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DOE OSTI2023

Nuclear fuel rods and heat pipes in a graphite moderator matrix for a micro-reactor, with the fuel rods having fuel pellets in a BeO sleeve

A reactor unit cell is disclosed including a graphite moderator structure, a heat pipe positioned in the graphite moderator structure, and a fuel assembly positioned in the graphite moderator structure. The fuel assembly comprises at least one fuel rod. Each fuel rod comprises a beryllium-oxide sleeve and nuclear fuel positioned in the beryllium-oxide sleeve.

Levinsky, Alex↗

DOE OSTI2020

Pitch Variation Experiments in Water-Moderated Square-Pitched U(6.90)O 2 Fuel Rod Lattices with Fuel to Water Volume Ratios Spanning 0.08 to 0.67

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Methods of forming fuel rods comprising porous fuel materials

A method of forming a fuel rod for a nuclear reactor comprises disposing a powder comprising particles of a fuel material on a substrate, exposing the powder to energy from an energy source to form a first layer of a nuclear fuel, the first layer comprising inter-granular bonds between the particles of the fuel material, disposing additional powder comprising particles of the fuel material over the first layer of the nuclear fuel, and exposing the additional powder to energy from the energy source to form a second layer of the nuclear fuel and to form the nuclear fuel to have a void fraction greater than about 0.20, the second layer comprising inter-granular bonds between the additional powder and the first layer of the nuclear fuel. Related nuclear fuels comprising a porous structure, fuel rods, nuclear reactors, and methods are disclosed.

O'Brien, Robert C.↗

DOE OSTI2020

Pitch Variation Experiments in Water-Moderated Square-Pitched U(6.9)O 2 Fuel Rod Lattices with Fuel to Water Volume Ratios Spanning 0.08 to 0.67

The US Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories. The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5% 235 U. The 7uPCX assembly is a water-moderated and -reflected array of aluminum-clad square-pitched U(6.90%)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMPTHERM- 096, LEU-COMP-THERM-097, and LEU-COMP-THERM-101. The twenty-seven critical experiments in this series were performed in 2020 in the SCX at the Sandia Pulsed Reactor Facility. The experiments are grouped by fuel rod pitch. Case 1 is a base case with a pitch of 0.8001 cm and no water holes in the array. Cases 2 through 6 have the same pitch as Case 1 but contain various configurations with water holes, providing slight variations in the fuel-to-water ratio. Similarly, Case 7 is a base case with a pitch of 0.854964 cm and no water holes in the array. Cases 8 through 11 have the same pitch as Case 7 but contain various configurations with water holes. Cases 12 through 15 have a pitch of 1.131512 cm and differ according to the number of water holes in the array, with Case 12 having no water holes. Cases 16 through 19 have a pitch of 1.209102 cm and differ according to number of water holes in the array, with Case 16 having no water holes. Cases 20 through 23 have a pitch of 1.6002 cm and differ according to number of water holes in the array, with Case 20 having no water holes. Cases 24 through 27 have a pitch of 1.709928 cm and differ according to number of water holes in the array, with Case 24 having no water holes. As the experiment case number increases, the fuel-to-water volume ratio decreases.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Pitch Variation Experiments in Water-Moderated Square-Pitched U(6.90)O 2 Fuel Rod Lattices with Fuel to Water Volume Ratios Spanning 0.08 to 0.67

The twenty-seven critical experiments in this series were performed in 2020 in the SCX at the Sandia Pulsed Reactor Facility. The experiments are grouped by fuel rod pitch. Case 1 is a base case with a pitch of 0.8001 cm and no water holes in the array. Cases 2 through 6 have the same pitch as Case 1 but contain various configurations with water holes, providing slight variations in the fuel-to-water ratio. Similarly, Case 7 is a base case with a pitch of 0.854964 cm and no water holes in the array. Cases 8 through 11 have the same pitch as Case 7 but contain various configurations with water holes. Cases 12 through 15 have a pitch of 1.131512 cm and differ according to the number of water holes in the array, with Case 12 having no water holes. Cases 16 through 19 have a pitch of 1.209102 cm and differ according to number of water holes in the array, with Case 16 having no water holes. Cases 20 through 23 have a pitch of 1.6002 cm and differ according to number of water holes in the array, with Case 20 having no water holes. Cases 24 through 27 have a pitch of 1.709928 cm and differ according to number of water holes in the array, with Case 24 having no water holes. As the experiment case number increases, the fuel-to-water volume ratio decreases.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2022

Characterization of modeling and experimental data inconsistencies from burst testing for high-burnup commercial fuel rod applications

Fuel fragmentation, relocation, and dispersal are some of the largest issues remaining in the nuclear industry before rod-average burnup can be increased beyond 62 GWd/tU. The issue is primarily related to the potential for fuel to be dispersed into the reactor primary system, which may increase public risk. One way to prevent dispersal is to avoid cladding burst. The objective of this work is to support the high burnup safety case by evaluating cladding burst under high-burnup, full-length fuel rods and to identify uncertainties that could improve model predictions. The results of this analysis will evaluate realistic, prototypic loss-of-coolant accident (LOCA) conditions; support future cladding burst test designs; and inform the development of mechanistic material models. Realistic high-burnup operating conditions were implemented in the BISON fuel performance code to simulate steady-state and LOCA transient fuel rod evolution to the point at which cladding burst occurred. Parametric studies are performed to assess code response to changes in rod internal pressures and heating rates. Results were compared with simulated LOCA experiments to identify inconsistencies between commercial fuel rod analysis and experimental validation. The representative full-length fuel rod LOCA simulation results did not agree with cladding burst tests. Cladding burst tests indicated burst occurring well below (100–150 °C) those calculated in the full-length fuel rod LOCA analysis. Further investigation indicated that the cladding burst tests do not appear to be representative for full-length fuel rods. The inconsistency investigated in this work showed that the differences between the BISON simulation and the experiment's cladding burst conditions arise from an incomplete characterization of the cladding surface temperature, detailed rodlet characterization, lack of cladding strain measurements, and uncertainty in the cladding creep and failure models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Partially-Reflected Water-Moderated Square-Pitched U(6.90)O 2 Fuel Rod Lattices with 0.52 Fuel to Water Volume Ratio (0.855 CM Pitch)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Enabling BWR fuel rod analysis in the BISON fuel performance code

Nuclear fuel vendors around the world are pursuing approaches to sustain the existing nuclear reactor fleet consisting primarily of pressurized-water reactors (PWRs) and boiling-water reactors (BWRs). To support the industry's efforts, advanced modeling and simulation tools need to be capable of analyzing both legacy reactor concepts. BWR fuel rods are significantly different than those used in PWRs, which can affect fuel performance analysis. BWR fuel rods include: (1) an extensive use of gadolinia dopant as a burnable absorber, (2) an axial variation in fuel enrichment and gadolinia content, (3) the inclusion of a liner on the inner cladding surface to mitigate the impact of pellet-clad mechanical interaction (which impacts hydrogen and hydride distribution), (4) a lower initial fill gas pressure, (5) bottom-entry control rods, and (6) a lower coolant pressure that results in the two-phase flow boiling phenomenon. Although the primary focus of BISON has been in the area of PWR and advanced reactor fuel analyses, this paper presents the developments in BISON to support BWR fuel performance analysis. An overview of the models that account for the effects of gadolinia is highlighted. Internal mesh generation capabilities to include a liner is presented. Normal operating and transient (reactivity insertion accident) demonstration problems are presented to illustrate the impact of gadolinia, the hydrogen and hydride evolution due to the presence of the liner, and BISON's ability to simulate axially varying enrichments and dopant concentration. Bottom-entry control effects are captured by the axial power peaking factors present in the demonstration cases. Comparisons to integral experiments from the Halden IFA-681 experiments are discussed as initial validation. Reasonable comparisons are obtained for fuel centerline temperature and rod internal pressure as a function of time. In conclusion, simulations of additional experiments containing Gd 2 O 3 -bearing fuel are necessary to completely validate the code for BWR applications.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

The Study of Lightbridge Metallic Fuel Rods in MOOSE for Meshing Capabilities and Studying Lightbridge Metallic Fuel Rods with MOOSE

Supporting INL’s mission to transform our nation’s energy future, notably through innovative nuclear energy solutions, this project focuses on modeling accidental tolerant fuel. In collaboration with MIT, we modeled with MOOSE-based tools the Lightbridge metallic fuel design. Lightbridge fuel is envisioned to enable higher power output and larger safety margins for both current and advanced nuclear reactors. We present here the advanced meshing capabilities developed and preliminary physics results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Key results from examinations of seven high burnup pressurized water reactor spent nuclear fuel rods

At present, spent nuclear fuel (SNF) assemblies discharged from US commercial power plants are placed into dry storage following a short cooling time (<10 years) in the plant’s spent fuel pool. The process of packaging the spent fuel into dry-storage canisters includes a drying step to remove residual water from the canister. During the drying process, the fuel rod cladding may reach temperatures as high as 400°C. Oak Ridge National Laboratory (ORNL) is performing destructive examinations of high burnup (HBU) (>45 GWd/MTU) SNF rods to address knowledge and data gaps related to extended interim storage and eventual transportation for disposal. The rods examined include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. Three rods were subjected to a thermal transient to assess the effects of decay-heat-driven high temperatures expected during vacuum drying of the fuel as it is prepared for interim dry storage. The examinations focus on the composite fuel rod performance, as compared with the performance of defueled rod cladding, and establish the baseline mechanical properties of a fuel rod before interim dry storage. The key results of these examinations are presented, including the measured mechanical and fatigue properties, observations of cladding hydrogen pickup and hydride reorientation effects on rod performance, effects of the simulated drying temperatures on rod performance, and general conclusions of SNF performance in extended interim dry storage and transport. The rods were found to be strong and durable in the expected loading conditions, even considering the formation of radial hydrides associated with vacuum drying. The combined testing provides a broad body of data supporting extended interim storage and transportation performance of HBU spent fuel.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Full Rod Length Gamma Spectroscopy Measurements of LWR Used Fuel Rods

Twenty-five high-burnup pressurized water reactor used fuel rods were scanned in the Irradiated Fuels Examination Laboratory at Oak Ridge National Laboratory with a high-resolution gamma spectrometer. A planar high-purity germanium detector was used across an energy range from 60 keV to 3 MeV. Gamma spectra of individual fuel rods were collected in 4.5 mm steps along the entire length of each rod. Additional spectra were collected on select rods in rotational increments of 30 degrees to provide data on the distribution of fission products along the rod perimeter.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Sister Rod Destructive Examinations (FY22) Appendix F2: Evaluation of Fuel Rod Fatigue During Spent Fuel Transportation

This report documents work performed under the Spent Fuel and Waste Disposition’s Spent Fuel and Waste Science and Technology program for the US Department of Energy (DOE) Office of Nuclear Energy (NE). This work was performed to fulfill Level 2 Milestone M2SF-23OR010201024, “FY22 Report on ORNL Sibling Rod Testing Results,” within work package SF-23OR01020102 and is an update to the work reported in M2SF-22OR010201047, M2SF-21OR010201032, M2SF-19ORO010201026, and M2SF- 19OR010201028. As a part of DOE NE High Burnup Spent Fuel Data Project, Oak Ridge National Laboratory (ORNL) is performing destructive examinations (DEs) of high burnup (HBU) (>45 GWd/MTU) spent nuclear fuel (SNF) rods from the North Anna Nuclear Power Station operated by Dominion Energy. The SNF rods, called sister rods or sibling rods, are all HBU and include four different kinds of fuel rod cladding: standard Zircaloy-4 (Zirc-4), low-tin (LT) Zirc-4, ZIRLO, and M5. The DEs are being conducted to obtain a baseline of the HBU rods’ condition before dry storage and are focused on understanding overall SNF rod strength and durability. Composite fuel and defueled cladding will be tested to derive material properties. Although the data generated can be used for multiple purposes, one primary goal for obtaining the post-irradiation examination data and the associated measured mechanical properties is to support SNF dry storage licensing and relicensing activities by (1) addressing identified knowledge gaps and (2) enhancing the technical basis for post-storage transportation, handling, and subsequent disposition. This appendix documents an evaluation of the fatigue data to enhance the technical basis for post-storage transportation, handling, and subsequent disposition and to identify future testing needs for Phase 2 of the project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Molybdenum Sleeve Experiments in Fully-Reflected Water-Moderated Triangular-Pitched U(6.90)O 2 Fuel Rod Lattices (1.55 cm Pitch)

The US Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories. The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5 % 235 U. The 7uPCX assembly is a water-moderated and -reflected array of aluminum-clad U(6.90 %)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMP-THERM-096, LEUCOMP-THERM-097, LEU-COMP-THERM-101, and LEU-COMP-THERM-102. The purpose of these experiments was to measure the effects of molybdenum in nearly-critical systems. The molybdenum was introduced into the fuel arrays as tubular sleeves that surrounded some of the fuel rods in the fuel arrays measured. Four hundred molybdenum tubes nominally 12.7 mm outside diameter, 498 mm long, with 0.762 mm wall thickness were provided for the experiments by the Institut de Radioprotection et de Sûreté Nucléaire (IRSN). Small polyethylene adapters at each end of the tubes were used to center each tube on a fuel rod in the assembly. The critical experiments were done using a set of triangular-pitched grid plates fabricated for these experiments. The grid plate set accommodated a fuel array of a total of 1261 fuel rod positions on a pitch of 0.610 in (1.5494 cm) in a series of 20 hexagonal rings surrounding the central fuel rod. The fuel used in these experiments was fabricated using unirradiated 6.90 % enriched UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The five critical experiments in this series were performed in August through December 2022, in the Sandia Critical Experiments (SCX) at the Sandia Pulsed Reactor Facility. Case 1 had no molybdenum sleeves, Case 2 had 208 molybdenum sleeves clustered at the center of the array, Case 3 had 397 molybdenum sleeves clustered at the center of the array, Case 4 had 175 molybdenum sleeves in the central position and in five alternating hexagonal rings, and Case 5 had 331 molybdenum sleeves in the central position and in seven alternating hexagonal rings. All five critical experiments are judged to be acceptable as benchmark experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Porous Flow Modeling of Axial Gas Redistribution in Fragmented LWR Fuel Rods using MOOSE

Understanding how gas axially redistributes within fragmented fuel pellets is crucial for predicting the behavior of Light Water Reactor (LWR) fuel rods, particularly during transient and accidental scenarios. The time scale of this phenomenon plays a fundamental role in determining the progression and hazard of a Loss Of Coolant Accident (LOCA), especially when high burn-up fuel in a severe state of fragmentation is involved. Here, this study presents a Computational Fluid Dynamics (CFD) model developed within the Multiphysics Object-Oriented Simulation Environment (MOOSE) to predict the time-scale of plenum depressurization in Light-Water Reactor (LWR) fuel rods driven by axial gas transport through fragmented pellets. The model examines the effects of incorporating non-linearities in the friction term by comparing the results with experimental data. The experiment employed surrogate fuel rods containing pellets subjected to mechanical and/or thermal loadings to simulate various severity of cracking, and aimed at studying the influence of fuel conditions on axial gas redistribution. The results of this analysis indicate that under certain flow regime conditions - determined by the value of an equivalent Reynolds number - accounting for the non-linear friction term in Navier-Stokes equations guarantees better predictions for the time-scale of plenum depressurization. Also, the model enabled the simulation of the pressure decay by assigning distinct permeability values to each pellet instead of a single uniform value. Multiple simulations were run across all possible pellet position combinations, having each pellet assigned with values of permeability extracted from the experimental data. This allows to quantify the impact of the considering various non-uniform distributions of permeability on the dynamics of axial gas redistribution. The present work findings enhance the understanding of axial gas transport, and provide valuable insights for the integration of a model for predicting the axial gas redistribution during a LOCA scenario into the BISON fuel performance code.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Hydride Reprecipitation in Prototypical 17x17 PWR Fuel Rods after Simulated Vacuum Drying Conditions

Light water reactor (LWR) fuel rod cladding picks up hydrogen as it oxidizes in reactor. Once the hydrogen concentration exceeds the solubility limit, zirconium hydride platelets precipitate, generally in the circumferential direction. In preparation for dry storage, elevated temperatures can dissolve some of the circumferential hydrides, which during cooling can then reprecipitate in a direction perpendicular to the hoop stress (radially). From 2019 to 2024, ORNL published a series of reports that included metallographic observations of cladding after a thermal transient to 400°C followed by slow cooling. The simulated dry storage process was performed on three full-length 17x17 PWR fuel rods at their as-discharged rod internal pressure. There were two important observations from the metallographic examinations of these heat-treated rods: (1) the propensity for hydride reorientation is strongly influenced by nearby as-discharged precipitated hydrides, (2) the radial hydrides observed near the cladding inner diameter were often associated with cracks in the pellet. Subsequent modeling using the BISON fuel performance code that considered the effects of pellet cracks and pellet-cladding bonding observed in high-burnup fuel support the conclusion that pellet cracks enhance the local hoop stress in the cladding creating preferential sites for hydride reorientation, and that the influence of the pellet cannot be ignored in accurate fuel rod performance predictions.

Montgomery, Rose [ORNL] (ORCID:0000000286038936)↗

DOE OSTI2021

Fork Experiments in the Hot Cell Using Spent Fuel Rods for International Nuclear Safeguards

This work leveraged the rare availability of 25 full-length pressurized water reactor spent fuel rods and 1 irradiated mixed-oxide rod at an Oak Ridge National Laboratory hot cell. This was done to collect measurement data with two Fork detectors to assess the detectors’ capability of verifying operator declaration data and detecting partial defects in spent fuel, which are the two primary goals of international safeguards on spent nuclear fuel. The data can also be used to benchmark the ORIGEN module, which has been adopted in the International Atomic Energy Agency’s (IAEA’s)/European Atomic Energy Community’s (Euratom’s) Integrated Review and Analysis Program to predict the Fork detector count rates in real time. In this project, the authors first calibrated two Fork detectors—a standard one and a modified one—by using known strong neutron and gamma sources. Then, the authors measured all 26 fuel rods at multiple locations along the length. The fuel rods were then assembled into three arrays—2 × 2, 3 × 3, and 5 × 5—by using specially designed support grids to mimic fuel assemblies and measure the arrays with both detectors. For the 5 × 5 array, 4 and 8 fuel rods of the array were replaced in two separate cases with short stainless-steel rods to mimic two partial defect scenarios, and the arrays were measured before and after the replacements. Polyethylene blocks were used in this experiment to mimic water. The results show that the Fork detectors were able to verify operator declarations and detect partial defects in spent fuel, and the authors were the first to demonstrate this through experiments. A discovery was also made that determined the root cause of the nonlinear response to gamma dose in the ion chambers used in IAEA and Euratom’s Fork detectors. After the experiments, both detectors were retrieved from the hot cell for future use. The data collected in this project will be used in a parallel International Nuclear Safeguards Engagement Program (INSEP) project to enhance the safeguards in the Finnish spent fuel encapsulation plant, and the data will be useful to other projects in the future given the increased safeguards needs due to spent fuel transfer and disposal activities worldwide.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

POST-TEST EXAMINATIONS OF A LOCA SAMPLE FROM AN IRRADIATED HIGH-BURNUP PWR M5 FUEL ROD

A LOCA integral test with high burnup PWR M5 fuel rod was conducted in the Irradiated Fuel Examination Laboratory through the complete LOCA sequence: heating the LOCA sample to 300ºC and pressurizing the internal pressure to 8.27 MPa, heating at 5ºC/s from 300 to 1200ºC, holding in steam for 90s at 1200ºC, cooling at 3ºC/s to 800ºC, followed by water quench and rapid cooling to 100ºC. After LOCA testing, examinations, such as the fuel fragmentation analysis, burst and ballooning characterization, axial strain measurement, and microstructural examinations were performed. Metallographic examinations of an as-irradiated high burnup sample adjacent to the LOCA test sample revealed a bonding layer between the fuel and cladding. The posttest LOCA examinations indicates the corrosion layer formed during normal operations in the commercial reactor might provide a protection against the steam oxidation at high temperatures for test times performed in this work. The microstructure of the as-irradiated fuel is compared to the microstructure of the post-LOCA test fuel. Posttest LOCA examination on unirradiated post-tests Zr cladding samples was conducted, which served as baseline data for in cell testing with irradiated samples. The results obtained with irradiated PWR high burnup M5 fuel rad were compared to the LOCA test data obtained with irradiated BWR high burnup Zircaloy-2 fuel rod at Argonne national Laboratory.

Yan, Yong↗

DOE OSTI2021

Resistance pressure weld for nuclear reactor fuel rod tube end plug

A fuel rod for a nuclear reactor, including a cladding tube having a first end with an annular end face, a second end with an annular end face, and a cylindrical body portion extending therebetween, and a first tube end plug including a front portion, an annular lip with an annular end face, and a substantially straight cylindrical body portion extending therebetween, wherein the surface area of the annular end face of the first end of the cladding tube and the annular end face of the annular lip of the first tube end plug are substantially equal, and the annular end face of the first end of the cladding tube and the annular end face of the annular lip of the first tube end plug are connected by a resistance pressure weld.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗