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NRC Licensing Status Summary Report for NGNP

The Next Generation Nuclear Plant (NGNP) Project, initiated at Idaho National Laboratory (INL) by the U.S. Department of Energy (DOE) pursuant to provisions of the Energy Policy Act of 2005, is based on research and development activities supported by the Department of Energy Generation IV Nuclear Energy Systems Initiative. The principal objective of the NGNP Project is to support commercialization of high temperature gas-cooled reactor (HTGR) technology. The HTGR is a helium-cooled and graphite moderated reactor that can operate at temperatures much higher than those of conventional light water reactor (LWR) technologies. The NGNP will be licensed for construction and operation by the Nuclear Regulatory Commission (NRC). However, not all elements of current regulations (and their related implementation guidance) can be applied to HTGR technology at this time. Certain policies established during past LWR licensing actions must be realigned to properly accommodate advanced HTGR technology. A strategy for licensing HTGR technology was developed and executed through the cooperative effort of DOE and the NRC through the NGNP Project. The purpose of this report is to provide a snapshot of the current status of the still evolving pre-license application regulatory framework relative to commercial HTGR technology deployment in the U.S. The following discussion focuses on (1) describing what has been accomplished by the NGNP Project up to the time of this report, and (2) providing observations and recommendations concerning actions that remain to be accomplished to enable the safe and timely licensing of a commercial HTGR facility in the U.S.

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RELAP5-3D Transient Modelling for NGNP Integrated Plant

The High-Temperature Gas-cooled Reactor (HTGR) is designed with outlet temperatures ranging between 750°C and 800°C. These high outlet temperatures enhance the power production efficiency and facilitate a variety of industrial applications. The objective of this study is to understand the response of the primary system to potential transients in the secondary system. For this analysis, the transient condition originates in the Intermediate Heat Exchanger (IHX) or Steam Generator (SG) of the HTGR-integrated plant. The transients analysed are: a loss of pressure; loss of feedwater flow; inadvertent closure of main steam valve; decrease in returning gas temperature and heat load step change. The results show a large dependence on the negative reactivity added to the fuel as a function of increased temperature. The returning gas temperature decrease transient resulted in the highest fuel temperature (1361°C). Fuel temperature was shown to be less than the 1600°C fuel limit for each case analysed.

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Transient Mixed Convection Validation for NGNP

The results of this project are best described by the papers and dissertations that resulted from the work. They are included in their entirety in this document. They are: (1) Jeff Harris PhD dissertation (focused mainly on forced convection); (2) Blake Lance PhD dissertation (focused mainly on mixed and transient convection). This dissertation is in multi-paper format and includes the article currently submitted and one to be submitted shortly; and, (3) JFE paper on CFD Validation Benchmark for Forced Convection.

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Experimental and CFD Studies of Coolant Flow Mixing within Scaled Models of the Upper and Lower Plenums of NGNP Gas-Cooled Reactors

A 1/16th scaled VHTR experimental model was constructed and the preliminary test was performed in this study. To produce benchmark data for CFD validation in the future, the facility was first run at partial operation with five pipes being heated. PIV was performed to extract the vector velocity field for three adjacent naturally convective jets at statistically steady state. A small recirculation zone was found between the pipes, and the jets entered the merging zone at 3 cm from the pipe outlet but diverged as the flow approached the top of the test geometry. Turbulence analysis shows the turbulence intensity peaked at 41-45% as the jets mixed. A sensitivity analysis confirmed that 1000 frames were sufficient to measure statistically steady state. The results were then validated by extracting the flow rate from the PIV jet velocity profile, and comparing it with an analytic flow rate and ultrasonic flowmeter; all flow rates lie within the uncertainty of the other two methods for Tests 1 and 2. This test facility can be used for further analysis of naturally convective mixing, and eventually produce benchmark data for CFD validation for the VHTR during a PCC or DCC accident scenario. Next, a PTV study of 3000 images (1500 image pairs) were used to quantify the velocity field in the upper plenum. A sensitivity analysis confirmed that 1500 frames were sufficient to precisely estimate the flow. Subsequently, three (3, 9, and 15 cm) Y-lines from the pipe output were extracted to consider the output differences between 50 to 1500 frames. The average velocity field and standard deviation error that accrued in the three different tests were calculated to assess repeatability. The error was varied, from 1 to 14%, depending on Y-elevation. The error decreased as the flow moved farther from the output pipe. In addition, turbulent intensity was calculated and found to be high near the output. Reynolds stresses and turbulent intensity were used to validate the data by comparing it with benchmark data. The experimental data gave the same pattern as the benchmark data. A turbulent single buoyant jet study was performed for the case of LOFC in the upper plenum of scaled VHTR. Time-averaged profiles show that 3,000 frames of images were sufficient for the study up to second-order statistics. Self-similarity is an important feature of jets since the behavior of jets is independent of Reynolds number and a sole function of geometry. Self-similarity profiles were well observed in the axial velocity and velocity magnitude profile regardless of z/D where the radial velocity did not show any similarity pattern. The normal components of Reynolds stresses have self-similarity within the expected range. The study shows that large vortices were observed close to the dome wall, indicating that the geometry of the VHTR has a significant impact on its safety and performance. Near the dome surface, large vortices were shown to inhibit the flows, resulting in reduced axial jet velocity. The vortices that develop subsequently reduce the Reynolds stresses that develop and the impact on the integrity of the VHTR upper plenum surface. Multiple jets study, including two, three and five jets, were investigated.

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Model validation using CFD-grade experimental database for NGNP Reactor Cavity Cooling Systems with water and air

This project has been focused on the experimental and numerical investigations of the water-cooled and air-cooled Reactor Cavity Cooling System (RCCS) designs. At this aim, we have leveraged an existing experimental facility at the University of Wisconsin-Madison (UW), and we have designed and built a separate effect test facility at the University of Michigan. The experimental facility at UW has underwent several upgrades, including the installation of advanced instrumentation (i.e. wire-mesh sensors) built at the University of Michigan. These provides highresolution time-resolved measurements of the void-fraction distribution in the risers of the water-cooled RCCS facility. A phenomenological model has been developed to assess the water cooled RCCS system stability and determine the root cause behind the oscillatory behavior that occurs under normal two-phase operation. Testing under various perturbations to the water-cooled RCCS facility have resulted in changes in the stability of the integral system. In particular, the effects on stability of inlet orifices, water tank volume have and system pressure been investigated. MELCOR was used as a predictive tool when performing inlet orificing tests and was able to capture the Density Wave Oscillations (DWOs) that occurred upon reaching saturation in the risers. The experimental and numerical results have then been used to provide RCCS design recommendations. The experimental facility built at the University of Michigan was aimed at the investigation of mixing in the upper plenum of the air-cooled RCCS design. The facility has been equipped with state-of-theart high-resolution instrumentation to achieve so-called CFD grade experiments, that can be used for the validation of Computational Fluid Dynanmics (CFD) models, both RANS (Reynold-Averaged) and LES (Large Eddy Simulations). The effect of risers penetration in the upper plenum has been investigated as well.

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Review and Assessment of NGNP PIRTs for TRISO and HTGR Technologies

The main objective of this technical report is to ensure that research and development (R&D) needs are identified to address the significant (highly ranked) technical challenges related to TRISO-coated particle fuel, high-temperature gas-reactor (HTGR) technologies, and other TRISO-related advanced designs by recognizing the existing foundation of identified R&D needs and augmenting that foundation with insights drawn from current TRISO-related research results and R&D needs related to novel applications of TRISO-related technologies that extend beyond the traditional HTGR designs.

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AGC-2 Irradiation Report

The Next Generation Nuclear Plant (NGNP) will be a helium-cooled, very high temperature reactor (VHTR) with a large graphite core. In past applications, graphite has been used effectively as a structural and moderator material in both research and commercial high temperature gas cooled reactor (HTGR) designs.[ , ] Nuclear graphite H 451, used previously in the United States for nuclear reactor graphite components, is no longer available. New nuclear graphites have been developed and are considered suitable candidates for the new NGNP reactor design. To support the design and licensing of NGNP core components within a commercial reactor, a complete properties database must be developed for these current grades of graphite. Quantitative data on in service material performance are required for the physical, mechanical, and thermal properties of each graphite grade with a specific emphasis on data related to the life limiting effects of irradiation creep on key physical properties of the NGNP candidate graphites. Based on experience with previous graphite core components, the phenomenon of irradiation induced creep within the graphite has been shown to be critical to the total useful lifetime of graphite components. Irradiation induced creep occurs under the simultaneous application of high temperatures, neutron irradiation, and applied stresses within the graphite components. Significant internal stresses within the graphite components can result from a second phenomenon—irradiation induced dimensional change. In this case, the graphite physically changes i.e., first shrinking and then expanding with increasing neutron dose. This disparity in material volume change can induce significant internal stresses within graphite components. Irradiation induced creep relaxes these large internal stresses, thus reducing the risk of crack formation and component failure. Obviously, higher irradiation creep levels tend to relieve more internal stress, thus allowing the components longer useful lifetimes within the core. Determining the irradiation creep rates of nuclear grade graphites is critical for determining the useful lifetime of graphite components and is a major component of the Advanced Graphite Creep (AGC) experiment.

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Baseline Concept Description of a Small Modular High Temperature Reactor

The objective of this report is to provide a description of generic small modular high temperature reactors (herein denoted as an smHTR), summarize their distinguishing attributes, and lay out the research and development (R&D) required for commercialization. The generic concepts rely heavily on the modular high temperature gas-cooled reactor designs developed in the 1980s which were never built but for which pre-licensing or certification activities were conducted. The concept matured more recently under the Next Generation Nuclear Plant (NGNP) project, specifically in the areas of fuel and material qualification, methods development, and licensing. As all vendor-specific designs proposed under NGNP were all both ‘small’ or medium-sized and ‘modular’ by International Atomic Energy Agency (IAEA) and Department of Energy (DOE) standards, the technical attributes, challenges, and R&D needs identified, addressed, and documented under NGNP are valid and appropriate in the context of Small Modular Reactor (SMR) applications. Although the term High Temperature Reactor (HTR) is commonly used to denote graphite-moderated, thermal spectrum reactors with coolant temperatures in excess of 650oC at the core outlet, in this report the historical term High Temperature Gas-Cooled Reactor (HTGR) will be used to distinguish the gas-cooled technology described herein from its liquid salt-cooled cousin. Moreover, in this report it is to be understood that the outlet temperature of the helium in an HTGR has an upper limit of 950 degrees C which corresponds to the temperature to which certain alloys are currently being qualified under DOE’s ARC program. Although similar to the HTGR in just about every respect, the Very High Temperature Reactor (VHTR) may have an outlet temperature in excess of 950 degrees C and is therefore farther from commercialization because of the challenges posed to materials exposed to these temperatures. The VHTR is the focus of R&D under the Generation IV program and its specific R&D needs will be included in this report when appropriate for comparison. The distinguishing features of the HTGR are the refractory (TRISO) coated particle fuel, the low-power density, graphite-moderated core, and the high outlet temperature of the inert helium coolant. The low power density and fuel form effectively eliminate the possibility of core melt, even upon a complete loss of coolant pressure and flow. The graphite, which constitutes the bulk of the core volume and mass, provides a large thermal buffer that absorbs fission heat such that thermal transients occur over a timespan of hours or even days. As chemically-inert helium is already a gas, there is no coolant temperature or void feedback on the neutronics and no phase change or corrosion product that could degrade heat transfer. Furthermore, the particle coatings and interstitial graphite retain fission products such that the source terms at the plant boundary remain well below actionable levels under all anticipated nominal and off-normal operating conditions. These attributes enable the reactor to supply process heat to a collocated industrial plant with negligible risk of contamination and minimal dynamic coupling of the facilities (Figure 1). The exceptional retentive properties of coated particle fuel in a graphite matrix were first demonstrated in the DRAGON reactor, a European research facility that began operation in 1964.

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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.

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Design and dynamic modeling of a printed circuit heat exchanger for the next generation nuclear plant

Printed circuit heat exchangers (PCHEs) are promising to be adopted in the design of the Next Generation Nuclear Plant (NGNP). A PCHE serves as an intermediate heat exchanger (IHX) to isolate the secondary loop from the reactor's primary system. The overall plant thermal efficiency relies on the PCHE performance and the reactor safety could be affected by the PCHE performance. It is therefore imperative to be able to accurately model PCHE's performance under various conditions. The aim of this study is to design an IHX-type PCHE for a reference NGNP design and conduct both steady-state and transient simulations for the designed PCHE. A countercurrent configuration and straight-channel geometry were adopted for the PCHE design and the classic log-mean temperature difference (LMTD) method was utilized to size the PCHE for the required thermal duty. A mathematical model was numerically solved to predict the steady-state and transient behavior of the PCHE. The steady-state temperature distributions of the fluids on the hot and cold sides and in the solid plates of the heat exchanger were initially obtained by dividing the PCHE into 1,000 segments along the flow direction, and were served as the initial condition for the transient simulations. A series of transient scenarios, including inlet temperature step changes, mass flow rate step changes, and inlet temperature step changes combined with mass flow step changes, were simulated and analyzed to examine the dynamic performance of the designed PCHE. The numerical results appear reasonable and it is evident that the dynamic model has the capability of predicting both steady-state and transient performance of the straight-channel PCHE. In addition, the numerical results could provide some insights for developing control strategies for PCHEs as IHXs in the NGNP. (authors)

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PCEA Baseline Characterization: Billet XCP01S8 11 Compressive, Tensile, and Flexure Strengths

Grade PCEA graphite is one of several grades being considered for the core structures of the Next Generation Nuclear Plant (NGNP). An experimental program is underway to describe the statistical nature of the mechanical properties of PCEA graphite, information needed to support the design of graphite components and licensing of the NGNP. It will be necessary to characterize several billets from various lots or batches. The exact number of billets will depend on the observed variability in properties.

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Baseline Characterization Database Verification Report - NBG-18 Billet 635-14

The purpose of this Engineering Calculations and Analysis Report is to present the data being collected in the Baseline Graphite Characterization program, which is directly tasked with supporting the Idaho National Laboratory’s (INL’s) research and development efforts on the Next Generation Nuclear Plant (NGNP)/Very High Temperature Reactor (VHTR)/Advanced Reactor Technology (ART). This program is populating a comprehensive database that will reflect the baseline properties of nuclear-grade graphite regarding individual grade, billet, and position within individual billets. The physical and mechanical property information being collected will be transferred to the NGNP Data Management and Analysis System (NDMAS), and from that database will help populate handbook of property data available to member nations of the Generation IV International Forum (GIF).

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ECAR-1930 BASELINE CHARACTERIZATION DATABASE VERIFICATION REPORT - NBG-18 BILLET 635-14

The purpose of this Engineering Calculations and Analysis Report is to present the data being collected in the Baseline Graphite Characterization program, which is directly tasked with supporting the Idaho National Laboratory’s (INL’s) research and development efforts on the Next Generation Nuclear Plant (NGNP)/Very High Temperature Reactor (VHTR). This program is populating a comprehensive database that will reflect the baseline properties of nuclear-grade graphite with regard to individual grade, billet, and position within individual billets. The physical and mechanical property information being collected will be transferred to the NGNP Data Management and Analysis System (NDMAS), and from that database will help populate handbook of property data available to member nations of the Generation IV International Forum (GIF). The transfer of this data from the applicable technical lead to the dissemination databases available to other end users requires a full review of the test procedures and data collection efforts through an analysis of the multiple summary spreadsheets and values being collected. This report represents that analysis for a single billet of nuclear grade graphite (NBG-18 billet 635-14) and facilitates the release of the associated data to the NDMAS custodians.

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Licensing basis event selection framework for advanced reactors - 18818

This paper describes key aspects of the risk-informed, performance-based licensing methodology as developed by the Department of Energy (DOE) for the Next Generation Nuclear Plant (NGNP) project. The discussion focuses on an event selection process using modular high temperature gas-cooled reactor (HTGR) design attributes and identifies how top-level regulatory criteria can be placed on a frequency-consequence (F-C) curve. Nuclear Regulatory Commission (NRC) staff evaluations of the proposed approach are included. In addition, important lessons learned during the NGNP prelicensing effort and their potential applications to alternative advanced reactor designs are presented. (authors)

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AGR-1 Irradiation Test Final As-Run Report, Rev. 3

This document presents the as-run analysis of the AGR-1 irradiation experiment. AGR-1 is the first of eight planned irradiations for the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program. Funding for this program is provided by the US Department of Energy (DOE) as part of the Next-Generation Nuclear Plant (NGNP) project. The objectives of the AGR-1 experiment are: 1. To gain experience with multi-capsule test train design, fabrication, and operation with the intent to reduce the probability of capsule or test train failure in subsequent irradiation tests. 2. To irradiate fuel produced in conjunction with the AGR fuel process development effort. 3. To provide data that will support the development of an understanding of the relationship between fuel fabrication processes, fuel product properties, and irradiation performance. In order to achieve the test objectives, the AGR-1 experiment was irradiated in the B-10 position of the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL) for a total duration of 620 effective full power days of irradiation. Irradiation began on December 24, 2006 and ended on November 6, 2009 spanning 13 ATR cycles and approximately three calendar years. The test contained six independently controlled and monitored capsules. Each capsule contained 12 compacts of a single type, or variant, of the AGR coated fuel. No fuel particles failed during the AGR-1 irradiation. Final burnup values on a per compact basis ranged from 11.5 to 19.6 %FIMA, while fast fluence values ranged from 2.21 to 4.39 x 10 25 n/m 2 (E >0.18 MeV). We’ll say something here about temperatures once thermal recalc is done. Thermocouples performed well, failing at a lower rate than expected. At the end of the irradiation, nine of the originally-planned 19 TCs were considered functional. Fission product release-to-birth (R/B) ratios were quite low. In most capsules, R/B values at the end of the irradiation were at or below 10 -7 with only one capsule significantly exceeding this value. A maximum R/B of around 2 x 10 -7 was reached at the end of the irradiation in Capsule 5. Several shakedown issues were encountered and resolved during the first three cycles. These include the repair of minor gas line leaks; repair of faulty gas line valves; the need to position moisture monitors in regions of low radiation fields for proper functioning; the enforcement of proper on-line data storage and backup, the need to monitor thermocouple performance, correcting for detector spectral gain shift, and a change in the mass flow rate range of the neon flow controllers.

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AGR-2 Daily As-run Thermal Analyses

This report documents the daily as-run thermal analyses performed on Advanced Gas-cooled Reactor (AGR) experiment AGR-2 in the Advanced Test Reactor (ATR) for capsules 2,3,5, and 6. Capsule 1 (French) results are in Appendix F, while Capsule 4 (South African) results are in Appendix G. Appendix F, and G are separate documents Several fuel and material irradiation experiments, which support the development of the Next Generation Nuclear Plant (NGNP), are planned for the Advanced Gas Reactor Fuel Development and Qualification Program. The goals of these experiments are to provide irradiation performance data to support fuel process development, to qualify fuel for normal operating conditions, to support development and validation of fuel performance and fission product transport models and codes, and to provide irradiated fuel and materials for post-irradiation examination (PIE) and safety testing. AGR-2 was the second in this series of planned experiments to test tristructural-isotropic (TRISO)-coated, low enriched uranium oxycarbide (LEUCO) fuel. The AGR-2 experiment was intended to serve as a follow-on to the AGR-1 experiment. The AGR-2 experiment is a high temperature fuel particle test. The test train planned for AGR-2 is based on the experience gained from previous irradiations in the ATR, using instrumented lead experiments. Instrumented lead experiments are used for irradiations requiring a controlled environment and monitored parameters. The experiment test train positions the fuel within the test location and contains sweep gas lines and thermocouple wiring that is routed through access ports to external support systems. The AGR-2 experiment is comprised of six individual capsules, approximately 1.375-in. in diameter by 6-in. long, stacked on top of each other to form the test train. Each capsule contains 12 fueled compacts that are approximately 0.5-in. in diameter by 1-in. long. The compacts are composed of fuel particles bound together by a carbon matrix. Each compact contains approximately 4,150 fissile particles (35 vol% particle packing fraction). Each capsule will be supplied with a flowing helium/neon gas mixture to control the test temperature and to sweep any fission gases that are released to the fission product monitoring system. Temperature control is accomplished by adjusting the gas mixture ratio of the two gases (helium and neon) with differing thermal conductivities. Many similarities exist between this thermal analysis for AGR-2 with the AGR-1 daily as-run report in [1]. Gas gaps were taken from as built drawings in Reference [2]. The finite element heat transfer code ABAQUS [3] was used to perform the thermal analysis. The AGR-2 experiment was placed in the B-12 position in the ATR core as shown in Figure 1. The AGR-2 experiment capsule assembly consists of six capsules axially stacked. Each capsule contains a graphite holder with three equally spaced fuel compact holder openings as shown in Figure 2. Each holder opening accommodates four axially stacked fuel compacts. Thus, each capsule has three stacks by four fuel compacts per stack for a total of 12 fuel compacts per capsule. So, within the entire AGR-2 experiment capsule assembly, there are six capsules by 12 fuel compacts per capsule for a total of 72 fuel compacts. Six finite element heat transfer models were created (one for each capsule), each with a corresponding gas gap.

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