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DOE OSTI2011

THE INTEGRATION OF PROCESS HEAT APPLICATIONS TO HIGH TEMPERATURE GAS REACTORS

A high temperature gas reactor, HTGR, can produce industrial process steam, high-temperature heat-transfer gases, and/or electricity. In conventional industrial processes, these products are generated by the combustion of fossil fuels such as coal and natural gas, resulting in significant emissions of greenhouse gases such as carbon dioxide. Heat or electricity produced in an HTGR could be used to supply process heat or electricity to conventional processes without generating any greenhouse gases. Process heat from a reactor needs to be transported by a gas to the industrial process. Two such gases were considered in this study: helium and steam. For this analysis, it was assumed that steam was delivered at 17 MPa and 540 C and helium was delivered at 7 MPa and at a variety of temperatures. The temperature of the gas returning from the industrial process and going to the HTGR must be within certain temperature ranges to maintain the correct reactor inlet temperature for a particular reactor outlet temperature. The returning gas may be below the reactor inlet temperature, ROT, but not above. The optimal return temperature produces the maximum process heat gas flow rate. For steam, the delivered pressure sets an optimal reactor outlet temperature based on the condensation temperature of the steam. ROTs greater than 769.7 C produce no additional advantage for the production of steam.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Effects of break geometry and orientation on helium-air mixing in simulated reactor cavities of high temperature gas reactors

Here, this study experimentally examined the spatial and temporal variations in air and helium concentrations and temperature fields within simulated reactor cavities of a High Temperature Gas Reactor (HTGR) following helium discharge into an initially air-filled reactor cavity system. Detailed temperature maps were generated using a combination of fiber optics temperature sensor and multiple thermocouple probes within the simulated reactor cavities. The research scenario involved a hypothetical small pipe break in the Reactor Pressure Vessel, resulting in the release of high-temperature helium into the surrounding cavity. A scaled multi-compartment experimental facility, modeled after the General Atomics Modular High Temperature Gas Reactor (GA-MHTGR) design, was constructed for helium and air mixing experiments. Oxygen sensors and thermocouple probes were installed in all five cavities to measure the concentrations of oxygen (or helium) and the temperature distributions of the gas mixture. The experimental findings highlighted the significant impact of the injected helium jet velocity on the gas mixing process and demonstrated how the direction of the helium jet influences the air-helium temperature profiles within the cavities.

Air-ingress↗

DOE OSTI2023

A Conceptual Design of the Reactor Cavity Cooling System for the Horizontal Compact High Temperature Gas Reactor (HC-HTGR)

Horizontal Compact High Temperature Gas Reactor (HC-HTGR) is being designed by a multi-disciplinary team of nuclear, mechanical, and structural engineers under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed HC-HTGR in 3 years and support its commercialization as a safe, low-cost HTGR. Argonne National Laboratory (Argonne) is responsible for the design and analysis of the reactor cavity cooling system (RCCS) as a safety system for passive decay heat removal of the reactor concept. This report documents the design study to derive a conceptual design study of the RCCS for the HC-HTGR. It includes the identification of the functions and requirements of the HC-HTGR RCCS, design analyses including high-level design consideration and the calculations for optimizing design space of the system with supporting component-level analysis to inform the material selection and performance of the water panel, the description of the conceptual design of the HC-HTGR RCCS derived based on the analyses results, and performance evaluation of the conceptual RCCS for the HC-HTGR. A detailed concept of the RCCS has been identified and high-level system requirements has been developed for the HC-HTGR. Design space focusing on the natural circulation loop portion of the RCCS has been investigated to optimize the system performance. The initial baseline dimensions were firstly derived based on the scoping calculations. A component level design analysis was conducted for the water panel to inform the material selection and to assess its conduction performance. A preliminary system-level performance analysis was performed for the 1/8th of the compartment of the initial baseline design of the RCCS using RELAP5-3D. To improve the system thermal performance, the RCCS design has been updated by exploring various design options by design parametric analyses. Based on the results, the conceptual design of the RCCS for the HC-HTGR has been derived, which satisfies the target performance of ~1 MWt at the elevated vessel wall temperature conditions. Transient simulations were conducted for the conceptual RCCS design for the HC-HTGR under various operation modes and heat load conditions using RELAP5-3D. The system dynamics in different operating states was investigated and the system performance under transients of interest was evaluated. The results demonstrated the overall system feasibility that the RCCS design maintains structures temperatures lower than maximum allowable temperature with sufficient system inventory without any active heat removal in the design process with certain transients addressed. The HC-HTGR RCCS will have additional design updates of subsystems or optimization of the system components during the preliminary and final design phases. Since the entire plant has not been integrated yet, this delivered conceptual design is subject to changes for integration, that require additional conceptual design activities and Quality and Assurance implementation (Q&A). The performance assessment of the RCCS for the HC-HTGR will be then revisited and optimized to finalize the system design, and the RCCS integrated primary system analysis will be utilized to simulate selective accident scenarios of interest where efforts are currently undergoing in the project.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Semi-Annual Report for Modular Integrated Gas High Temperature Reactor Development during Performance Period April 2022 - September 2022

Horizontal Compact High Temperature Gas Reactor (HC-HTGR) is being designed by a multidisciplinary team of nuclear, mechanical, and structural engineers under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed HC-HTGR in 3 years and support its commercialization as a safe, low-cost HTGR. Argonne National Laboratory (Argonne) is responsible for the design and analysis of the reactor cavity cooling system (RCCS) as a safety system for passive decay heat removal of the reactor concept. Additionally, Argonne is providing analysis of the primary coolant system to ensure temperatures within the core remain below safety margins during steady-state and potential accident scenarios. This second semi-annual report summarized the progress made at Argonne on the two tasks during the second half of FY22. As a part of the RCCS design task, a scoping calculation in estimating HVAC capability for the HC-HTGR reactor building was performed. A water panel modeling study was first performed with the test case, which confirms the capability of the RELAP5-3D modeling approach to explore various design options of the HC-HTGR RCCS under consideration. Then, a reference RELAP5-3D model for the unit geometry of the preliminary design of the HC-HTGR RCCS was developed. A preliminary performance analysis was conducted to evaluate the performances of a single-phase natural circulation and panel conduction in various operating conditions. For the primary coolant system analysis task, preliminary thermal hydraulic analysis of the HC-HTGR core design was performed with a high resolution 1D fluid-3D solid coupled model using the System Analysis Module (SAM) to assess the assembly coolant channel and bypass flow mass flow rate distribution. Some preliminary work on the development of a full core reduced order model was discussed following the assembly level model to predict the core wide coolant flow distribution and to model certain operational and accidental transients.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Helium-air mixing in simulated reactor cavities of high temperature gas reactors

Not provided.

Nuclear Science & Technology↗

DOE OSTI2024

Primary System Thermal Fluids Analysis Model Development for the Compact High Temperature Gas Reactor (HC-HTGR) (Final Report)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

A High Temperature Gas Reactor Integrated Energy System Using Energy Storage as a Buffer for Hydrogen Production

Analysis of an integrated energy system producing hydrogen in a high temperature steam electrolysis system via steam provided by a sensible heat thermal energy storage system charged by a high temperature gas reactor. Preliminary results over a continuous discharge cycle and single charging cycle shows minimal reactor impact despite 25% electrical power load change. Hydrogen production is held constant with steam provided by the thermal energy storage system.

08 HYDROGEN↗

DOE OSTI2021

Economic solution for low carbon process heat: A horizontal, compact high temperature gas reactor

In 2018, nuclear energy generated 55% of United States’ and one third of the world’s carbon free electricity, making nuclear energy a key tool in efforts to mitigate climate change before 2050. However, the current nuclear technology, light water reactors (LWRs), is limited to 300°C, so it cannot be used to decarbonize industrial process heat which accounts for 12% of US greenhouse gas emissions. High temperature gas reactors (HTGRs) can meet the high temperature demand with carbon free nuclear heat. The estimated cost of HTGRs, such as the Next Generation Nuclear Plant (NGNP), are even higher than state-of-the-art LWRs. In this paper, we expanded our nuclear cost estimating tool to include HTGRs and find that the NGNP overnight capital costs were 32% higher than an advanced LWR per unit capacity. The higher cost will naturally result in larger risk to cost overrun as recently experienced by larger LWRs in western nations. With a design-to-build mindset to minimize cost and construction risk, we introduce the horizontal, compact HTGR (HC-HTGR). The reactor core and steam generator are mounted horizontally on rails and in-line with one another, decreasing the size of the reactor building relative to the power capacity four times when compared to traditional HTGRs. The HC-HTGR reduced overnight civil structure costs by 42%, indirect costs by 38%, and total capital costs by 20% from NGNP. We discussed the required engineering of new systems for the HC-HTGR including vessel supports, the reactor cavity cooling system, and steam generator design. Finally, we estimated the fuel and operations costs of the HC-HTGR, and a survey of low-carbon industrial process heat technology showed the HC-HTGR can deliver a highly competitive levelized cost of heat in the range of $6.13–12.48/GJ.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Presentation Deck A High Temperature Gas Reactor Integrated Energy System Using Energy Storage as a Buffer for Hydrogen Production

Presentation on results of submitted paper "A High Temperature Gas Reactor Integrated Energy System Using Energy Storage as a Buffer for Hydrogen Production."

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Semi-Annual Report for Modular Integrated Gas High Temperature Reactor Development during Performance Period October 2021 - March 2022

Modular Integrated Gas High Temperature Reactor (MIGHTR) is being designed by a multidisciplinary team of nuclear, mechanical, and structural engineers under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed MIGHTR in 3 years and support its commercialization as a safe and low-cost HTGR. Argonne National Laboratory is responsible for the design and analysis of the reactor cavity cooling system (RCCS) as a safety system for passive decay heat removal of the reactor concept. Work performed by Argonne also includes the thermal hydraulics analysis of the primary heat transport system including reactor pressure vessel (RPV) internals for normal operation, shutdown, and accident conditions. This first semi-annual report summarizes the progress made at Argonne on the two tasks since the start of the project. For the RCCS design task, high-level design work was performed including identification of design requirements for the conceptual MIGHTR RCCS and initial design calculations. The baseline dimensions of the MIGHTR RCCS were derived from scoping analysis results and preliminary steady state performance was estimated. At the initial stage of the primary system analysis task, the primary system thermal fluids model for the MIGHTR core was outlined to use a simplified two-dimensional model to predict the temperature distribution and coolant pressure losses in the fuel assembly blocks.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Semi-Annual Report for Horizontal Compact High Temperature Gas Reactor (HC-HTGR) Development during Performance Period October 2022-March 2023

Horizontal Compact High Temperature Gas Reactor (HC-HTGR) is being designed by a multi-disciplinary team of nuclear, mechanical, and structural engineers under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed HC-HTGR in 3 years and support its commercialization as a safe, low-cost HTGR. Argonne National Laboratory (Argonne) is responsible for the design and analysis of the reactor cavity cooling system (RCCS) as a safety system for passive decay heat removal of the reactor concept. Additionally, Argonne is providing analysis of the primary heat transport system to ensure temperatures in the reactor systems, structures and components with significant safety margins during normal operation and design basis accident scenarios. This third semi-annual report summarized the progress made at Argonne on the two tasks during the first half of FY23. As a part of the RCCS design task, a design process for the water panel and the system configuration was performed to improve the thermal performance of the RCCS. The updated water panel design had achieved enhanced thermal performance with 0.96 MWth capability with major design updates made in structural interfaces with the RPV and initial configuration of the water tanks. The loop configuration of the RCCS has been proposed to have two independently working loops for system redundancy. A water panel material study was performed focusing on the use of carbon steel in water systems. Additional modeling strategies of primary system thermal fluids analyses were developed to meet modeling needs that are not well suited for the 1D-3D assembly level approach. The first of these is a reduced order assembly model, in which fuel centered unit cells are used to represent a fuel assembly. The 2D approach used in this model is much more computationally efficient, making this model useful for full core transient scenarios where fuel to coolant heat transfer is still the dominant flow path. The next model is the 3D core conduction model to be used to analyze decay heat removal in loss of primary system flow scenarios. Because these scenarios require a large domain to be modeled, a homogenized core model is being pursued to reduce the required computational costs. To accurately model decay heat scenarios it is necessary to couple a RCCS model to the 3D core conduction model. A simplified case is presented to demonstrate how the coupling methodology will be applied to the full core 3D conduction model.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Semi-Annual Report for Horizontal Compact High Temperature Gas Reactor (HC-HTGR) Development during Performance Period April 2023 – September 2023

Horizontal Compact High Temperature Gas Reactor (HC-HTGR) is being designed by a multi-disciplinary team of nuclear, mechanical, and structural engineers under the support of a DOE-NE Advanced Reactor Demonstration Program’s Advanced Reactor Concepts-20 (ARC-20) award. The objective of this ARC-20 project is to deliver a conceptual design for the proposed HC-HTGR in 3 years and support its commercialization as a safe, low-cost HTGR. Argonne National Laboratory (Argonne) is responsible for the design and analysis of the reactor cavity cooling system (RCCS) as a safety system for passive decay heat removal of the reactor concept. Additionally, Argonne is providing analysis of the primary coolant system to ensure temperatures within the core remain below safety margins during steady-state and potential accident scenarios. This fourth semi-annual report summarized the progress made at Argonne on the two tasks during the second half of FY23. As a part of the RCCS design task, recent efforts have been made to complete a conceptual design of the RCCS for the HC-HTGR, including the design update of the water panel and system configuration favorable in point of view of fabrication and system operation. Design calculations were conducted under various heat load conditions to validate the system design. Transient simulations using RELAP5-3D were conducted to investigate system dynamics under transients of interest and to evaluate the system performance in the design condition. The results demonstrated the overall system feasibility that the RCCS design maintains structures temperatures lower than maximum allowable temperature with sufficient system inventory without any active heat sink. In the primary system thermal hydraulics task, the preliminary analysis was performed for a long term pressurized conduction cooldown (PCC) transient. This analysis used a combination of a fully resolved and coarse homogenized mesh to predict the temperature distribution for the steady-state initial condition and the PCC transient. The steady-state initial condition was determined using a fully resolved full core model with 3D solid to 1D fluid coupling. The fully resolved mesh was also used to model the first 20 seconds of the PCC. The temperature difference between fuel pins and the graphite matrix becomes minimal and the dominant heat transfer shifts to a larger scale radially towards the RCCS. After 20 seconds, a homogenized coarse mesh is used, greatly reducing the computational costs of the model. These results demonstrate that the core is designed to passively remove enough decay heat in a protected loss of primary coolant flow to prevent an unsafe rise of core temperatures.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2012

Development of a coolant channel helium and nitrogen gas ratio sensor for a high temperature gas reactor

To measure the changing gas composition of the coolant during a postulated High Temperature Gas Reactor (HTGR) accident, an instrument is needed. This instrument must be compact enough to measure the ratio of the coolant versus the break gas in an individual coolant channel. This instrument must minimally impact the fluid flow and provide for non-direct signal routing to allow minimal disturbance to adjacent channels. The instrument must have a flexible geometry to allow for the measurement of larger volumes such as in the upper or lower plenum of a HTGR. The instrument must be capable of accurately functioning through the full operating temperature and pressure of a HTGR. This instrument is not commercially available, but a literature survey has shown that building off of the present work on Capacitance Sensors and Cross-Capacitors will provide a basis for the development of the desired instrument. One difficulty in developing and instrument to operate at HTGR temperatures is acquiring an electrical conductor that will not melt at 1600 deg. C. This requirement limits the material selection to high temperature ceramics, graphite, and exotic metals. An additional concern for the instrument is properly accounting for the thermal expansion of both the sensing components and the gas being measured. This work covers the basic instrument overview with a thorough discussion of the associated uncertainty in making these measurements. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Transient Physical Modelling for the Coupling of a High Temperature Gas Reactor with Thermal Energy Storage

Improving the flexibility of nuclear reactors to meet fluctuating demand on grids with high renewable energy generation penetration is key to improving reactor economics. Economic optimization using the code HERON gives maximum profit of coupling high temperature gas reactors (HTGRs) to thermal energy storage (TES) systems in the configuration shown in Figure 1 when following the demand in Figure 3. We look to model the physics of operation for a HTGR-TES using the HYBRID library in the code Modelica.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Modeling and Simulations of Thermal-Fluid Phenomena Related to Pressurized Conduction Cooldown in High Temperature Gas Reactor

Under the support of DOE-NE’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) Program, an effort is being pursued to support High Temperature Gas Reactors (HTGR) technology development and its modeling and simulation needs. There is a particular need for advanced modeling & simulation tools to predict thermal-fluid behavior in the nuclear reactor primary system—especially the core and lower and upper plena—during safety-related transients.To help accomplish this, we must provide confidence in the reliability and accuracy of the thermal fluid simulation tools being developed under the NEAMS program for HTGR applications. The benchmark simulations of the available experimental tests would help us in this effort.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Coupled Monte Carlo and thermal-fluid modeling of high temperature gas reactors using Cardinal

Cardinal is an open-source application that couples OpenMC Monte Carlo transport and NekRS computa-tional fluid dynamics to the Multiphysics Object-Oriented Simulation Environment (MOOSE), closing neutronics and thermal-fluid gaps in conducting high-resolution multiscale and multiphysics analyses of nuclear systems. Here, we provide an introduction to Cardinal's software design, data mapping, and multi -physics coupling strategy to highlight our approach to overcoming common challenges in multiphysics simulation. We then describe an application of Cardinal to prismatic High Temperature Gas Reactors (HTGRs) with various combinations of NekRS, OpenMC, BISON, and THM. A high-resolution coupling of NekRS, OpenMC, and BISON provides a reference solution at the unit cell level and shows excellent agree-ment with a lower-resolution coupling of THM, OpenMC, and BISON. A full core coupling of THM, OpenMC, and BISON resolving the three-dimensional conjugate heat transfer and sub-pin power distri-bution then provides detailed predictions of HTGR temperatures and the fission distribution.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2012

Safeguards-by-Design: Guidance for High Temperature Gas Reactors (HTGRs) With Pebble Fuel

The following is a guidance document from a series prepared for the U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA), under the Next Generation Safeguards Initiative (NGSI), to assist facility designers and operators in implementing international Safeguards-by-Design (SBD). SBD has two main objectives: (1) to avoid costly and time consuming redesign work or retrofits of new nuclear fuel cycle facilities and (2) to make the implementation of international safeguards more effective and efficient at such facilities. In the long term, the attainment of these goals would save industry and the International Atomic Energy Agency (IAEA) time, money, and resources and be mutually beneficial. This particular safeguards guidance document focuses on pebble fuel high temperature gas reactors (HTGR). The purpose of the IAEA safeguards system is to provide credible assurance to the international community that nuclear material and other specified items are not diverted from peaceful nuclear uses. The safeguards system consists of the IAEA’s statutory authority to establish safeguards; safeguards rights and obligations in safeguards agreements and additional protocols; and technical measures implemented pursuant to those agreements. Of foremost importance is the international safeguards agreement between the country and the IAEA, concluded pursuant to the Treaty on the Non-Proliferation of Nuclear Weapons (NPT). According to a 1992 IAEA Board of Governors decision, countries must: notify the IAEA of a decision to construct a new nuclear facility as soon as such decision is taken; provide design information on such facilities as the designs develop; and provide detailed design information based on construction plans at least 180 days prior to the start of construction, and on "as-built" designs at least 180 days before the first receipt of nuclear material. Ultimately, the design information will be captured in an IAEA Design Information Questionnaire (DIQ), prepared by the facility operator, typically with the support of the facility designer. The IAEA will verify design information over the life of the project. This design information is an important IAEA safeguards tool. Since the main interlocutor with the IAEA in each country is the State Regulatory Authority/SSAC (or Regional Regulatory Authority, e.g. EURATOM), the responsibility for conveying this design information to the IAEA falls to the State Regulatory Authority/SSAC.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2012

Safeguards-by-Design:Guidance for High Temperature Gas Reactors (HTGRs) With Prismatic Fuel

Introduction and Purpose The following is a guidance document from a series prepared for the U.S. Department of Energy (DOE) National Nuclear Security Administration (NNSA), under the Next Generation Safeguards Initiative (NGSI), to assist facility designers and operators in implementing international Safeguards-by-Design (SBD). SBD has two main objectives: (1) to avoid costly and time consuming redesign work or retrofits of new nuclear fuel cycle facilities and (2) to make the implementation of international safeguards more effective and efficient at such facilities. In the long term, the attainment of these goals would save industry and the International Atomic Energy Agency (IAEA) time, money, and resources and be mutually beneficial. This particular safeguards guidance document focuses on prismatic fuel high temperature gas reactors (HTGR). The purpose of the IAEA safeguards system is to provide credible assurance to the international community that nuclear material and other specified items are not diverted from peaceful nuclear uses. The safeguards system consists of the IAEA’s statutory authority to establish safeguards; safeguards rights and obligations in safeguards agreements and additional protocols; and technical measures implemented pursuant to those agreements. Of foremost importance is the international safeguards agreement between the country and the IAEA, concluded pursuant to the Treaty on the Non-Proliferation of Nuclear Weapons (NPT). According to a 1992 IAEA Board of Governors decision, countries must: notify the IAEA of a decision to construct a new nuclear facility as soon as such decision is taken; provide design information on such facilities as the designs develop; and provide detailed design information based on construction plans at least 180 days prior to the start of construction, and on "as-built" designs at least 180 days before the first receipt of nuclear material. Ultimately, the design information will be captured in an IAEA Design Information Questionnaire (DIQ), prepared by the facility operator, typically with the support of the facility designer. The IAEA will verify design information over the life of the project. This design information is an important IAEA safeguards tool. Since the main interlocutor with the IAEA in each country is the State Regulatory Authority/SSAC (or Regional Regulatory Authority, e.g. EURATOM), the responsibility for conveying this design information to the IAEA falls to the State Regulatory Authority/SSAC. For the nuclear industry to reap the benefits of SBD (i.e. avoid cost overruns and construction schedule slippages), nuclear facility designers and operators should work closely with the State Regulatory Authority and IAEA as soon as a decision is taken to build a new nuclear facility. Ideally, this interaction should begin during the conceptual design phase and continue throughout construction and start-up of a nuclear facility. Such early coordination and planning could influence decisions on the design of the nuclear material processing flow-sheet, material storage and handling arrangements, and facility layout (including safeguards equipment), etc.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗