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NASA NTRS2020

KRUSTY Reactor Design

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a reactor design, development, and test program to demonstrate the nuclear operation of a Kilopower reactor. Kilopower systems are intended to provide between 1 and 10 kW(electric) in space, or on the surface of planets or moons, with a clear evolution to substantially higher power systems. KRUSTY was a prototype of a 1-kW(electric) highly enriched uranium–fueled Kilopower system. In March of 2018, KRUSTY successfully operated as a fission power system and was the first nuclear-powered operation of any truly new reactor concept in the United States in over 40 years. This paper discusses the design of the KRUSTY reactor along with the philosophy, goals, and engineering work that ultimately led to KRUSTY’s success.

Kilopower↗
NASA NTRS2017

Electrically Heated Testing of the Kilowatt Reactor Using Stirling Technology (KRUSTY) Experiment Using a Depleted Uranium Core

The Kilopower project aims to develop and demonstrate scalable fission-based power technology for systems capable of delivering 110 kW of electric power with a specific power ranging from 2.5 - 6.5 Wkg. This technology could enable high power science missions or could be used to provide surface power for manned missions to the Moon or Mars. NASA has partnered with the Department of Energys National Nuclear Security Administration, Los Alamos National Labs, and Y-12 National Security Complex to develop and test a prototypic reactor and power system using existing facilities and infrastructure. This technology demonstration, referred to as the Kilowatt Reactor Using Stirling TechnologY (KRUSTY), will undergo nuclear ground testing in the summer of 2017 at the Nevada Test Site. The 1 kWe variation of the Kilopower system was chosen for the KRUSTY demonstration. The concept for the 1 kWe flight system consist of a 4 kWt highly enriched Uranium-Molybdenum reactor operating at 800 degrees Celsius coupled to sodium heat pipes. The heat pipes deliver heat to the hot ends of eight 125 W Stirling convertors producing a net electrical output of 1 kW. Waste heat is rejected using titanium-water heat pipes coupled to carbon composite radiator panels. The KRUSTY test, based on this design, uses a prototypic highly enriched uranium-molybdenum core coupled to prototypic sodium heat pipes. The heat pipes transfer heat to two Advanced Stirling Convertors (ASC-E2s) and six thermal simulators, which simulate the thermal draw of full scale power conversion units. Thermal simulators and Stirling engines are gas cooled. The most recent project milestone was the completion of non-nuclear system level testing using an electrically heated depleted uranium (non-fissioning) reactor core simulator. System level testing at the Glenn Research Center (GRC) has validated performance predictions and has demonstrated system level operation and control in a test configuration that replicates the one to be used at the Device Assembly Facility (DAF) at the Nevada National Security Site. Fabrication, assembly, and testing of the depleted uranium core has allowed for higher fidelity system level testing at GRC, and has validated the fabrication methods to be used on the highly enriched uranium core that will supply heat for the DAF KRUSTY demonstration.

Briggs, Maxwell H.↗
NASA NTRS2018

Electrically Heated Testing of the Kilowatt Reactor Using Stirling TechnologY (KRUSTY) Experiment Using a Depleted Uranium Core

The Kilopower project aims to develop and demonstrate scalable fission-based power technology for systems capable of delivering 1 to 10 kW of electric power with a specific power ranging from 2.5 to 6.5 W/kg. This technology could enable high-power science missions or could be used to provide surface power for manned missions to the Moon or Mars. NASA has partnered with the U.S. Department of Energy's National Nuclear Security Administration, Los Alamos National Laboratory, Nevada National Security Site (NNSS), and Y−12 National Security Complex to develop and test a prototypic reactor and power system using existing facilities and infrastructure. This technology demonstration, referred to as the "Kilowatt Reactor Using Stirling TechnologY (KRUSTY)," will undergo nuclear ground testing by the end of calendar year (CY) 2017 at the NNSS. The 1-kWe variation of the Kilopower system was chosen for the KRUSTY demonstration. The concept for the 1-kWe flight system consists of a 4 kWt highly enriched uranium-molybdenum reactor operating at 800 degC coupled to sodium heat pipes. The heat pipes deliver heat to the hot ends of eight 125-W Stirling convertors producing a net electrical output of 1 kW. Waste heat is rejected using titanium-water heat pipes coupled to carbon composite radiator panels. The KRUSTY test, based on this design, uses a prototypic highly enriched uranium-molybdenum core coupled to prototypic sodium heat pipes. The heat pipes transfer heat to two Advanced Stirling Convertors (ASC−E2s) and six thermal simulators, which simulate the thermal draw of full-scale power conversion units. Thermal simulators and Stirling engines are gas cooled. The most recent project milestone was the completion of nonnuclear system-level testing using an electrically heated depleted uranium (DU) (nonfissioning) reactor core simulator at the NASA Glenn Research Center. System-level testing has validated performance predictions and has demonstrated system-level operation and control in a test configuration that replicates the one to be used at the Device Assembly Facility (DAF) at the NNSS. Fabrication, assembly, and testing of the DU core has allowed for higher fidelity system-level testing at Glenn, and has validated the fabrication methods to be used on the highly enriched uranium core that will supply heat for the DAF KRUSTY demonstration.

Briggs, Maxwell H.↗
NASA NTRS2020

Kilopower Project: The KRUSTY Fission Power Experiment and Potential Missions

The Kilopower Project was initiated by NASA’s Space Technology Mission Directorate/Game Changing Development Program in fiscal year 2015 to demonstrate subsystem-level technology readiness of small space fission power in a relevant environment (Technology Readiness Level 5) for space science and human exploration power needs. The Kilopower Project centerpiece is the Kilowatt Reactor Using Stirling TechnologY (KRUSTY) test, which consists of the development and testing of a ground technology demonstrator of a 1-kW(electric)–class fission power system (FPS). The technologies to be developed and validated by KRUSTY are extensible to space FPSs from 1 to 10 kW(electric), which can enable modular surface FPSs for human exploration as well as higher-power future potential deep space science missions. The KRUSTY demonstration is cofunded by NASA and the U.S. Department of Energy National Nuclear Security Administration. The KRUSTY demonstration in the National Critical Experiment Research Center’s Device Assembly Facility was completed in the first quarter of 2018.

Space nuclear reactor↗
NASA NTRS2020

Results of the KRUSTY Warm Critical Experiments

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a prototypic nuclear-powered test of a 5-kW(thermal) Kilopower space reactor. This paper presents results from the KRUSTY warm critical experiments, which were completed prior to the final system test. The first set of criticals comprised cold or zero-power criticals; i.e., the core was not heated by fission power. These were followed by three warm criticals, where fission power heated the core to 200°C, 300°C, and 450°C, respectively. These criticals provided the data, confidence, and regulatory framework that were needed to proceed with the KRUSTY nuclear system test. The criticals also provided valuable data for the benchmarking of codes applicable to all nuclear systems. Finally, a comparison of KRUSTY results to pretest predictions is provided, and overall, the models matched the experimental results very closely.

David I. Poston↗
DOE OSTI2025

Multiphysics Simulation of KRUSTY Warm Critical Experiments Using MOOSE Tools

A series of critical experiments were performed during the Kilopower Reactor Using Stirling TechnologY (KRUSTY) project, producing valuable and unique data for the validation of corresponding microreactor models. In this paper, the development of a high-fidelity multiphysics model of the KRUSTY microreactor within the MOOSE ecosystem is presented, with a focus on the microreactor configuration during the warm critical experiments. The model was established by coupling a deterministic neutronics model using the Griffin code, with a BISON thermomechanical model. The multiphysics model successfully simulated the KRUSTY 15 ¢ and 30 ¢ warm critical reactivity insertion experiments in satisfactory agreement with the experimental measurement data. In conclusion, the modeling results demonstrated the performance of MOOSE-based multiphysics tools in microreactor simulations, and spotlighted the useful applications of these tools in supporting microreactor design, qualification, and licensing activities.

KRUSTY↗
DOE OSTI2024

Model Validation and Uncertainty Quantification on the KRUSTY Microreactor Design Using GRIFFIN Neutron Transport Code [Poster]

Argonne National Laboratory (ANL) and INL have developed a GRIFFIN steady state neutronics model for the multiphysics simulations of the Kilopower Reactor Using Sterling TechnologY (KRUSTY) microreactor in the Multiphysics Object Oriented Simulation Environment (MOOSE). The reliability of such deterministic neutronics models can be validated by comparing with computations from Monte Carlo codes (e.g. MCNP, SERPENT, OpenMC, Shift, etc). Furthermore, potential modeling/design improvements can be identified by incorporating uncertainty quantification (UQ), which can be performed by MOOSE’s Stochastic Tools Module (STM). KRUSTY is a prototype for a 5-kW thermal nuclear-powered space reactor. Its primary components consist of nuclear fuel, heat pipes, a control rod, a reflector, and the shielding. The fuel consists of 3 stacked U-7.65Mo cylinders with a hole in the center for the control rod. 8 liquid sodium heat pipes transfer fission energy from the solid fuel block to the Sterling power conversion system where the energy is extracted, and the cooled sodium flows back to the core via capillary action . The movable Boron Carbide control rod regulates the neutron population during startup or when a reactor temperature boost is needed . The beryllium oxide reflector is in 3 places in the reactor; it surrounds the core axially, it lies beneath the core on a platen, and it is present in the shim. The axial and lower reflectors rest on an adjustable stainless-steel platen that moves upward to cover the fuel and help the reactor reach criticality. Lastly, radial stainless steel surrounds the core offering protection from radiation exposure .

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Multiphysics Modeling of Microreactors with NEAMS codes, and Validation Based on KRUSTY Reactivity Insertion

The NEAMS Multiphysics Applications team continues to assess code usability and functionality for microreactor design and safety analyses, while demonstrating that NEAMS tools capture both steady-state and transient behavior across distinct microreactor concepts. In FY2025, the team advanced full-core, high-fidelity, multiphysics models that solve more complex problems and strengthen verification/validation for several microreactor systems: heat-pipe microreactor (HPMR), gas-cooled microreactor (GCMR), and the KRUSTY experiment. These models employ the MOOSE MultiApp/Transfers architecture with Griffin for neutronics, BISON for heat conduction/thermomechanics, Sockeye for heat pipes, SAM/THM for coolant channels and loops, and SWIFT for hydride behavior, with meshes generated via the MOOSE Reactor Module. The graphite models available in the Grizzly code were also investigated for future analyses. For the HPMR, a Na-HPMR variant was constructed to align with recently validated heat-pipe experiments and Sockeye’s LCVF capability, enabling mechanistic heat-pipe transients and startup modeling. The Na-HPMR will serve as the primary model for HPMR investigations in upcoming tasks. The load-following and single heat-pipe failure scenarios (Griffin/BISON/Sockeye), which were previously modeled for the K-HPMR, were replicated for the Na-HPMR, showing strong negative temperature feedback and highly localized thermal effects, respectively, while the startup case captured vapor-front progression and heat-removal activation. Solid mechanics was added to the previously built K-HPMR full-core model in BISON, showing minimal impact on steady-state reactivity yet enabling stress-field predictions that prepare the path for full-core TRISO performance analyses. For the GCMR, automated steady-state and four transient scenarios were executed using Griffin/BISON/SAM/SWIFT. Results confirm robust inherent safety: power collapses promptly in loss-of-cooling events, the inlet-temperature drop settles to a new equilibrium, and a single-channel blockage yields only a ~30 K local fuel-temperature rise with <0.4% power decrease. SWIFT-predicted hydrogen redistribution affects reactivity during both steady-state and transient conditions, underscoring its importance. A Brayton-cycle balance of plant (BOP) model in SAM/THM demonstrated stable startup behavior, and xenon-driven reactivity during load following was analyzed. To improve TRISO-compact temperature fidelity, a fast multiscale Heat Source Decomposition (HSD) treatment was implemented. Against heterogeneous benchmarks, HSD reduces underprediction of kernel temperatures and lowers predicted peak powers in reactivity-insertion transients compared to previous homogenized models. KRUSTY warm-critical validation progressed from FY2024 baselines: the 15Ȼ insertion shows excellent agreement in peak power (~2% high) and temperature trends, and the 30Ȼ case was automated via a feedback controller that maintained power near 3 kW for ~150 s with close agreement to data. The successful modeling of the warm critical tests has laid a strong foundation for simulating more complex nuclear system tests in the years ahead. Throughout FY2025, developer feedback was provided (e.g., MOOSE batch mesh generation, distributed pre-split meshes, Griffin sweeper on displaced meshes), several new models were contributed to the Virtual Test Bed, and an OECD-NEA WPRS multiphysics benchmark based on the HPMR was initiated to enable broader cross-comparison and best-practice development with the nuclear community at large.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2018

The Kilopower Reactor Using Stirling TechnologY (KRUSTY) Nuclear Ground Test Results and Lessons Learned

The Kilopower nuclear ground testing nicknamed KRUSTY (Kilopower Reactor Using Stirling TechnologY) was completed at the Nevada Nuclear Security Site (NNSS) on March 21, 2018. This full scale nuclear demonstration verified the Kilopower reactor neutronics during startup, steady state, and transient operations in a space simulated environment. This was the first space reactor test completed for fission power systems in over 50 years and marked a turning point in NASA's nuclear program. The completed reactor power system design incorporated flight prototypic materials and full scale components in an effort to study the reactor dynamics at full power and significantly reduce follow on risk of a future flight demonstration. This design provided a unique opportunity for the power system to simulate several expected and unexpected mission scenarios that allowed the designers to verify that the reactor dynamics could tolerate many worst case conditions regarding reactor stability and control. The dynamic changes imposed on the reactor validated the ability of the reactor to load follow the power conversion system and passively control the fuel temperature and overall system stability. With successful completion of the KRUSTY experiment, the NASA/DOE team will evaluate the lessons learned throughout the project and apply them towards a flight demonstration of a Kilopower reactor.

Gibson, Marc A.↗
NASA NTRS2018

Kilopower Reactor Using Stirling TechnologY (KRUSTY) Nuclear Ground Test Results and Lessons Learned

The Kilopower nuclear ground testing nicknamed KRUSTY (Kilopower Reactor Using Stirling TechnologY) was completed at the Nevada Nuclear Security Site (NNSS) on March 21, 2018. This full scale nuclear demonstration verified the Kilopower reactor neutronics during startup, steady state, and transient operations in a space simulated environment. This was the first space reactor test completed for fission power systems in over 50 years and marked a turning point in NASA's nuclear program. The completed reactor power system design incorporated flight prototypic materials and full-scale components in an effort to study the reactor dynamics at full power and significantly reduce follow on risk of a future flight demonstration. This design provided a unique opportunity for the power system to simulate several nominal and off-nominal mission scenarios that allowed the designers to verify that the reactor dynamics could tolerate many worst case conditions regarding reactor stability and control. The dynamic changes imposed on the reactor validated the ability of the reactor to load follow the power conversion system and passively control the fuel temperature and overall system stability. With successful completion of the KRUSTY experiment, the NASA/DOE team will evaluate the lessons learned throughout the project and apply them towards a flight demonstration of a Kilopower reactor.

Gibson, Marc A.↗
NASA NTRS2018

Kilopower Reactor Using Stirling Technology (KRUSTY) Nuclear Ground Test Results and Lessons Learned

The Kilopower nuclear ground testing nicknamed KRUSTY (Kilopower Reactor Using Stirling TechnologY) was completed at the Nevada Nuclear Security Site (NNSS) on March 21, 2018. This full scale nuclear demonstration verified the Kilopower reactor neutronics during startup, steady state, and transient operations in a space simulated environment. This was the first space reactor test completed for fission power systems in over 50 years and marked a turning point in NASA's nuclear program. The completed reactor power system design incorporated flight prototypic materials and full scale components in an effort to study the reactor dynamics at full power and significantly reduce follow on risk of a future flight demonstration. This design provided a unique opportunity for the power system to simulate several expected and unexpected mission scenarios that allowed the designers to verify that the reactor dynamics could tolerate many worst case conditions regarding reactor stability and control. The dynamic changes imposed on the reactor validated the ability of the reactor to load follow the power conversion system and passively control the fuel temperature and overall system stability. With successful completion of the KRUSTY experiment, the NASA/DOE team will evaluate the lessons learned throughout the project and apply them towards a flight demonstration of a Kilopower reactor.

Gibson, Marc↗
NASA NTRS2020

Results of the KRUSTY Nuclear System Test

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a prototypic nuclear-powered test of a 5-kW(thermal) Kilopower space reactor. This paper presents results from the KRUSTY nuclear system test, which operated the power system at various temperatures and power levels for 28 consecutive hours. The testing showed that the system operated as expected and that the reactor is highly tolerant of possible failure conditions and transients. The key feature demonstrated was the ability of the reactor to load-follow the demand of the power conversion system. The thermal power of the test ranged from 1.5 to 5.0 kW(thermal), with a fuel temperature up to 880°C. Each 80-W(electric)–rated Stirling converter produced ~90 W(electric) at a component efficiency of ~35% and an overall system efficiency of ~25%.

David I. Poston↗
DOE OSTI2025

KRUSTY: Advancing Space Nuclear Power for Future Missions [Slides]

For more than 70 years, LANL has conducted subcritical and critical experiments in support of space reactors, small modular reactors (SMRs), and criticality safety programs. These experiments were performed first at Los Alamos Critical Experiments Facility (LACEF) at TA-18 and in more recent years at the National Criticality Experiments Research Center (NCERC) in Nevada.

LACEF↗
NASA NTRS2017

Kilopower: Small and Affordable Fission Power Systems for Space

The Nuclear Systems Kilopower Project was initiated by NASA's Space Technology Mission Directorate Game Changing Development Program in fiscal year 2015 to demonstrate subsystem-level technology readiness of small space fission power in a relevant environment (Technology Readiness Level 5) for space science and human exploration power needs. The Nuclear Systems Kilopower Project centerpiece is the Kilopower Reactor Using Stirling Technology (KRUSTY) test, which consists of the development and testing of a fission ground technology demonstrator of a 1 kWe-class fission power system. The technologies to be developed and validated by KRUSTY are extensible to space fission power systems from 1 to 10 kWe, which can enable higher power future potential deep space science missions, as well as modular surface fission power systems for exploration. The Kilopower Project is cofounded by NASA and the Department of Energy National Nuclear Security Administration (NNSA).KRUSTY include the reactor core, heat pipes to transfer the heat from the core to the power conversion system, and the power conversion system. Los Alamos National Laboratory leads the design of the reactor, and the Y-12 National Security Complex is fabricating it. NASA Glenn Research Center (GRC) has designed, built, and demonstrated the balance of plant heat transfer and power conversion portions of the KRUSTY experiment. NASA MSFC developed an electrical reactor simulator for non-nuclear testing, and the design of the reflector and shielding for nuclear testing. In 2016, an electrically heated non-fissionable Depleted Uranium (DU) core was tested at GRC in a configuration identical to the planned nuclear test. Once the reactor core has been fabricated and shipped to the Device Assembly Facility at the NNSAs Nevada National Security Site, the KRUSTY nuclear experiment will be assembled and tested. Completion of the KRUSTY experiment will validate the readiness of 1 to 10 kWe space fission technology for NASAs future requirements for sunlight-independent space power. An early opportunity for demonstration of In-Situ Resource Utilization (ISRU) capability on the surface of Mars is currently being considered for 2026 launch. Since a space fission system is the leading option for power generation for the first Mars human outpost, a smaller version of a planetary surface fission power system could be built to power the ISRU demonstration and ensure its end-to-end validity. Planning is underway to start the hardware development of this subscale flight demonstrator in 2018.

Space nuclear power↗
NASA NTRS2019

The Kilopower Space Nuclear Fission Power Reactor

Nuclear fission power offers an attractive alternative to solar electric or radioisotope power systems for certain applications on the Moon, Mars, and deep space science missions. The advantages of independence from solar irradiance, high energy density, and abundance of fuel allow fission power systems to enable novel, high power mission architectures. While NASA has had numerous fission power programs throughout its history, few have gone far beyond the design phase. The recent test campaign called the Kilopower Reactor Using Stirling Technology project (KRUSTY) focused on a low power, kilowatt-scale design for simplicity and reduced cost, with the driving motivation to perform a full nuclear hardware prototype test. Following the successful completion of the KRUSTY nuclear hardware test in March of 2018, NASA has begun the formulation process for a Technology Demonstration Mission (TDM) using the Kilopower reactor technology. In support of NASA's lunar surface initiatives, the Kilopower TDM will target a 1-3 kW fission electric power system that can survive the lunar night and operate for one year. The system will be heavily influenced by the KRUSTY reactor design, using a solid Uranium metal core with high temperature heat pipes and Stirling engine power conversion. During this formulation phase, continued engineering efforts are ongoing to improve heat transfer efficiency in the system, examine fission radiation damage effects, and begin to address the thermal and structural requirements of a Kilopower flight system.

Chaiken, Max↗
DOE OSTI2024

Assessment and validation of NEAMS tools for high-fidelity multiphysics transient modeling of microreactors: Application of NEAMS codes to perform multiphysics modeling analyses of micro-reactor concepts

The NEAMS Multiphysics Applications team aims at providing assessment of code useability and functionality for microreactor design and analyses, together with demonstration of their capabilities to properly capture the steady-state and time-dependent behavior of different microreactor concepts. In FY-24, significant progress was achieved in improving multi-physics models of several microreactors systems: HP-MR, GC-MR and KRUSTY. These efforts focused on solving more complex multiphysics problems enabled by enhanced tools capability, verifying and validating results obtained, providing feedback to developers for suggested improvements, and sharing these models to facilitate user training. A series of new multiphysics transients were completed on the HP-MR (using Griffin/BISON/Sockeye) with core startup transient, control drum inadvertent rotation accident, and hydrogen leakage from hydride moderator (also including SWIFT). On the GC-MR, a new full-core model was developed and analyzed through a series of new multiphysics (Griffin/BISON/SAM) transients to simulate moderator leakage (also including SWIFT), flow blockage and coolant depressurization. Additional and updated TRISO failure analyses were completed on the HP-MR unit-cell and GC-MR assembly models leveraging improved TRISO modeling capabilities. The amount of SiC failure following accidental transients at end-of-life was null. However, GC-MR assembly TRISO analysis highlighted Pd penetration rate can be problematic and may require design changes on the studied microreactor concept. The neutronics discrepancies observed on the KRUSTY model in previous years were resolved using hybrid set of Monte Carlo/Deterministic cross-sections. The multiphysics (Griffin neutronics / BISON thermal-mechanics) 15₵ insertion transient simulation displayed good agreement when comparing with experimental data. Initial modeling of the 30 ₵ reactivity insertion also displays promising results. Such close agreement provides important validation data that can be leveraged by the NEAMS program and by microreactor vendors to support licensing of their technology. Finally, important experience was gathered with the NEAMS tools leading to several user feedback shared with tools developers, especially with regards to MOOSE mesh generator and Griffin. This project led to many publications demonstrating modeling capabilities, and to three models shared on the Virtual Test Bed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗