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DOE OSTI2022

MOOGLE: A Multi-Objective Optimization tool for three-dimensional nuclear fuel assembly design

MOOGLE is a new genetic algorithm methodology for the three-dimensional design of nuclear fuel assemblies. MOOGLE uses common fuel rod types as the decision variable to develop a suite of three-dimensional fuel assemblies to provide optimized solutions to the design problem. Pressurized Water Reactor (PWR) fuel assemblies were optimized using IFBA and gadolinium (Gd 2 O 3 ) as burnable poisons in order to compare how burnable poison choice affects optimization results. Boiling Water Reactor (BWR) fuel bundles were also optimized using three unique fuel rod palettes to study how the size of the design space affects optimization results. Burnable poison analysis showed that utilizing IFBA and Gd 2 O 3 as burnable poisons produced the best and widest range of optimized solutions. Further, BWR fuel bundle optimization results indicate that the inclusion of additional fuel rod types produced a wider solution space but did not improve optimization results for regions explored using fewer unique fuel rods. These tests demonstrate MOOGLE's ability to analyze the tradeoffs between the inclusion of different fuel elements and their effects on assembly performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

AN ESTIMATE OF SPENT NUCLEAR FUEL MECHANICAL LOADS IN THE GENERAL 30 CM PACKAGE DROP SCENARIO

The US Department of Energy Spent Fuel and Waste Science and Technology (SFWST) program is performing research to determine the mechanical loading conditions applied to spent nuclear fuel (SNF) during normal conditions of transport to inform mechanical tests of SNF and close an important knowledge gap related to the practical disposition of SNF in the US. Researchers at Pacific Northwest National Laboratory (PNNL) have completed an extensive finite element study to characterize and estimate the potential mechanical loads on SNF during a hypothetical 30 cm drop of an SNF transportation package. This modeling study is validated with test data collected by the SFWST program during a physical test campaign that included one-third scale package drop tests and full-scale single fuel assembly drop tests. The test campaign was led by Sandia National Laboratories (SNL) and included international collaboration with Equipos Nucleares S.A, S.M.E (ENSA) and Bundesanstalt für Materialforschung und -prüfung (BAM). The key contribution of the modeling study is to go beyond the limitations of the limited number of physical tests to estimate the impact response to variations in impact angle, initial gap conditions, fuel assembly design, burnup and other parameters that affect the mechanical loads. The methodology of this study included a classic parametric study to calculate the impact response of highly detailed fuel assemblies over many combinations of parameters. Models of a 17x17 pressurized water reactor fuel assembly and a generic 10x10 boiling water reactor fuel assembly were both used in this study to cover the major fuel assembly types in the US inventory. Over 2,000 impact responses were calculated. The results of the parametric study were evaluated using traditional methods and basic statistics. The results were also used to construct a damage model using multiple nonlinear regression techniques to predict the mechanical loads over the full range of all input parameters. The damage model was found to work very well for all impact angle cases where the cask came to rest on its side. It was concluded that end drop cases where the cask remained vertical (instead of tipping over onto its side) were not sufficiently characterized by the current set of parametric study cases to include in the damage model, but it was not a priority to fully investigate that range because the highest mechanical loads were observed in the broader range of side impact cases. This modeling work provides sufficient insight into the mechanical loads on SNF during a hypothetical 30 cm package drop that, when considered along with the physical test data collected by the SNL-led team, the SFSWT program can consider the knowledge gap closed.

Klymyshyn, Nicholas A.↗

DOE OSTI2025

Multi-cycle reload analysis of a long cycle gas-cooled fast modular reactor

There is currently significant interest in deploying HALEU-fueled fast reactors, including the General Atomics (GA) Fast Modular Reactor (FMR). Such reactors can achieve very long fuel cycles, but with multi-batch loading will take decades to reach equilibrium. This motivates design and analysis of both the initial core and multi-cycle reload, which is typically performed using fast-running, deterministic fast reactor codes such as the Argonne Reactor Computation (ARC) codes. In this paper, multicycle reload of the GA FMR is analyzed using the ARC codes. The GA FMR utilizes 19.75 % enriched fuel in a 16 year cycle with a three-batch strategy, with twice-burned fuel placed on the core periphery. The GA FMR has a softened neutron spectrum due to reflecting elements in the core, so the neutronic solution is first benchmarked against the OpenMC Monte Carlo code. Discrepancy on k eff is 400–600 pcm, likely due to the softened neutron spectrum, heterogeneous fuel assembly design and central reflector. However, the rms discrepancy on the assembly power distribution is only 0.6 %, despite the presence of the central reflector. A reload strategy is devised for the first three cycles of such a reactor, ultimately spanning the first 45–48 years of its operation. The fresh core uses 19.75 %, 19.25 % and 16.75 % enriched fuel in place of fresh, once-burned and twice-burned and is then subsequently refueled with only 19.75 % enriched fuel. The cycle length is varied over 3 cycles of operation to balance fuel utilization and reactor availability, specifically with use of an extended 18-year Cycle 1, followed by a shortened 11-year Cycle 2. Cycle 3 is close to the target 16-year length. Finally, placing twice burned assemblies next to the GA FMR central reflector can reduce power peaking by 3 %, at the expense of slightly reducing the cycle length.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Technical report Letter: RAFM, ODS steels and MMLC for Nuclear energy application

The lifetime, thermodynamic efficiency, safety and economic viability of new generation fission and fusion reactor concepts can largely be tied to the mechanical performance and stability of structural alloys under extreme environments. In this context, engineered nano materials could have broad-reaching impact on the future of advanced nuclear fuel-cycle and reactors. These systems are characterized by a large number density of interfaces which are efficient sinks for point defects and moderately biased; therefore limiting the deleterious effects of irradiation. Broadly, nuclear nano-technology deals with the use of the latest engineered-nanomaterials for improving the nuclear power performances and safety in all areas of nuclear energy production to bring new generations of nuclear power units. New advanced fuel assembly designs also have implications for securities and safeguards. To support the readiness for potential future license applications, an understanding of the technologies that would enable new reactor designs in the areas of component performance and domestic safeguards is necessary. This technical report letter work explores the technical issues and potential regulatory considerations associated with developing and adopting fuel claddings made of advanced nano- materials. Specifically three classes of nanomaterials are considered: (i) reduced activation ferritic/martensitic (RAFM) steels, (ii)oxide dispersed steels (ODS) and (iii) multi-metallic layered composites (MMLC).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Core Physics Characteristics of Extended Enrichment and High Burnup Boiling Water Reactor Fuel

This paper presents the highlights of boiling water reactor (BWR) core physics studies performed at Oak Ridge National Laboratory as part of a series of studies conducted to compare low-enriched uranium (LEU) with LEU+ fuel. The studies analyzed isotopic fuel content, lattice parameters (Phase 1), and core physics (Phase 2) to identify challenges in operation, storage, and transportation for BWRs and pressurized water reactors (PWRs). Because of a lack of publicly available lattice and core designs for modern BWR fuel assemblies and reactor cores, several optimized lattice designs were generated, and different core loading strategies were investigated. Twelve optimized lattice designs with 235 U enrichments ranging from 1.6% to 9% and gadolinia loadings ranging from 3 to 8 wt% were used to model axial enrichment and geometry variations in fuel assemblies for core designs. Each core shares a common set of approximations in design and analysis to allow for consistent comparisons between LEU and LEU+ fuel. The objective is to highlight anticipated changes in core behavior with respect to the reference LEU core. The results of this study show that the differences in LEU and LEU+ core reactor physics characteristics are less significant than the differences in lattice physics characteristics reported in the Phase 1 studies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Design of a Loss of Coolant Blowdown Capsule for Remote Assembly with High Burnup Fuel

The Transient Water Irradiation System is an enhanced capability capsule type irradiation vehicle designed to support fuel safety research for light water reactor specimens in the Transient Reactor Test Facility and is designed to simulate loss of coolant and reactivity-initiated accidents. The capsule was designed, deployed, and commissioned with fresh fuel specimens to validate instrumentation and prepare for previously irradiated high burnup specimens. The irradiation system features an extensive in-situ instrumentation package to detect phenomena typical to light water reactor fuels. To accommodate the assembly with high burnup specimens inside the Hot Fuel Examination Facility, and to ensure instrumentation integrity is maintained throughout assembly, the design was updated to support remote handling. The updated design features a hinge mechanism which allows for remote pre-irradiated specimen loading and assembly while protecting sensitive instrumentation by relocating during loading. Fixtures and equipment have been developed to handle the experiment capsule and components in cell, and to support remote assembly. The experiment module also includes radiation shielding and contamination control to support operations after removal from the hot cell.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Modeling Non-UO2 Fuel With UNF-ST&DARDS

The U.S. Department of Energy’s Used Nuclear Fuel-Storage, Transportation & Disposal Analysis Resource and Data System (UNF-ST&DARDS) provides an easy-to-use interface to analyze irradiated UO2 fuel by allowing all analysis to be performed within the software and being able to store and use dozens of fuel assembly, canister, and cask designs [1]. However, performing these same analyses with non-UO2 fuel, such as UN or U3Si2, requires more user intervention in the process. This work uses UN, UN-ZrO2, and U3Si2 fuel to demonstrate how to perform criticality analyses in the current versions of UNF-ST&DARDS and how a non-UO2 fuel will compare to UO2. This work is part of a larger effort that also includes shielding and thermal analyses, but they will not be discussed.

Ivanusa, Pavlo↗

DOE OSTI2026

USABILITY EXTENSION OF THE ŠKODA VPVR/M CASK FOR TRANSPORTING IRRADIATED FUEL ASSEMBLIES

New abstract from the final version being submitted now: This paper discusses the evolution and enhanced usability of the ŠKODA VPVR/M cask for the transport of irradiated fuel assemblies, particularly within the context of the demand for the delivery of newly appearing irradiated HEU fuel types for which the cask did not yet have a license to transport. Over time, the cask’s internal basket construction has demonstrated notable adaptability to accommodate various exotic HEU fuel types from research reactors of differing origins. The paper outlines sever-al custom internal baskets developed for specific fuel types, including those from Belarus and Serbia, as well as from Georgia, Uzbekistan, and MNSR cores, as well as a recently designed basket for MTR and TRIGA assemblies. The findings high-light the high flexibility and adaptability of the cask, supported by successful rede-signs and licensing efforts, underscoring its value for the safe and secure transport of nuclear material. Old abstract from the draft version that was already approved: The Russian Research Reactor Fuel Return (RRRFR) program, since its inception, has continuously used the ŠKODA VPVR/M Cask fleet designed for the repatriation of irradiated highly enriched uranium (HEU) fuel. As the program progressed (from shut-down and a quasi-abandoned reactor, and/or as it began to include fuels of Chinese and US origin), new challenges emerged for the transport Cask. These were fuel types that had not yet been licensed for the Cask. Although these requirements did not arise during the design of the basic ŠKODA VPVR/M Cask, as revealed by the retrospective analyses, the Internal Basket of the ŠKODA VPVR/M Cask gives a high degree of flexibility to accommodate additional fuel types. This paper provides a brief overview of the ŠKODA VPVR/M Cask, which holds a B(U) type license, and introduces the different types of Internal Baskets that have already been licensed to transport so-called exotic irradiated HEU fuel types, in addition to the original license. The paper presents a new Internal Basket design for accommodating MTR-type and TRIGA-type irradiated HEU fuel assemblies. This includes a detailed presentation of the design basis and the new MTR-TRIGA Internal Basket, as well as the licensing matters of the package under the name ŠKODA MTR-TRIGA Cask, and the conformity test (dry- and wet-run) operations made to verify compliance with the new Internal Basket. Then, as a summary, the usage record for the Cask fleet is presented, and finally, the paper concludes with the consolidated experiences gained during the utilization of the ŠKODA VPVR/M Cask fleet, emphasizing the high degree of Cask flexibility ensured by the Internal Basket’s construction.

42 - ENGINEERING↗

DOE OSTI2024

Mini-99 Experiment Design and Target Assembly

Qualification of nuclear fuels requires an understanding of a myriad of fuel performance variables, which requires time-consuming irradiations in test reactors. Accelerating burnup accumulation to reduce the irradiation time has historically been accomplished by increasing the 235 U enrichment in integral fuel tests, which inherently couples the fuel’s temperature and fission heat generation. Separate effects irradiation testing of nuclear fuel, using the MiniFuel target in the Oak Ridge National Laboratory’s (ORNL’s) High Flux Isotope Reactor (HFIR), offers an approach for decoupling fuel temperature and fission rate by reducing the quantity of the fuel and relying primarily on gamma heating in the surrounding components to drive fuel temperatures. However, if the fission rate is high enough, the fuel temperature will still vary over time as the fission heating changes, primarily due to poor heat conduction between the fuel and the surrounding components. This work details the design, analysis, and fabrication of a MiniFuel target which utilizes sodium bonding to improve the heat rejection from the fuel specimen, enabling the testing of higher 235 U enrichments (~8wt.%) to further accelerate burnup accumulation without prohibitively large temperature variations throughout the course of the irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Concept Descriptions for the VTR Rabbit System and Driver Fuel Test Assemblies

Two of the experiment vehicles being developed for the Versatile Test Reactor (VTR) are presented here. The first is a rabbit system that will enable rapid insertion of small test capsules into the high fast flux of the VTR core for relatively short durations. The rabbit concept development includes the construction/demonstration of a near-full-scale system in a deep-water pool to demonstrate functionality, development of a concept of operations and initial procedures, and validation of thermal-hydraulic modeling. In addition, modeling efforts are underway to simulate the thermal and neutronic environment of a rabbit capsule. The second type of experiment vehicle presented here is a driver fuel test assembly for inserting fuel and materials tests into the core by replacing a driver fuel assembly. Here, a novel design for dismountable test assemblies is proposed for the VTR.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Integral Experiments Request 441 CED-3b Summary Report

Under IER-441, critical experiments were done with and without tantalum test rods within a central test region surrounded by 7uPCX fuel rods. The experiments were done in new critical assembly hardware designed to support the 7uPCX fuel in a 1.02 cm triangular-pitched array. Appendix I is a draft of section 1 of the ICSBEP benchmark evaluation of the experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Integral Experiment Request 441 CED-4a Summary Report

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Operation of the Fast Neutron Coincidence Collar (FNCL) with a DD-Neutron Generator

For more than 30 years, the quantitative assay of the 235 U content of light water reactor fresh fuel assemblies relied on measuring coincidence neutrons from fissions induced by an Am(Li) neutron source using 3 He based detectors. The Fast Neutron Collar (FNCL) developed by the International Atomic Energy Agency (IAEA), replaces traditional 3 He proportional counters with an array of liquid scintillator detectors arranged about the fuel assembly to provide improved measurement precision and reduced sensitivity to gadolinium poison rods. The FNCL relies on Am(Li) neutron sources that are no longer commercially available. This work examines the replacement of Am(Li) sources with a commercial off the-shelf deuterium–deuterium (DD) neutron generator. In addition to mitigating supply concerns, the neutron generator offers advantages in measurement precision and potential automation of sequential passive/active neutron measurements. This report presents the initial performance results for both the integrated DD/FNCL and Am(Li)/FNCL assays of compact depleted uranium, low-enriched uranium, and highly enriched uranium standards along with an estimate of the expected performance for fresh fuel assemblies. A discussion of the design and operation of the “FNCL Analysis and Simulation Software” is also provided.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Conjugate Heat Transfer Modeling of Salt-Filled Fuel Pins for Stable Salt Reactor Safety Analysis

The Stable Salt Reactor (SSR) combines the proven structural design of light water reactor fuel assemblies with the inherent safety and fuel-cycle advantages of molten salt technology. In its fast reactor configuration, the SSR utilizes recycled nuclear waste as fuel, sealed within narrow salt-filled fuel pins and cooled by a surrounding liquid salt coolant. Reliable transfer of heat from the molten fuel salt through the cladding to the external coolant is essential for both reactor safety and performance. This work investigates conjugate heat transfer (CHT) in the SSR’s salt-filled fuel pins using NekRS, a high-fidelity spectral element computational fluid dynamics (CFD) solver. The analyses capture internal natural convection within the molten fuel salt and external forced convection in the coolant, under steady-state and transient operating conditions. Parametric studies evaluate how variations in reactor power and coolant flow rate influence heat transfer distributions and system response. The high-fidelity CFD results are time-averaged and post-processed for direct comparison with moderate-fidelity Reynolds-averaged Navier–Stokes (RANS) models, and for the development of reduced-order models within the SAM system code. These validated models support fast-running safety analyses of normal and off-normal transients, improving predictive capability for key safety margins. By integrating advanced CFD with system-level safety tools, this study strengthens the modeling framework for SSR design, reduces uncertainty in molten salt CHT simulations, and accelerates the engineering and licensing of next-generation nuclear reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Fuel Behavior Implications of Reactor Design Choices in Pressurized Water SMRs

Small pressurized water reactors (PWRs) can feature boron free operation, natural circulation mode, reduced height assemblies and/or long refueling cycles. This paper attempts to explore core design optimization for each of these design evolutions. In consequence, five core design layouts are developed incorporating boron free operation with continuous control rods insertion, natural circulation with low burnup/low power density design, natural circulation with high burnup/low power density design, forced circulation with standard core power density design, and forced circulation with high power density design. These cores’ performance is compared to a standard 4-loop PWR. The design process aims to improve the fuel cycle cost under safety constraints through core design optimization using CASMO4E/SIMULATE3 reactor physics codes and FRAPCON4.1 fuel performance assessment tool. Core modeling assumes standard 17x17 PWR fuel assemblies loaded with low enriched uranium (LEU) up to 5wt% or LEU+ (i.e., below 10wt% enrichment) pellets with gadolinium oxide (Gd2O3) as the burnable poison. Satisfactory core and fuel performances are obtained for all the designed cores under steady state and considered overpower transients. For low power density operation, long cycle lengths are achieved reaching a 2.5- and a 5-year cycles and peak rod-average burnup is pushed to 83 MWd/kgU. Other cycle lengths are maintained at 18 months. Boron free operation exhibits the ability to achieve longer cycle lengths at the cost of higher peaking factors leading to high local power and fuel temperatures which prevents sizable power uprates and is deemed uneconomical. Fuel assembly height reduction allows coolant velocity retrofit which enables higher core power density without violating structural integrity of the fuel assembly. As a result, a core power density of 123 kW/l is reached where total cladding hoop strain becomes the limiting parameter.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Specification of EBR-II Fabricated Fuel Diameter Data

All IFR EBR-II fuel pins were fabricated at one of the related fuel fabrication facilities at Argonne National Laboratory-West, at the EBR-II site [1]. U-Pu-Zr experimental pins were fabricated at the Experimental Fuels Laboratory (EFL), which was established in April of 1984 after the positive acceptance of the IFR concept, while the U-Zr experimental pins were fabricated at the Fuel Manufacturing Facility (FMF), along with the driver fuel pins [2]. The injection-casting fabrication process is described in detail in ref [1]. All the fuel pins that were loaded into EBR-II were examined after fabrication to ensure that they met the design dimensional requirements and tolerances prior to assembly. Fuel slug diameter was measured with either a laser profilometer (at FMF) or a hand micrometer (at EFL), at a minimum of 1-inch intervals over the length of the fuel slug, as shown in Figure 1 [2]. In all cases the average fuel diameter is reported, in some cases with additional summary statistics (e.g., minimum, maximum), and in rare cases the complete record of axially-varying fuel diameters is available. It should be noted that in cases where axial varying data is available, in general the orientation of the slug was not recorded or carried over to loading of the pin, so a diameter measurement at the bottom of the fabricated slug does not necessarily correspond to the bottom of the loaded slug, as it may have been loaded in either orientation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Precise Control of Dissipative Self-assembly by Light and Electricity

Nature-inspired synthetic dissipative self-assemblies have attracted much attention recently. However, it remains a major challenge to achieve precise control over dissipative supramolecular assembly structures and functions of self-contained systems. Here we combine light and electricity as two clean, and spatiotemporally addressable fuels to provide precise control over the morphology for dissipative self-assembly of a perylene bisimide glycine (PBIg) building block in a self-contained solution. In this design, electrochemical oxidation provides the positive fuel to activate PBIg self-assembly while photoreduction supplies the negative fuel to deactivate the system for disassembly. Further, through programming the two counteracting fuels, we demonstrated the control of PBIg self-assembly into a variety of assembly morphologies in a self-contained system. In addition, by exerting light and electrical dual fuels simultaneously, we could create an active homeostasis exhibiting dynamic instability, leading to morphological change to asymmetric assemblies with curvatures. Such precise control over self-assembly of self-contained systems may find future applications in programming complex active materials as well as formulating pharmaceutical reagents with desired morphologies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Full Length Assembly Testing in PELICAN (Final Report)

In support of the development of the U.S. Department of Energy (DOE) Versatile Test Reactor (VTR), a thermal hydraulics test facility was constructed to generate experimental measurement of the pressure drop across a single full-scale assembly containing prototypic axial reflectors, fuel, and plena components. Constructed and operated at Argonne National Laboratory, the Pressure drop Experimental Loop for Investigations of Core Assemblies in Nuclear reactors (PELICAN) facility was designed to achieve hydraulic conditions identical to those anticipated for a full-scale fuel assembly located in the VTR core in the region with the highest flow rate. Using water as surrogate for liquid sodium, the flow loop was operated at elevated temperatures and pressures to match the thermophysical properties of liquid sodium and ensure matching Reynolds and Euler numbers. The measurement objectives for data generated from this test facility was driven primarily by the validation needs for code calculations and simulations of the reference VTR core. These objectives focused on the need to validate pressure drop results across the various segments of the fuel assembly as they relate directly to the pumping power and safety of the reactor. Presented in this report are experimental results and analytical comparisons based on testing of a full-length assembly in PELICAN. Housed within a hexagonal test section extending 3.4 m in length, the tested assembly features a prototypic lower reflector, grid plates, wire-wrapped rod bundle, upper reflector, and exit region. The rod bundle extends over 1.5 m in length and contains 217 individual wire-wrapped rods with dimensions that best reflect the reference VTR design. The as-tested bundle assembly was fabricated using 316 stainless steel 0.25-inch (6.35-mm) diameter rods wrapped with 0.04-inch (1.016-mm) diameter wire at a helical pitch of 10.51 inch (26.6 cm). Details of the method for in-house wire-wrapping, assembly, and installation are provided later in this report. Experimental measurements of pressure drop at 19 positions along the test assembly were recorded for a range of flow conditions, with special attention paid to key locations within the assembly, including component inlet and outlet, transition, and wire-wrapped rod bundle regions. Testing conditions were based on 110°C water with flow rates ranging from 50 to 450 GPM (3 to 27 kg/s) at the inlet of the test assembly generating Reynolds numbers and velocities up to ~8.0×10 4 and ~7.8 m/s, respectively, within the rod bundle region. Non-dimensional values for the friction factor were then calculated based on these experimental measurements and compared against those predicted by various analytical correlations available from open literature. Predictions by the upgraded Cheng and Todreas, Rehme, and Novendstern correlations fell within 4% to those values measured experimentally.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗