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This document is a presentation intended to be provided as a status update on current work developing compact-level TRISO fuel performance analyses.
The TRi-structural ISOtropic (TRISO) fuel multilayered coating structure offers multiple barriers to fission product release, enhancing safety and performance. The heterogeneous nature of TRISO fuel compacts, comprising thousands of randomly distributed coated fuel particles embedded in a graphite matrix, creates intricate stress fields and thermal gradients that cannot be accurately modeled using simplified one-dimensional or homogenized approaches. Consequently, three-dimensional modeling enables the prediction of fuel compact dimensional changes, internal pressure buildup, and fission product transport pathways under diverse irradiation and thermal conditions. This capability facilitates detailed analysis of particle-to-particle interactions, matrix cracking mechanisms, and the statistical distribution of coating failures, which directly impact fuel performance and safety margins. This capability is particularly critical for advanced reactors, such as high-temperature gas-cooled reactors and other Generation IV reactor designs where TRISO fuel operates at elevated temperatures and burn-up levels. This work introduces a novel method to generate an optimized packing of TRISO compacts and a complete 3D mesh with random distribution of TRISO particles, which are discretized into each coating component layer.
TRISO (TRi-structural ISOtropic) – compact-type micro-particle fuels – are next generation nuclear fuel compacts designed with safety in mind. Structural integrity and characterisation before and after irradiation are important to determine the performance of the fuel compacts under real reactor conditions. X-ray computed tomography can be an important tool for non-destructive evaluation of these fuel compacts. The fuel particles are highly attenuating for X-rays which creates metal artefact, rendering the images unusable. Our artefact correction can mitigate these artefacts significantly. The proposed method works by first segmenting highly-attenuating structures (metal) and forward projecting to localise the source of artefacts in the projection domain, then, using a traditional or U-net-based deep learning architecture, contextually interpolating those regions to remove the artefacts. Finally the reconstruction from the modified projection is fused with the segmented metal. The proposed method shows a significant improvement in the image quality while significantly reducing the reconstruction time compared to the standard technique.
A natural uranium-based, unirradiated tristructural isotropic (TRISO) fuel compact was nondestructively imaged using both X-ray (XCT) and neutron computed tomography (nCT). While XCT of compacts can provide information on fuel kernels, imaging artifacts preclude examination of the graphite matrix. In this work, nCT was used for the first time on a TRISO compact to examine the graphite matrix. A crack was clearly resolved within the graphite matrix, proving that nCT is a viable tool for nondestructive volumetric examination of the matrix material in TRISO fuel compacts. The XCT and nCT data were then fused together to create a more comprehensive dataset containing both matrix and fuel kernels.
This work studies the impact of explicit and homogenized modeling approaches on the multiphysics simulation of TRistructural ISOtropic (TRISO) fuel compacts in prismatic High Temperature Gas Reactors (HTGRs) and the silver release predictions. TRISO fuel compacts exhibit complex double heterogeneity that significantly affects heat conduction, neutron transport, and fission products release. In this work, we use Cardinal, a multiphysics tool based on the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, to couple neutron transport and heat conduction. OpenMC is used for neutron transport and the MOOSE heat transfer module is used for the heat conduction. Then, we use BISON for the silver release predictions. Two different modeling approaches—explicit modeling of individual TRISO particles and homogenized representation using effective thermal properties—are compared at high TRISO packing fractions (20% and 40%) across varying power densities. Results demonstrate that homogenization significantly under-predicts peak temperatures, for the case of high power/TRISO, there is a difference of 83.73 K in the maximum temperature. Additionally, homogenization underestimates the silver release predictions compared to explicit modeling. Specifically, the temperature and power density differences lead to significant differences in silver release predictions. This work demonstrates the importance of accurately modeling heterogeneity of the TRISO particles to reliably predict fission product release and assess reactor safety margins.
The AGR-3/4 irradiation tests combined the third and fourth planned irradiation experiments in the US Department of Energy’s Advanced Gas Reactor (AGR) testing campaign of tri-structural isotropic (TRISO) fuel compacts. In this article, we present post-irradiation examination (PIE) using X-ray computed tomography (XCT) of two unirradiated and two irradiated compacts from the AGR-3/4 irradiation tests. The irradiated compacts studied (compact 7–1 and compact 12–4) represent the upper and lower limit of burnup within the AGR-3/4 irradiation experiment. This article presents a detailed quantitative analysis on the post-irradiation structure of TRISO fuel compacts. Various quantitative parameters including shape, size, and packing of kernels, and their spatial distribution, were utilized to gain insights into the structural changes caused by irradiation. The equivalent diameter and sphericity were found to increase and decrease, respectively, in irradiated compact 7–1 due to its higher burnup. Nearest neighbor distance between fuel kernels decreased after irradiation, suggesting irradiation-induced shrinkage of graphitic matrix. Furthermore, each compact in AGR-3/4 irradiation tests contained 20 designed-to-fail (DTF) fuel particles that were meant to act as a source of fission product release to the experiment test train. Furthermore, in the present work, all DTF fuel particles in the four compacts studied were identified, and it was found that they exhibited larger kernel swelling in compact 12–4 and smaller kernel swelling in compact 7–1, compared to the driver particles.
Four post-irradiation heating tests of fuel compacts from the U.S. Advanced Gas Reactor (AGR)-3/4 irradiation experiment were completed. In addition to tristructural isotropic (TRISO)-coated driver fuel, each compact contained designed-to-fail (DTF) particles with fuel kernels coated only in pyrocarbon so as to simulate exposed kernels. Tests at 1600/1700°C, 1400°C, and 1200°C were performed to measure fission product release as a function of time and temperature. Silver release was highest in the 1200°C test, supporting the observation that silver release rates are highest in the 1100–1300°C range. Compared to tests of AGR-1 compacts with no exposed kernels, the Cs-134 and Kr-85 releases were noticeably higher in AGR-3/4. The exposed kernels’ contributions to Eu and Sr release are inconclusive, due to the difficulty in distinguishing among the combined effects of higher irradiation temperatures in these particular AGR-3/4 compacts, the presence of the DTF particles, and the Fuel Accident Condition Simulator (FACS) test temperatures. These data can be used to make inferences about fission product retention in exposed kernels as a function of time and temperature.
Seven as-irradiated Advanced Gas Reactor (AGR) 5/6/7 compacts underwent destructive post-irradiation examination via deconsolidation-leach-burn leach at Idaho National Laboratory (INL). The selection of the compacts extended the upper and lower limits of time-average volume-average (TAVA) temperature for compacts that had gone through deconsolidation-leach-burn leach so far. The measured inventories of fission products and actinides in the compact matrix and outer pyrolytic carbon were reported. Results indicated unexpectedly higher rates of fuel kernel leaching compared to compacts from AGR-1 and AGR-2. These failure rates were attributed to damage during post-irradiation sample handling, rather than irradiation itself. AGR-5/6/7 compacts have little or no matrix coverage for some particles at the top and bottom ends of cylindrical fuel compacts, making them more fragile. Sixty particles were randomly sampled from each compact, and the gamma results were reported. Three SiC shells from were identified, one of which showed signs of chemical attack in the high-irradiation temperature compact.
Five AGR-3/4 fuel compacts were previously heated in the Fuel Accident Condition Simulator (FACS) furnace. Three of these compacts were also reirradiated in the Neutron Radiography (NRAD) reactor before the FACS tests. One of these was heated to 1200°C, two were heated to 1400°C, one was heated to 1600°C, and one was held for a period of time at 1600 and 1700°C. After these FACS tests, the compacts were subjected to destructive post-irradiation examination (PIE) via radial-deconsolidation-leach-burn-leach (RDLBL) at INL. The RDLBL process deconsolidated the compacts in multiple radial steps, followed by a final, single-step axial deconsolidation. The samples generated at each step were analyzed for isotopes of key fission products and actinides. After each deconsolidation step, the compact volume was assessed, and this was used to normalize the measured quantities of nuclides of interest to give volumetric concentrations as a function of radial position within the compact. The total inventories of measured fission products and actinides and the radial concentration profiles were compared with their sibling compacts within the same capsule (similar irradiation conditions) that went through RDLBL in the as-irradiated state. These data will be used to refine the fission product transport models.
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.
The TRI-structural ISOtropic (TRISO) layered fuel particle is a robust nuclear fuel form offering enhanced safety and performance for advanced reactor concepts, including high-temperature gas-cooled reactors and other Generation IV designs. These poppy-seed-sized particles are embedded in a graphite matrix to form fuel elements that must withstand elevated temperatures and high burn-up levels. The heterogeneous nature of these fuel elements — comprising thousands of randomly distributed TRISO particles — produces complex stress fields and thermal gradients that one- and two-dimensional models cannot accurately capture. While three-dimensional modeling has improved predictions of dimensional changes, internal pressure buildup, and fission product transport under irradiation, current approaches rely on homogenized material properties that are known to have considerable divergence from experimental observations. This work presents a methodology for optimized random packing of TRISO fuel compacts and full three-dimensional mesh generation within the BISON fuel performance code, with each particle coating layer individually discretized. The resulting mesh was demonstrated through heat conduction simulations under representative in-reactor operating conditions, showing strong agreement with expected behavior. This capability enables detailed analysis of particle-to-particle interactions, matrix cracking mechanisms, and the statistical distribution of coating layer failures — all of which directly govern fuel performance and safety margins.
Five capsules containing varying configurations of TRISO fuel compacts were irradiated in the most recent Advanced Gas Reactor (AGR) TRISO test campaign, AGR-5/6/7. As part of the post-irradiation examination (PIE) of this work all the fuel compacts and capsule graphite holders were measured with the Precision Gamma Scanner (PGS) to determine isotopic activities and locations using gamma spectrometry. Measuring the compacts allowed for the comparison of physics model depletion calculations with the measured compact activity to validate models. These measurements also are used to find compacts of interest with low fission product retention that may be tested in subsequent PIE. Measurements of the holders can confirm fission product distribution and migration. Of the isotopes measured, Cs-137 and Cs-134 were used to estimate location of failed particles as well as determine a measured burnup estimation. Results from Capsule 1 compacts and the holder indicate many fuel particle failures occurred. There are high amounts of cesium in the holder near Stack 9 of Capsule 1 that corresponds to low fractions?measured-to-calculated (M/C) ratio?of cesium remaining in those compacts. All other capsules had cesium retention ratios near 1. The isotope 110mAg had less consistent results. Capsule 2 compacts exhibited a M/C of 0.20, much lower than anticipated for the temperatures these compacts underwent. Capsule 3 experienced much higher temperatures, >1300C and had an average M/C of 0.75. These are the opposite results than what was predicted by past AGR experiments for the relationship between temperature and isotope retention. Capsule 4 and 5 showed good fission product retention and agreement with the physics model predictions. The burnup results from the PGS measurements showed strong agreement between the physics models and the measured values. Using a ratio of Cs-134/Cs-137 to calculate the burnup match closely with the physics models. Additionally, the Cs-137 burnup results were less accurate but extremely close to the model results.
Idaho National Laboratory (INL) performs post irradiation examination (PIE) of tri-structural isotropic (TRISO)-coated particle fuel to help qualify it for high temperature gas cooled reactors. TRISO fuel compacts are re-irradiated in the Neutron Radiography Reactor (NRAD) to generate the short lived fission products needed for fission product release testing. The Fuel Accident Condition Simulator (FACS) furnace and newly added Screen Neutron Irradiated Fuel for Failure (SNIFF) furnace heat the compacts in helium to temperatures of up to 2,000°C, prompting fission product release—predominantly gaseous xenon and krypton isotopes and condensable products such as cesium—from failed particles. These released isotopes are transported to a fission gas monitoring system (FGMS 1 or FGMS 3), where they accumulate in cryogenic cold traps and are quantified using high-purity germanium (HPGe) detectors. The addition of SNIFF and FGMS 3 increases throughput by enabling simultaneous testing of multiple compacts. Furthermore, automated INL developed software provides continuous, near-real time monitoring of fission product inventories and manages the liquid nitrogen cooling of the traps. These system enhancements improve the efficiency, data quality, and testing capacity of TRISO fuel performance evaluations.
This presentation includes work performed developing a computational benchmark for the AGR 1 and 2 experiments. These experiments involve irradiation of TRISO particle compact in the Advanced Test Reactor (ATR). Many post-irradiation measurements were made from these experiments, including isotopic concentrations of fission products. The benchmark involves a MCNP-ORIGEN coupled model of the ATR and AGR experiment capsules to calculate a comprehensive inventory of fission product and actinide concentrations in the compacts. This presentation describes the experiments, the measurements obtained, the benchmark model, and results of the model evaluation.
To address the lack of data on the behavior of short-lived fission products I-131 (t1/2 = 8.02 d) and Xe-133 (t1/2 = 5.24 d) in the TRISO fuel system, loose AGR-2 particles and kernels were reirradiated in NRAD and subjected to post-reirradiation heating in the FACS furnace. This provided data on the release of fission products from exposed kernels, and the results were used to establish FACS condensation plate collection efficiencies for temperatures of 1000, 1200, and 1400°C where previously, the only collection efficiencies were for 1600°C tests. These new collection efficiencies were then applied to the NRAD-FACS tests of entire AGR-3/4 fuel compacts. Understanding the relative behavior of short-lived I-131, for example, is important because it is a significant contributor to offsite dose during postulated accidents, and Xe-133 has previously been used as a conservative indicator of I-131 behavior. These data will be used to support refinement of fission product transport models and HTGR source-term analyses.
This report documents the application of the SCALE code to the analysis of a TRistructural-ISOtropic (TRISO)-based heat pipe microreactor (HPMR) within the context of its nuclear fuel cycle stages. The evaluation was conducted in support of the US Nuclear Regulatory Commission’s ongoing efforts to assess modeling capabilities for advanced non–light-water reactor technologies. The generic HPMR selected as a representative microreactor concept features a compact core design that incorporates TRISO fuel compacts, passive heat removal via heat pipes, and a transportable configuration intended for deployment in remote environments.
The fuel performance modeling code BISON was used to predict the release of fission products iodine-131 (131I), xenon-133 (133Xe), and krypton-85 (85Kr) from four re-irradiated AGR-3/4 fuel compacts containing tristructural isotropic (TRISO) coated particles during high-temperature isothermal heating tests. The AGR-3/4 fuel compacts were irradiated in the Advanced Test Reactor (ATR) as part of the third and fourth series of planned experiments to support the Advanced Gas Reactor (AGR) Program. They were subsequently stored and re-irradiated in the Neutron Radiography (NRAD) reactor for approximately five days and then stored for another five to eight days before being subjected to isothermal heating tests in the Fuel Accident Condition Simulation (FACS furnace) for 200 to 300 hours at temperatures between 1000°C and 1600°C to evaluate fission product release at elevated temperatures. New nuclide-specific fission product source term models for the three nuclides of interest were developed using the reactor multiphysics code Griffin and implemented into BISON to support this work. The new source term models were incorporated into coupled compact- and particle-scale BISON simulations, which predict spatially- and temporally-resolved radionuclide generation, radioactive decay, transport, and release throughout the entire irradiation history, including the initial ATR irradiation, NRAD re-irradiations, FACS heating tests, and intermediate periods spent in storage. The experimentally measured fission product release from the heating tests were compared to modeling release predictions calculated by BISON to evaluate how well the code compares to experimental results. Overall, the experimental measured and BISON predicted comparative release results varied but generally agreed to within 5 particle equivalents. Comparative release results identified general observations to take into consideration to help refine future models and reduce uncertainties associated with both the measurement results and predictive results. This includes developing new uranium oxycarbide (UCO) specific kernel diffusivities for the three isotopes examined to more accurately reflect the material properties of the fuel form. Deriving new diffusivities will aid in producing a more informed BISON model