AMANDA process has been demonstrated in this project to be both safe and effective for deactivation of sodium and NaK. It has also been used in other venues to treat other highly reactive alkali metals, such as lithium (Li), potassium (K), NaK and Cesium (Cs). (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Phase Stability of an HT-9 Duct Irradiated in FFTF

A fuel test assembly known as ACO-3 duct made out of a fully tempered ferritic/martensitic steel (HT-9) was previously irradiated in the Fast Flux Test Reactor Facility (FFTF) up to 155 dpa at a temperature range of 380-504°C. The microstructures of the samples from 5 different zones along the face of the duct were analyzed using a combination of TEM based techniques, SANS and APT. A high density of Cr rich a' precipitates together with moderate density G-phase precipitates with an average sizes of 5 and 11 nm respectively were found at 20 dpa, 380°C zone. It was found that the precipitations of the second phases are more sensitive to temperature then the dose. In general, the density of both precipitates decreases with increasing irradiation temperature. No significant change is observed in average size of a' while the average size of G-phase precipitates increases up to 27 nm at 440°C. Voids are seen at 100 (410°C) and 155 (440°C) dpa zones but none was detected at 96 dpa (466°C) zone. In contrast to what is reported in the literature, no laves or Chi phases were found in any of the zones.

36 MATERIALS SCIENCE↗