INL Materials and Fuel Complex and the Nuclear Materials Performance Division
INL Materials and Fuel Complex and the Nuclear Materials Performance Division.
36 - MATERIALS SCIENCE↗
SEARCH · Search NASA
Results for “Materials and Fuels Complex”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Lead Service Line Inventory at the Materials and Fuels Complex
In 1986, Congress amended the Safe Drinking Water Act prohibiting the use of lead in pipes for providing water. This was due to research on lead poisoning showing lead was extremely detrimental to the development of kids and cognitive abilities in adults. Now, because of the amendment of 1986, the EPA 2021 Lead and Copper Rule Revision came out since then to promote progress in the inventory and elimination of lead pipes. The Idaho Department of Environmental Quality(IDEQ) adopted this rule for the state which means every water system in Idaho fall under the new regulation. By October 16, 2024, the INL must report to the IDEQ, the pipe materials in a Lead Service Line Inventory(LSLI) in hopes of finding lead. If lead is found, a Lead Service Line Replacement Plan is required. This poster only specifically talks about the results for the largest site out on the desert, Materials and Fuels Complex(MFC), as the INL also consists of ATR, INTEC, SMC, and CFA.
54 ENVIRONMENTAL SCIENCES↗
Materials and Fuels Complex FY-24 -- FY-28 Five-Year Investment Strategy
MFC supports current RD&D missions while enabling new projects and missions working with DOE-NE sponsors, other federal agencies, private industry, and academia. The investment strategy described in this document guides the efforts to build, expand, and sustain DOE-NE research capabilities at MFC, increase access to MFC capabilities by industry and the nuclear RD&D community, and revitalize existing MFC nuclear infrastructure. The strategy also anticipates and guides the preparations necessary for demonstration of advanced nuclear energy technologies in support of NRIC, the DOE Gateway for Accelerated Innovation in Nuclear (GAIN) initiative, and nuclear energy and other related critical outcomes identified in the INL Laboratory Plan. The investment strategy for MFC addresses building and improving on these core competencies, introducing new and revitalized RD&D capabilities, and maturing the NRIC test bed. MFC is also implementing new business and operations models to help transform MFC into a complex that supports an advanced nuclear technology development test bed. The strategy for MFC is presented in several parts, each focusing on an element needed for success.
99 GENERAL AND MISCELLANEOUS↗
Idaho National Laboratory Water Assessment
Established in 1949, Idaho National Laboratory (INL) is part of the U.S. Department of Energy’s (DOE) complex of national laboratories. INL performs work in each of the strategic goal areas of the department: energy, national security, science, and environment, and is the nation’s center for nuclear energy research and development. Located in southeastern Idaho, its physical footprint includes 569,180 acres of federally owned land. A water balance for the fiscal year (FY) 2022 year was conducted for INL to identify major water using equipment and calculate the end-use categories. FY 2022 was selected as the evaluation year per the DOE Sustainability Performance Office. This report provides an analysis of facilities on the INL Site operated by Battelle Energy Alliance, LLC (BEA). This water balance report focused on the Advanced Test Reactor (ATR) Complex, Materials and Fuels Complex, Idaho Falls campus, and Central Facilities Area campuses, which consumed 98% of the 540,611 thousand gallons (kGal) of water used by INL in FY 2022. The resulting water balance identified the use categories for 75.3% of the FY 2022 water consumption.
99 GENERAL AND MISCELLANEOUS↗
Sodium Components Maintenance Shop (SCMS) Carbonation Vessel – Partial HWMA/RCRA Closure Certification Report
This report documents the Hazardous Waste Management Act (HWMA)/ Resource Conservation and Recovery Act (RCRA) Partial Closure Certification of the Sodium Components Maintenance Shop (SCMS) Carbonation Vessel. The HWMA/RCRA Closure followed the multi step review and evaluation closure process identified in the Idaho National Laboratory (INL) Materials and Fuels Complex (MFC) HWMA/RCRA Partial Permit Closure Plan, October 1, 2015. This closure certification report documents that the SCMS Carbonation Vessel was removed from the SCMS, packaged as hazardous waste and stored for future treatment and disposal, and therefore has met the closure performance standards in accordance with the Department of Energy Idaho National Laboratory Materials and Fuels Complex HWMA/RCRA Partial Permit Closure Plan (EPA No. ID4890008952, October 1, 2015).
99 GENERAL AND MISCELLANEOUS↗
2025 Intern Poster
The Hot Fuel Examination Facility (HFEF) at the Materials and Fuels Complex (MFC) houses the largest U.S. inert atmosphere hot cell for nuclear material research. Key features include the precision gamma scanning (PGS), Fuel Accident Condition Simulator (FACS), Neutron Radiography Reactor (NRAD), and the focus of this project, the Metallograph Loading Cell (MET Cell). The MET Cell performs tests on spent nuclear fuel, such as microhardness testing, microscopy, and neutron radiography. However, the MET Cell’s existing pressure and lighting control systems are outdated and inefficient, with inadequate documentation for system changes over time. This project aims to design a new automated control system for the MET Cell, ensuring longevity (minimum ten years), ease of troubleshooting/repair, and integration into the building monitoring system. The design process addressed challenges such as space restrictions, varied voltages within enclosures, sourcing new components, and security limitations. Compliance with NFPA 70, UL508A, MFC Physical Security, and INL Engineering standards was essential. The project involves repurposing an existing PLC to manage lighting and pressure control using digital and analog signals, simplifying wiring, and ensuring thorough documentation for future reference.
42 - ENGINEERING↗
MFC and Fuel Evaluation for KSU
Idaho National Laboratory's Materials and Fuels Complex is well equipped for research, development, and demonstration of nuclear fuel designs and reactor components. The capabilities for fuels RD&D at MFC are briefly presented and the observation of fuel behavior that merit RD&D at MFC are introduced, with emphasis on metal fast reactor fuel.
Materials and Fuels Complex↗
Progress Towards Microcalorimeter Gamma Spectroscopy Analysis for Nuclear Fuel Separations
The High Efficiency and Resolution Microcalorimeter Spectrometer, 400 pixels (HERMES-400) is an ultra-high resolution gamma-ray spectrometer at Idaho National Laboratory’s Materials and Fuels Complex. HERMES-400 is intended to enable precise nondestructive analysis of advanced fuel cycle materials. Key upgrades and repairs of the instrument were performed this year to improve performance. First, the fourth and final microcalorimeter detector module was installed, meeting the milestone for its integration into the system. Operation with all four modules enables higher detector efficiency than any previous microcalorimeter gamma-ray system. Second, a thinner magnetic shield was installed. This shields the sensitive microcalorimeter pixels from stray magnetic fields while allowing transmission of lower-energy gamma rays, which are important to isotopic analysis. Finally, the cryostat, which provides cooling of the modules to their operating temperature, was found to have a helium coolant leak, which was repaired. HERMES-400 is in a stable state to perform repeated, long-term gamma-ray measurements with good detector efficiency and energy resolution. In FY25, irradiated TRISO fuel and salts from advanced electrochemical recycling techniques are candidates for microcalorimeter measurements. A final upgrade of the magnetic shielding and vibration damping of the system is also planned to maximize the system performance.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Integrated Approach to Post-Irradiation Examination of Nuclear Materials at Idaho National Laboratory
Idaho national Laboratory (INL) is the U.S. lead national laboratory for the Department of Energy’s Office of Nuclear Energy (DOE-NE), providing much of the nuclear research, development and demonstration capability needed to move nuclear innovation forward to deployment. INL’s Materials and Fuels Complex hosts a unique combination of personnel, facilities and infrastructure and offers the ability to perform post-irradiation examinations (PIE) of nuclear materials spanning multiple length scales. The ability to combine engineering-scale analysis and sub-microscopic characterization provides valuable insights into fuel and structural material behavior and degradation mechanisms. The holistic approach is used to accelerate these materials demonstration and deployment. Selected studies will be presented, highlighting the impact of these techniques on improving fuel reliability, safety, and efficiency, thereby advancing the development of sustainable and advanced nuclear energy technologies.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Precision Local Burnup Assessment Through Dynamic Peak Fitting in Atom Probe Tomography for Depleted, Enriched, and Irradiated Metallic and Ceramic Fuels
Abstract Burnup estimation in nuclear fuels is vital for evaluating fuel performance, transportation, and safe fuel storage. Accurate assessments of burnup from service period and spent fuels involve tracking the consumption of fissile isotopes of uranium (U) offering a direct insight into energy changes within the fuels especially for thermal spectrum reactors. In current approach, mass spectroscopic technique in atom probe tomography (APT) is utilized for accurate quantification of U isotopes. Quantification of U peaks in mass spectrum is performed on asymmetric shapes due to delayed signals, known as thermal tails, particularly for poorly conducting samples analyzed in laser mode. In this study, we introduce a novel quantification tool for isotopic analysis from APT datasets by developing a fitting algorithm based on shapes of the peaks. A MATLAB-based dynamic peak fitting toolbox is developed and designed to adapt to various peak shapes, ensuring accurate quantification of U isotopes. The effectiveness of this approach is demonstrated in standard Ni-Cr sample, depleted and enriched U samples, and U-based fuels with different burnup levels. The viability of this approach for isotopic quantification is demonstrated on both metallic and ceramic fuels.
Burnup↗
Fuel Salt Synthesis for the Molten Chloride Reactor Experiment: Scale-up, Operations, and Production Update
Over the previous 5 years, Idaho National Laboratory (INL) has been working with Southern Co. and TerraPower on the Advanced Reactor Demonstration Program (ARDP) funded Molten Chloride Reactor Experiment (MCRE) project. As part of this effort, INL has developed a fuel synthesis process to produce the NaCl-UCl3 fuel salt that MCRE will need for operation. Dr. Phillips will present on process development and scale-up testing and results, as well as provide an update on the current status of fuel production for MCRE. To date, the fuel synthesis process has been demonstrated at full scale using depleted uranium, and the equipment necessary for production of the fuel for MCRE has been installed in the Fuel Manufacturing Facility (FMF) at the INL’s Materials and Fuels Complex (MFC). The NaCl-UCl3 produced to-date has been shown to be of 99.99% purity or greater, and be within tolerance for all relevant parameters. Overall process efficiency in terms of uranium utilization has been demonstrated to be above 90%. The synthesis operation has also been shortened to allow for completion of the reaction within a single 10 hour working shift. Consequently, the process developed is expected to be capable of meeting all project objectives for efficiency, purity, scale, and scheduling. Production of NaCl-UCl3 fuel salt for MCRE is projected to begin during the Summer of 2025.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
FUEL PERFORMANCE STUDIES AT IDAHO NATIONAL LABORATORY MAKING USE OF THE BYRON FUEL SHIPMENT
In December of 2023 a shipment of commercially irradiated fuel rods from the Byron Generating Station in Illinois was successfully shipped to the Materials and Fuels Complex (MFC) at Idaho National Laboratory (INL). The make-up of the rods includes a mix of cladding types from traditional ZirloTM, advanced zirconium alloys, and chrome coated ZirloTM. Burnups range from regular end of life values to over 70 GWd/MTU rod average. The R&D plan for the rods involves multiple projects from developing licensing data for new claddings to integral transient tests to support burnup extension efforts in the United States. The R&D began in early 2024 with the nondestructive examinations of the rods after which they will be sectioned for microscopy, mechanical testing, and analytical chemistry. Additionally, many rod segments will be refabricated into new test pins and inserted into a static water capsule for integral Reactivity Initiated Accident (RIA) and Loss of Coolant Accident (LOCA) testing at the TREAT reactor.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
First-of-a-Kind Fuel-bearing Molten Chloride Irradiation Experiment
As a dozen MSR developers in the U.S. work toward an aggressive commercialization timeline, many of their fueled-salts—notably, chloride-based compositions—have never been irradiated. Licensing and operating these reactors requires an understanding of (1) the source term, radiation chemistry, and gas generation; (2) unanticipated irradiation-induced corrosion effects; and (3) the impact of burnup on thermophysical properties, all of which can be deduced through irradiation testing. Idaho National Laboratory (INL) is ideally suited to leverage its expertise in chloride salt chemistry, as well as its Neutron Radiography Reactor (NRAD) facility in the Hot Fuels Examination Facility (HFEF) at the Materials and Fuels Complex (MFC), to conduct the world’s first fuel-bearing chloride salt irradiation and fill in the knowledge gaps pertaining to salt chemistry under irradiation. Molten-salt Research Temperature-controlled Irradiation (MRTI) consists of a salt-containing capsule that is internally heated inside of a secondary containment. The experiment must rely on resistive heating to melt the salt before irradiation (to avoid the impact of radiolysis) and once the reactor is turned on and fission reactions commence in the salt, the resistive power can then be reduced. Salt-immersed thermocouples coupled to a controller allow for the heater power to be adjusted as needed to meet experimental objectives. The bulk of the experimental results will be achieved through Post-Irradiation Examination (PIE). At which point a range of different measurements are anticipated to assess the salt/plenum/wall composition, the capsule corrosion rate, and the evolution of salt properties.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
The Digital Engineering Vision for DOME: Facilitating Design, Deployment, and Operations [Poster]
DOME is a planned microreactor test facility at INL’s Materials and Fuels Complex. It is a complex system with several interdependent sub-systems such as the reactor (up to 20 MWth), radioactive confinement, temperature and pressure regulation system, ventilation system, etc. The engineering design process for such a system traditionally involves several documents from various sources and the system information is scattered across these documents. Digital engineering represents a paradigm shift through which systems are designed using digital models and integrated data. The digital engineering vision for DOME utilizes a model-based systems engineering (MBSE) approach. The system architecture, physical components, control logic, and verification experiments are all designed using MathWorks MATLAB and Simulink. This hierarchical model can combine data from multiple sources at various levels of abstraction. It can be used to simulate the facility’s operations and to test the system using different sets of parameters. Its capabilities can be expanded by interfacing it with high-fidelity multi-physics models, risk analysis tools, etc. The same model can evolve into a digital twin that can monitor operations and conduct predictive analysis using real-time sensor data from the facility. The eventual goal of this effort is to transform the end-to-end engineering of nuclear facilities in every phase of their lifecycle, including design, deployment, and operations.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
SinhaRoy_TechPresentation_2024 [Slides]
DOME is a planned microreactor test facility at INL’s Materials and Fuels Complex. It is a complex system with several interdependent sub-systems such as the reactor (up to 20 MWth), radioactive confinement, temperature and pressure regulation system, ventilation system, etc. The engineering design process for such a system traditionally involves several documents from various sources and the system information is scattered across these documents. Digital engineering represents a paradigm shift through which systems are designed using digital models and integrated data. The digital engineering vision for DOME utilizes a model-based systems engineering (MBSE) approach. The system architecture, physical components, control logic, and verification experiments are all designed using MathWorks MATLAB and Simulink. This hierarchical model can combine data from multiple sources at various levels of abstraction. It can be used to simulate the facility’s operations and to test the system using different sets of parameters. Its capabilities can be expanded by interfacing it with high-fidelity multi-physics models, risk analysis tools, etc. The same model can evolve into a digital twin that can monitor operations and conduct predictive analysis using real-time sensor data from the facility. The eventual goal of this effort is to transform the end-to-end engineering of nuclear facilities in every phase of their lifecycle, including design, deployment, and operations.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NRIC DOME Crane Trade Study and Recommendation
The National Reactor Innovation Center (NRIC) is a national program that was established as part of the Nuclear Energy Innovation Capabilities Act (NEICA). NRIC’s mission is to accelerate the demonstration and deployment of advanced nuclear energy through its mission to inspire stakeholders and the public, empower innovators, and deliver successful outcomes through efficient coordination of partners and resources. NRIC is designed to bridge the gap between research, development, and the marketplace to help convert some of the nation’s most promising advanced nuclear reactors into commercial applications. The NRIC Demonstration of Microreactor Experiments (DOME) facility, formerly known as Experimental Breeder Reactor II (EBR II), located at the Materials and Fuels Complex (MFC) at the Idaho National Laboratory (INL) is intended to allow industrial and other partners the opportunity to test Advanced Microreactors up to 20MW thermal power. The 75-ton capacity polar crane located in the EBR II facility was rendered inoperable to support planned facility demolition in 2015; small holes were flame cut in the girders; hoists and cables were removed; oil was drained from gear boxes; trolley drive, and then filled with absorbent; and the electrical and control umbilical’s were disconnected, removed and disposed. Subsequently, the decision was made to convert the EBR II facility into the DOME test bed.
21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
Idaho National Laboratory CY 2025 National Emission Standards for Hazardous Air Pollutants Analysis, Methodology, and Results for Radionuclides
This report details calculations of potential dose—at public receptor locations surrounding the Idaho National Laboratory (INL) Site boundary and INL in-town facilities—from radionuclides reported to be in use and potentially emitted from INL facilities during calendar year (CY) 2025. All calculations were performed in accordance with the requirements of Code of Federal Regulations (CFR), Title 40, “Protection of the Environment,” Part 61, “National Emission Standards for Hazardous Air Pollutants (NESHAPs),” Subpart H, “National Emission Standards for Emissions of Radionuclides Other than Radon from Department of Energy Facilities” (40 CFR 61, Subpart H). Modeling methodology, model-input parameters, and contribution to dose by facility, source, and radionuclide at the maximally exposed individual (MEI) location are also discussed. The information in this report supports the “National Emission Standards for Hazardous Air Pollutants—Calendar Year 2025 INL Report for Radionuclides” (DOE-ID 2026). During CY 2025, the estimated annual potential dose at the INL Site MEI location was 2.45E-02 mrem/yr, up from the previous year, but remaining far less than the regulatory standard of 10 mrem/yr (CFR 40 Part 61, Subpart H). Approximately 92% of the total dose to the INL Site MEI originated from Materials and Fuels Complex sources. Emissions from INL in-town facilities resulted in an estimated annual potential dose of 4.50E-03 mrem/yr to the MEI, down slightly from the CY 2024 estimated dose. Year-to-year variations in estimated annual dose can be attributed to adjustments in laboratory operations, changes to facility infrastructure, and variation in meteorological conditions.
42 - ENGINEERING↗
01-22 HFEF-15 Cask
Technical Description – Upgrading the HFEF-15 shipping cask to allow larger format experiments includes designing, fabricating, and installing new components, updating procedures, and performing an INL-internal informal readiness assessment. Location – INL: Materials and Fuels Complex (TREAT & HFEF)
22 GENERAL STUDIES OF NUCLEAR REACTORS↗