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Review includes data on the chemical and physical properties of tellurium, its oxides, and fluorides, pertinent to the process problem of handling fission product tellurium in fluoride form. The technology of tellurium handling in nonaqueous processing of nuclear fuels is also reviewed.
With renewed interest in developing nuclear-powered deep space probes, attention will return to improving the metallurgical processing of potential nuclear fuels so that they remain dimensionally stable over the years required for a successful mission. Previous work on fuel alloys at the NASA Glenn Research Center was primarily empirical, with virtually no continuing research. Even when empirical studies are exacting, they often fail to provide enough insight to guide future research efforts. In addition, from a fundamental theoretical standpoint, the actinide metals (which include materials used for nuclear fuels) pose a severe challenge to modern electronic-structure theory. Recent advances in quantum approximate atomistic modeling, coupled with first-principles derivation of needed input parameters, can help researchers develop new alloys for nuclear propulsion.
A comparison was made between the environmental impact of the present nuclear-heated process and the currently commercial hydrogen-producing process utilizing coal for heating, i.e., the Lurgi coal gasification process. This comparison is based on the assumption that both plants produce the same quantity of H2, i.e., 269 cu m/sec of approximately the same purity, that all pollution abatement equipment is of the same design and efficiency for both the Lurgi process and the nuclear process, and that the energy required for the fresh nuclear fuel and the fuel recycle is generated in a power plant which is also provided with pollution abatement equipment. The pollution caused by the auxiliary units is also taken into account. As regards process water usage, the data show that the water required for the nuclear route, including the nuclear fuel production, is approximately 78% of that required for the Lurgi route.
W-UO2 CERMET fuels are under development to enable Nuclear Thermal Propulsion (NTP) for deep space exploration. Research efforts with an emphasis on fuel fabrication, testing, and identification of potential risks is underway. One primary risk is fuel loss due to CTE mismatch between W and UO2 and the grain boundary structure of W particles resulting in higher thermal stresses. Mechanical failure can result in significant reduction of the UO2 by hot hydrogen. Fuel loss can be mitigated if the UO2 particles are coated with a layer of high density tungsten before the consolidation process. This paper discusses the work to date, results, and advances of a fluidized bed chemical vapor deposition (CVD) system that utilizes the H2-WCl6 reduction process. Keywords: Space, Nuclear, Thermal, Propulsion, Fuel, CERMET, CVD, Tungsten, Uranium
This paper presents the results of a brief study performed for MSFC on the conceptual design of a nuclear satellite power station which delivers 5 GWe net power to earth by microwave transmission. The system contains 26 modules each consisting of a reactor, fuel processing plant, Brayton PCU, space radiator, and nuclear shield. A high-temperature, gas-cooled, pebble-bed plutonium breeder concept was selected which is resupplied with fertile U-238. Sections of this core are periodically replaced and the spent fuel is chemically processed, the radioactive wastes separated, and stored for eventual space disposal. Fresh fuel pellets, formed from the U-238 and the bred plutonium, are recycled back to the reactor. The hot (1317 C) helium gas exiting the reactor serves as the working fluid in a 30%-efficient Brayton PCU.
A unique numerical method has been developed to model the dynamic processes of bulk evaporation and condensation processes, associated with internal heat generation and natural convection under different gravity levels. The internal energy formulation, for the bulk liquid-vapor phase change problems in an encapsulated container, was employed. The equations, governing the conservation of mass, momentum and energy for both phases involved in phase change, were solved. The thermal performance of a multiphase uranium tetra-fluoride fuel element under zero gravity, micro-gravity and normal gravity conditions has been investigated. The modeling yielded results including the evolution of the bulk liquid-vapor phase change process, the evolution of the liquid-vapor interface, the formation and development of the liquid film covering the side wall surface, the temperature distribution and the convection flow field in the fuel element. The strong dependence of the thermal performance of such multiphase nuclear fuel cell on the gravity condition has been revealed. Under all three gravity conditions, 0-g, 10(exp -3)-g, and 1-g, the liquid film is formed and covers the entire side wall. The liquid film covering the side wall is more isothermalized at the wall surface, which can prevent the side wall from being over-heated. As the gravity increases, the liquid film is thinner, the temperature gradient is larger across the liquid film and smaller across the vapor phase. This investigation provides valuable information about the thermal performance of multi-phase nuclear fuel element for the potential space and ground applications.
Nuclear Thermal Propulsion (NTP) engines have been deemed a key technology to enable human missions to Mars due to their high efficiency, also known as specific impulse (Isp). Ground testing the NTP engine is critical in maturing the technology and increasing the design’s Technology Readiness Level (TRL), thus mitigating risk from NTP engine performance/operations. NTP engine development began with open-air ground testing through the Rover/NERVA program back in the 1960s when regulatory requirements were not as stringent as they are today. Due to the formation of regulatory bodies, increase in oversight and environmental requirements, the exhaust gas released from NTP engines must be captured or processed to gain approval in the case that the exhaust gas contains fission products from the nuclear fuel elements within the reactor. Ground test campaigns following Rover/NERVA focused on the certification of a full scale NTP engine, which led to exhaust processing systems such as the Rocket Exhaust Capture System (RECS) and Real Time (RT) exhaust processing. These systems were deemed favorable for regulatory compliance but have a high initial investment cost. Reassurance on the feasibility of ground testing and the NTP engine technology likely need to be achieved before NASA invests in these systems. Recently the objectives for NTP engine ground testing have shifted from certification testing of a full scale engine to demonstration testing of a subscale engine. The shift to demonstration testing allows for a shorter testing duration and a lower operational thrust (for demo testing purposes only) to demonstrate the NTP engine (5k-12.5k lbf). Due to these factors, the infrastructure, consumables, total footprint, and exhaust system complexity are able to be drastically reduced, thus reducing cost significantly. The High-pressure Exhaust Capture System (HECS) concept was designed for a NTP engine ground test demonstration. The HECS concept greatly reduces cost compared to previous concepts and suggests favorable regulatory acceptance due to its ability to capture all of the exhaust gas from the NTP engine.
Nuclear Thermal Propulsion (NTP) engines have been deemed a key technology to enable human missions to Mars due to their high efficiency, also known as specific impulse (Isp). Ground testing the NTP engine is critical in maturing the technology and increasing the design’s Technology Readiness Level (TRL), thus mitigating risk from NTP engine performance/operations. NTP engine development began with open-air ground testing through the Rover/NERVA program back in the 1960s when regulatory requirements were not as stringent as they are today. Due to the formation of regulatory bodies, increase in oversight and environmental requirements, the exhaust gas released from NTP engines must be captured or processed to gain approval in the case that the exhaust gas contains fission products from the nuclear fuel elements within the reactor. Ground test campaigns following Rover/NERVA focused on the certification of a full scale NTP engine, which led to exhaust processing systems such as the Rocket Exhaust Capture System (RECS) and Real Time (RT) exhaust processing. These systems were deemed favorable for regulatory compliance but have a high initial investment cost. Reassurance on the feasibility of ground testing and the NTP engine technology likely need to be achieved before NASA invests in these systems. Recently the objectives for NTP engine ground testing have shifted from certification testing of a full scale engine to demonstration testing of a subscale engine. The shift to demonstration testing allows for a shorter testing duration and a lower operational thrust (for demo testing purposes only) to demonstrate the NTP engine (5k-12.5k lbf). Due to these factors, the infrastructure, consumables, total footprint, and exhaust system complexity are able to be drastically reduced, thus reducing cost significantly. The High-pressure Exhaust Capture System (HECS) concept was designed for a NTP engine ground test demonstration. The HECS concept greatly reduces cost compared to previous concepts and suggests favorable regulatory acceptance due to its ability to capture all of the exhaust gas from the NTP engine.
A fission reactor combined with Stirling convertor power generation is one promising candidate in on-going Fission Surface Power (FSP) studies for future lunar and Martian bases. There are many challenges for designing and qualifying space-rated nuclear power plants. In order to have an affordable and sustainable program, NASA and DOE designers want to build upon the extensive foundation in nuclear fuels and structural materials. This talk will outline the current Fission Surface Power program and outline baseline design options for a lunar power plant with an emphasis on materials challenges. NASA first organized an Affordable Fission Surface Power System Study Team to establish a reference design that could be scrutinized for technical and fiscal feasibility. Previous papers and presentations have discussed this study process in detail. Considerations for the reference design included that no significant nuclear technology, fuels, or material development were required for near term use. The desire was to build upon terrestrial-derived reactor technology including conventional fuels and materials. Here we will present an overview of the reference design, Figure 1, and examine the materials choices. The system definition included analysis and recommendations for power level and life, plant configuration, shielding approach, reactor type, and power conversion type. It is important to note that this is just one concept undergoing refinement. The design team, however, understands that materials selection and improvement must be an integral part of the system development.
A panel was organized by NASA/DOE/DOD to study nuclear fuels, materials, and related nuclear propulsion technologies for SEI, and the panel findings are discussed. The fuels/materials requirements for nuclear thermal propulsion and nuclear electric propulsions are reviewed, and the development items such as 'element' development and characterization, fabrication process development, nuclear capsule tests, nuclear loop tests, and nuclear furnace tests are examined for selected classes of fuels.
Processing techniques are being developed to fabricate refractory metal and ceramic cermet materials for Nuclear Thermal Propulsion (NTP). Significant advances have been made in the area of high-temperature cermet fuel processing since RoverNERVA. Cermet materials offer several advantages such as retention of fission products and fuels, thermal shock resistance, hydrogen compatibility, high conductivity, and high strength. Recent NASA h d e d research has demonstrated the net shape fabrication of W-Re-HfC and other refractory metal and ceramic components that are similar to UN/W-Re cermet fuels. This effort is focused on basic research and characterization to identify the most promising compositions and processing techniques. A particular emphasis is being placed on low cost processes to fabricate near net shape parts of practical size. Several processing methods including Vacuum Plasma Spray (VPS) and conventional PM processes are being evaluated to fabricate material property samples and components. Surrogate W-Re/ZrN cermet fuel materials are being used to develop processing techniques for both coated and uncoated ceramic particles. After process optimization, depleted uranium-based cermets will be fabricated and tested to evaluate mechanical, thermal, and hot H2 erosion properties. This paper provides details on the current results of the project.
In view of the difficult times the US and global economies are experiencing today, funds for the development of advanced fission reactors nuclear power systems for space propulsion and planetary surface applications are currently not available. However, according to the Energy Policy Act of 2005 the U.S. needs to invest in developing fission reactor technology for ground based terrestrial power plants. Such plants would make a significant contribution toward drastic reduction of worldwide greenhouse gas emissions and associated global warming. To accomplish this goal the Next Generation Nuclear Plant Project (NGNP) has been established by DOE under the Generation IV Nuclear Systems Initiative. Idaho National Laboratory (INL) was designated as the lead in the development of VHTR (Very High Temperature Reactor) and HTGR (High Temperature Gas Reactor) technology to be integrated with MMW (multi-megawatt) helium gas turbine driven electric power AC generators. However, the advantages of transmitting power in high voltage DC form over large distances are also explored in the seminar lecture series. As an attractive alternate heat source the Liquid Fluoride Reactor (LFR), pioneered at ORNL (Oak Ridge National Laboratory) in the mid 1960's, would offer much higher energy yields than current nuclear plants by using an inherently safe energy conversion scheme based on the Thorium --> U233 fuel cycle and a fission process with a negative temperature coefficient of reactivity. The power plants are to be sized to meet electric power demand during peak periods and also for providing thermal energy for hydrogen (H2) production during "off peak" periods. This approach will both supply electric power by using environmentally clean nuclear heat which does not generate green house gases, and also provide a clean fuel H2 for the future, when, due to increased global demand and the decline in discovering new deposits, our supply of liquid fossil fuels will have been used up. This is expected within the next 30 to 50 years, as predicted by the Hubbert model and confirmed by other global energy consumption prognoses. Having invested national resources into the development of NGNP, the technology and experience accumulated during the project needs to be documented clearly and in sufficient detail for young engineers coming on-board at both DOE and NASA to acquire it. Hands on training on reactor operation, test rigs of turbomachinery, and heat exchanger components, as well as computational tools will be needed. Senior scientist/engineers involved with the development of NGNP should also be encouraged to participate as lecturers, instructors, or adjunct professors at local universities having engineering (mechanical, electrical, nuclear/chemical, and/or materials) as one of their fields of study.
Microcomputer Intelligence for Technical Training (MITT) uses Intelligent Tutoring System (OTS) technology to deliver diagnostic training in a variety of complex technical domains. Over the past six years, MITT technology has been used to develop training systems for nuclear power plant diesel generator diagnosis, Space Shuttle fuel cell diagnosis, and message processing diagnosis for the Minuteman missile. Presented here is an overview of the MITT system, describing the evolution of the MITT software and the benefits of using the MITT system.
Nuclear Thermal Propulsion (NTP) development efforts in the United States have demonstrated the technical viability and performance potential of NTP systems. For example, Project Rover (1955 - 1973) completed 22 high power rocket reactor tests. Peak performances included operating at an average hydrogen exhaust temperature of 2550 K and a peak fuel power density of 5200 MW/m3 (Pewee test), operating at a thrust of 930 kN (Phoebus-2A test), and operating for 62.7 minutes in a single burn (NRX-A6 test). Results from Project Rover indicated that an NTP system with a high thrust-to-weight ratio and a specific impulse greater than 900 s would be feasible. Excellent results were also obtained by the former Soviet Union. Although historical programs had promising results, many factors would affect the development of a 21st century nuclear thermal rocket (NTR). Test facilities built in the US during Project Rover no longer exist. However, advances in analytical techniques, the ability to utilize or adapt existing facilities and infrastructure, and the ability to develop a limited number of new test facilities may enable affordable development, qualification, and utilization of a Nuclear Cryogenic Propulsion Stage (NCPS). Bead-loaded graphite fuel was utilized throughout the Rover/NERVA program, and coated graphite composite fuel (tested in the Nuclear Furnace) and cermet fuel both show potential for even higher performance than that demonstrated in the Rover/NERVA engine tests.. NASA's NCPS project was initiated in October, 2011, with the goal of assessing the affordability and viability of an NCPS. FY 2014 activities are focused on fabrication and test (non-nuclear) of both coated graphite composite fuel elements and cermet fuel elements. Additional activities include developing a pre-conceptual design of the NCPS stage and evaluating affordable strategies for NCPS development, qualification, and utilization. NCPS stage designs are focused on supporting human Mars missions. The NCPS is being designed to readily integrate with the Space Launch System (SLS). A wide range of strategies for enabling affordable NCPS development, qualification, and utilization should be considered. These include multiple test and demonstration strategies (both ground and in-space), multiple potential test sites, and multiple engine designs. Two potential NCPS fuels are currently under consideration - coated graphite composite fuel and tungsten cermet fuel. During 2014 a representative, partial length (approximately 16") coated graphite composite fuel element with prototypic depleted uranium loading is being fabricated at Oak Ridge National Laboratory (ORNL). In addition, a representative, partial length (approximately 16") cermet fuel element with prototypic depleted uranium loading is being fabricated at Marshall Space Flight Center (MSFC). During the development process small samples (approximately 3" length) will be tested in the Compact Fuel Element Environmental Tester (CFEET) at high temperature (approximately 2800 K) in a hydrogen environment to help ensure that basic fuel design and manufacturing process are adequate and have been performed correctly. Once designs and processes have been developed, longer fuel element segments will be fabricated and tested in the Nuclear Thermal Rocket Element Environmental Simulator (NTREE) at high temperature (approximately 2800 K) and in flowing hydrogen.
Production of finely divided cubes of boron involves vacuum-deposition technology and requires making of template. Template supports pattern of checkered squares 25 micrometers on side, which are etched 25 micrometers into template material. Template coasted uniformly with paralyene or some similar vacuum coating with low coefficient of adhesion. Intended application to solid rocket fuels, explosives, and pyrotechnics; process used for other applications, from manufacture of pharmaceuticals to processing of nuclear materials.
The three parts of a program directed toward creating a cost-effective nuclear hydrogen production system are described. The discussion covers the development of a very high temperature nuclear reactor (VHTR) as a nuclear heat and power source capable of producing the high temperature needed for hydrogen production and other processes; the development of a hydrogen generation process based on water decomposition, which can utilize the outputs of the VHTR and be integrated with many different ultimate hydrogen consuming processes; and the evaluation of the process applications of the nuclear hydrogen systems to assess the merits and potential payoffs. It is shown that the use of VHTR for the manufacture of synthetic fuels appears to have a very high probability of making a positive contribution to meeting the nation's energy needs in the future.
Nuclear Thermal Propulsion (NTP) is under development for deep space exploration. NTP's high specific impulse (> 850 second) enables a large range of destinations, shorter trip durations, and improved reliability. W-60vol%UO2 CERMET fuel development efforts emphasize fabrication, performance testing and process optimization to meet service life requirements. Fuel elements must be able to survive operation in excess of 2850 K, exposure to flowing hydrogen (H2), vibration, acoustic, and radiation conditions. CTE mismatch between W and UO2 result in high thermal stresses and lead to mechanical failure as a result UO2 reduction by hot hydrogen (H2) [1]. Improved powder metallurgy fabrication process control and mitigated fuel loss can be attained by coating UO2 starting powders within a layer of high density tungsten [2]. This paper discusses the advances of a fluidized bed chemical vapor deposition (CVD) system that utilizes the H2-WCl6 reduction process.
At present, nearly all of the hydrogen consumed in the world is produced by reacting hydrocarbons with water. As the supply of hydrocarbons diminishes, the problem of producing hydrogen from water alone will become increasingly important. Furthermore, producing hydrogen from water is a means of energy conversion by which thermal energy from a primary source, such as solar or nuclear fusion of fission, can be changed into an easily transportable and ecologically acceptable fuel. The attraction of thermochemical processes is that they offer the potential for converting thermal energy to hydrogen more efficiently than by water electrolysis. A thermochemical hydrogen-production process is one which requires only water as material input and mainly thermal energy, or heat, as an energy input. Attention is given to a definition of process thermal efficiency, the thermodynamics of the overall process, the single-stage process, the two-stage process, multistage processes, the work of separation and a process evaluation.