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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.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Modeling of Prismatic High Temperature Reactors in Pronghorn

Pronghorn is a Multiphysics Object-Oriented Simulation Environment (MOOSE) based thermal-hydraulics code developed at Idaho National Laboratory (INL) for advanced reactor analysis. It has been previously applied to model Pebble-Bed High Temperature Reactors (High Temperature Reactor (HTR)s), Liquid-Metal Cooled Reactors, and Molten Salt Reactors, among others. This work applies the coarse-mesh thermal hydraulics capabilities in Pronghorn to model Prismatic-Core HTRs. In particular, the Oregon State University (OSU)’s High Temperature Test Facility (HTTF) is modeled with Pronghorn. The HTTF is a 1:4 height scaled-down facility of General Atomics’ Modular High Temperature Gas-cooled Reactor.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Specimen sizing and remaining life sample calculations for high temperature reactor material surveillance

Advanced high-temperature nuclear reactors rely on structural components that will operate for decades under combined mechanical, thermal, and environmental loading. Materials surveillance programs are a promising strategy for managing the resulting uncertainty in long-term structural integrity by monitoring degradation in service using passively actuated mechanical test articles. Previous reports have developed a simplified, spreadsheetimplementable framework for sizing these test articles and for inferring accumulated creep damage and remaining life from ex-situ test data. This report advances that work toward practical deployment by providing a sample-problem book: a collection of worked, end-toend examples in which the ASME Section III, Division 5 design analysis of a representative high-temperature reactor component is carried through to a sized surveillance article, verified with detailed finite-element analysis, and concluded with a remaining-life assessment based on an assumed ex-situ creep-rate measurement on the retrieved specimen. The report also summarizes ongoing ANL engagement with ASTM Committee E10 on Nuclear Technology and Applications toward drafting a standard covering surveillance procedures for advanced reactors.

Barua, Bipul (ORCID:0000000247184113)↗
DOE OSTI2024

Neutronics and Thermo-Fluids Simulation of Generic Pebble-Bed Fluoride-Salt-Cooled High-Temperature Reactor

The fluoride-salt-cooled high-temperature reactor (FHR) is one of the advanced reactors that has been attracting considerable interest from both the research community and the nuclear industry. To help facilitate the nuclear community's familiarity with the FHR, Kairos Power has developed a generic FHR (gFHR) benchmark. In the research performed here, this benchmark was used to assess innovative modeling methods that combine stochastic and deterministic computer codes to perform the design and analysis of the gFHR. Further, the Monte Carlo code Serpent 2 was used to generate few-group cross sections that were then used in the neutron diffusion and thermal-fluids code AGREE to perform full-core neutronics and thermal-fluids steady-state and transient core analysis. The Argonne National Laboratory code SAM was then used to model the gFHR system and to simulate the load-follow operation of the gFHR.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Demonstration of Microwave Cavity Transducer Performance in High Temperature Fluid Flow Sensing: Development of Microwave Cavity Flow Meter for Advanced Reactor High Temperature Fluids

We are investigating a microwave resonant cavity transducer for flow sensing in the vessel of a high temperature fluid advanced reactor (AR), such as a molten salt cooled reactor (MSCR) or a sodium fast reactor (SFR). This transducer is a hollow metallic cylindrical cavity, with one of the flat walls of the cylinder flexible enough to undergo microscopic deflection due to dynamic fluid pressure. Membrane deflection leads to a shift in the microwave resonant frequency, which can be detected with a spectrum analyzer. We have performed a preliminary proof-of-principle test of flow sensing in high temperature liquid sodium in environment, which is similar to that of an advanced reactor. The liquid sodium setup consists of a cylindrical vessel with a center feed line, where a transducer inserted through the top cap of the vessel measures velocity of the impinging liquid jet. For this test, we have developed a cylindrical resonator, which was machined from stainless steel 316 and electroplated with silver on the interior surfaces. Outer diameter of the cylindrical cavity is approximately 3cm, and the thin wall is approximately 200µm thick. We have also developed and insertion probe consisting of a 50cm WR-42 brass waveguide enclosed in a protective SS316 tube. The cavity was excited through a WR-42 waveguide through a subwavelength hole on the side of the wall of the cylinder in the TE 011 mode with resonant frequency f ≈ 17.8GHz. As a calibration experiment, we have assembled a water vessel with a center feed, and with dimensions similar to those of the liquid sodium setup. Frequency shift of the cavity spectral response was obtained at room temperature and ambient pressure by gradually increasing water flow rate from 0 to 25GPM (gallons per minute). Corresponding monotonic increase of resonant frequency by several hundred KHz was observed. Next, a sodium flow rate sensing study was performed in a liquid sodium vessel at 340° C temperature and ambient pressure. The flow rate was changed by varying sodium pump power, and a frequency shift of several hundred KHz was observed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Codes and standards for ceramic composite core materials for High Temperature Reactor applications

Fiber-reinforced ceramic matrix composites are attractive for high-temperature nuclear applications due to excellent thermal and mechanical properties as well as reasonable-to-outstanding radiation resistance. Over the past 20 years, the use of ceramic matrix composite applications expanded to many commercial non-nuclear industries as fabrication and application of the technologies mature. The ASME Boiler Pressure Vessel Code, under Section III Division 5, provides the design and construction rules for High Temperature Reactor components. It published the first rules for ceramic matrix composites to be used for reactor core components. The rules lay out the quality requirements together with the design and materials criteria for the use and application of silicon carbide- and carbon-based matrix material technologies. As with the established graphite rules, the ceramic composite material rules are structured in Subsection HH (from Section III), that addresses the criteria for class SN nonmetallic core components. The code rules rely heavily on the development and publication of standards for composite specification, classification, and testing of mechanical, thermal, and other properties. These test methods are developed in ASTM Committee C28 on Advanced Ceramics, with a current focus on ceramic composite tubes. This article describes the detail of the composites code, the design methodology and similarities to the graphite code, the guidance for the development of specifications for ceramic composites (for nuclear applications) including recent standard developments, and it mentions the next steps to support licensing aspects by validating the code with benchmarking data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Modeling of Prismatic High Temperature Reactors in Pronghorn

Pronghorn is a MOOSE based thermal-hydraulics code developed at Idaho National Laboratory (INL) for advanced nuclear reactor analysis. It has been previously applied to model pebble-bed high temperature reactors (HTRs), liquid-metal cooled reactors, and molten salt reactors, among others. This work leverages the coarse-mesh modeling capabilities in Pronghorn to model the Oregon State University (OSU)'s High Temperature Test Facility (HTTF). The HTTF is a 1:4 height scaled-down facility of General Atomics' Modular High Temperature Gas-cooled Reactor (MHTGR). The facility is primarily built to generate data for code and model validation, and does not precisely replicate MHTGR conditions. Nevertheless, it encompasses the main physics associated with MHTGR transients.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

A hybrid surrogate modeling framework for the Digital Twin of a Fluoride-salt-cooled High-temperature Reactor (FHR)

While nuclear energy is a non-greenhouse-gas emitting energy source, expensive operational costs due to the high-level of safety requirements decreases their competitiveness in the sustainable energy market. Advanced reactor concepts paired with Digital Twins aim to increase the commercialization gains of nuclear energy by reducing operational costs, increasing reactor reliability and enhancing power generation. To support Digital Twin tasks such as real-time autonomous control, proactive maintenance monitoring or optimizing power demand operations, a fast and accurate virtual representation of the Nuclear Power Plant (NPP) is required. The computational cost of high-fidelity, physics-based models are unsuitable for real-time analysis or scalability. Here, in this work, a hybrid surrogate modeling framework is developed fora Fluoride-salt-cooled High-temperature Reactor (FHR) that leverages physics-inspired models for key reactor components and uses data-driven methods for rapid system state space prediction. The Xenon reactivity feedback model is integrated to inform the surrogate model about the reactor core and the homologous pump theory model is the basis for representing pump degradation. Using a detailed, two dimensional thermal hydraulics model to generate data on the FHR, we train a network of Vectorized Autoregressive Moving-Average with eXogenous input (VARMAX) models to predict the remaining state values. The result is a surrogate model that provides a detailed reactor state representation of 41 system states and a pump degradation analysis. The framework is applied to Load Follows profiles, yielding high accuracy and a speedup that is more than 4000x faster compared to the higher- fidelity thermal hydraulics model, enabling real-time operational intelligence and applications in long horizon predictions. While the surrogate model framework is demonstrated for the particular case of FHR, the hybrid physical/data-driven modeling approach including the network of surrogates and the underlying modularity has the potential to be applied to other physical asset systems.

Digital Twins↗
DOE OSTI2023

SAM Code Development for Source Term Modeling in Fluoride-salt-cooled High-temperature Reactors

The SAM code is under development and supported by DOE-NE’s Nuclear Energy Advanced Modeling and Simulation program as a modern system-level modeling and simulation tool for advanced non-light water reactor safety analyses. These advanced reactor concepts incorporate novel and improved approaches to achieve safety and economic feasibility. Many concepts leverage higher operating temperatures for improved efficiency with a variety of coolants and structural materials to support those needs. Such design choices may also pose unique radiological source term risks. There are continuous efforts to incorporate new physics and phenomena relevant to advanced reactor concepts, including capabilities to enable system-level source term modeling. The Pebble-Bed Fluoride-salt-cooled High-temperature Reactor (PB-FHR) is a promising candidate among advanced nuclear reactor concepts with its improved passive safety characteristics and high thermal efficiency. In addition to past efforts to support the development and utilization of SAM for PB-FHR safety analysis, the species transport modeling capabilities in SAM have been extended to simulate source term phenomena in concepts like the PB-FHR. The PB-FHR concept utilizes pebble-form TRISO fuel and FLiBe salt coolant to provide robust barriers to the release of almost all fission products and radiological source terms. However, tritium poses a unique radiological risk due to its significant production from neutron interactions with 6 Li and 9 Be in the FLiBe as well as its high mobility at elevated temperatures where it can permeate through structural metals. Secondly, the use of graphite at elevated temperatures poses the risk of oxidation damage to any structural components or fuel pebbles that are exposed to accidental air ingress. This report summarizes progress made in modeling these phenomena in SAM, which leverages the system-level multi-physics thermal hydraulic simulation to support an effective engineering-scale source term modeling capability. A tritium transport model is developed to simulate the various transport pathways in FHR and MSR concepts and is presented through verification and validation examples as well as demonstrations simulating experimental test loops and reference plant FHR models. A graphite oxidation model is also introduced to calculate local oxidation rates and is presented with initial validation results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Coupled SAM/Griffin Model of a Reference Fluoride-Salt-Cooled High-Temperature Reactor for Multi-Physics Simulations

A multi-physics coupled simulation model of a reference pebble bed fluoride-salt-cooled high-temperature reactor (PB-FHR) has been developed with SAM and Griffin computer codes for transient safety analysis. The reference problem of a prototypical reactor design serves as the foundation for the U.S. NRC (Nuclear Regulatory Commission) to verify the adequacy of computer codes and evaluation models for specific reactor types. In this work, the previously developed SAM model for PB-FHR primary loop has been updated for the coupled simulation. The updated SAM PB-FHR model includes a 2-D axial symmetric core region and external core components in 0-D/1-D. In addition to the primary loop, a detailed model of the RCCS (reactor cavity cooling system) is added. The 2-D and 1-D domains are tightly coupled using the single-solve approach developed in SAM. In the pebble bed region, the SAM multiscale explicit pebble model is applied to calculate the pebble and TRISO fuel kernel temperatures. The Griffin model used in this work is based on a model developed at Idaho National Laboratory in collaboration with the U.S. NRC. The Griffin neutronics model and SAM thermal hydraulics model is coupled with the Comprehensive Reactor Analysis Bundle (CRAB or alternately BlueCRAB) application. Both steady-state and transient scenarios are simulated to demonstrate the model's suitability for multi-physics simulations of PB-FHR transients.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Final Report on Development of Microwave Resonant Cavity Transducer for Fluid Flow Sensing: Development of Microwave Cavity Flow Meter for Advanced Reactor High Temperature Fluids

We are investigating a microwave resonant cavity transducer for flow sensing in the vessel of a high temperature fluid advanced reactor (AR), such as a molten salt cooled reactor (MSCR) or a sodium fast reactor (SFR). This transducer is a hollow metallic cylindrical cavity, with one of the flat walls of the cylinder flexible enough to undergo microscopic deflection due to dynamic fluid pressure. Membrane deflection leads to a shift in the microwave resonant frequency, which can be detected with a spectrum analyzer. We have developed a continuum electromechanics model of the microwave resonant cavity transducer performance. The deflection of the membrane is calculated using equations from the theory of plates and shells for deflection of radially constrained thin circular disk under uniform load. The microwave frequency shift is calculated using the equations from the microwave cavity perturbation theory. The transducer model was validated with proof-of-concept experimental data of water flow sensing with a Brass 360 right circular cylinder with 22.2mm diameter and 203µm thick wall. The cavity was excited through a subwavelength hole in TE 011 mode with resonant frequency f ≈ 17.8GHz. Subsequently, we have performed a preliminary proof-of-principle test of flow sensing in high temperature liquid sodium in environment. For this test, we have developed a cylindrical resonator with the same dimensions as for the Brass 360 cavity. The resonator for high temperature liquid sodium test was machined from stainless steel 316 and electroplated with silver on the interior surfaces. We have also developed and insertion probe consisting of a 50cm WR-42 brass waveguide enclosed in a protective SS316 tube. The cavity was excited through a subwavelength hole on the side of the wall of the cylinder in the TE 011 mode with resonant frequency f ≈ 17.8GHz. The liquid sodium setup consists of a cylindrical vessel with a center feed line, where a transducer inserted through the top cap of the vessel measures velocity of the impinging liquid jet. The sodium flow sensing study was performed in a liquid sodium vessel at 340°C temperature and ambient pressure. The flow rate was changed by varying sodium pump power, and a frequency shift of several hundred kHz was observed. The transducer was removed after 70 days of testing. No visual damage was observed, and the electromagnetic response remained the same. As a calibration experiment, we have assembled a water vessel with a center feed, and with dimensions similar to those of the liquid sodium setup. Water flow sensing was performed before and after liquid sodium test. The responses in both cases are similar and agree with COMSOL computer simulations. Because long-term (multi-year) experimental tests of transducer resilience to harsh environment are not practical, we have developed a probabilistic model of creep to estimate transducer resilience to the harsh environment. The probabilistic model considers diffusion creep under the condition of high temperature and low stress, where the stress and temperature are allowed to be random variables with Gaussian distributions. Using the probabilistic model, we estimate inelastic membrane deflections due to creep for several temperature ranges. We conclude that for temperatures less than 650°C, creep has negligible long-term effect on the transducer performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Employing a Hardware-in-the-Loop Approach to Realize a Fully Homomorphic Controller for a Small Modular Advanced High Temperature Reactor

This paper addresses the cybersecurity challenges of advanced nuclear reactors by integrating fully homomorphic encryption (FHE) into their control systems, enabling encrypted processing of control signals without compromising functionality. Advanced nuclear reactors, including Small Modular Reactors (SMRs) and microreactors, aim to achieve autonomous and remote operations, reducing costs and enhancing competitiveness. However, these advancements expand the attack surface for cyberattacks, particularly in autonomous and remote operation scenarios. Cyberattacks can exploit vulnerabilities to manipulate physical processes, causing shutdowns, asset damage, or public harm. Such attacks begin with passive reconnaissance, where adversaries intercept communications or observe behaviors to gather information, which is then leveraged to execute cyber-physical attacks by injecting malicious commands. Nuclear power must adopt cybersecurity protection measures to secure the integrity and availability of their digital control systems. This paper demonstrates the application of FHE to secure operations by enabling encrypted processing of sensitive signals and parameters -- ensuring privacy without exposing data. FHE supports secure mathematical operations on encrypted data without requiring decryption. Using a hardware-in-the-loop (HIL) approach, this paper implements an FHE-integrated controller on a BeagleBone Black (BBB) controlling a simulation of the Small Modular Advanced High Temperature Reactor (SmAHTR). By doing so, the encrypted controller protects the integrity of critical set points and control signals during transmission and processing. Thus, FHE-integrated controllers enhance secure operations of advanced nuclear reactors while maintaining functionality.

control systems↗
DOE OSTI2023

HydroGEN Seedling: High-Temperature Reactor Catalyst Material Development for Low-Cost and Efficient Solar-Driven Sulfur-Based Processes

The HyS process, driven by solar power, has great potential to reach high-efficiency and low-cost hydrogen production without greenhouse gas emissions. The high-temperature section of the HyS cycle, which operates the catalytic decomposition of sulfuric acid into sulfur dioxide, oxygen, and water, is a fundamental part of the cycle affecting the overall plant efficiency and cost. Therefore, a high-performance catalyst (i.e., low cost, high catalytic activity, and low degradation catalyst) is of critical importance to achieve high efficiency and low hydrogen cost. Research and development has highlighted that a Pt-based monometallic catalyst had unacceptable catalytic activity and performance degradation for a high-efficiency and low-cost hydrogen production process. A high-efficiency solar receiver-reactor system, which incorporates the new catalyst, also needs to be developed to achieve the required plant efficiency and cost. Greenway Energy (GWE) and the University of South Carolina (USC), partnering with HydroGEN node laboratories Idaho National Laboratory (INL), Savannah River National Laboratory (SRNL), and National Renewable Energy Laboratory (NREL), propose the development of a new catalyst formulation, included in a novel solar receiver-reactor concept, to be tested experimentally in the last part of the project.

08 HYDROGEN↗
DOE OSTI2023

ASME Section III, Division 5, High Temperature Reactors

Section III, Division 5 stands ready to support near-term deployment of advanced reactors. Progress on improving design rules, extending design lifetimes, adding more materials, and adding advanced component fabrication methods. Lessons-learned from Alloy 617 Code Case effort have streamlined the balloting workflow for Class A material code cases. After requester submitted material design parameters and supporting data package to ASME, Division 5 could turn around a material code case in about three Code Week cycles (less than a year). Data requirements for new materials are described in Division 5, “Nonmandatory Appendix HBB-Y, Guidelines For Design Data Needs For New Materials”.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Effects of break geometry and orientation on helium-air mixing in simulated reactor cavities of high temperature gas reactors

Here, this study experimentally examined the spatial and temporal variations in air and helium concentrations and temperature fields within simulated reactor cavities of a High Temperature Gas Reactor (HTGR) following helium discharge into an initially air-filled reactor cavity system. Detailed temperature maps were generated using a combination of fiber optics temperature sensor and multiple thermocouple probes within the simulated reactor cavities. The research scenario involved a hypothetical small pipe break in the Reactor Pressure Vessel, resulting in the release of high-temperature helium into the surrounding cavity. A scaled multi-compartment experimental facility, modeled after the General Atomics Modular High Temperature Gas Reactor (GA-MHTGR) design, was constructed for helium and air mixing experiments. Oxygen sensors and thermocouple probes were installed in all five cavities to measure the concentrations of oxygen (or helium) and the temperature distributions of the gas mixture. The experimental findings highlighted the significant impact of the injected helium jet velocity on the gas mixing process and demonstrated how the direction of the helium jet influences the air-helium temperature profiles within the cavities.

Air-ingress↗
DOE OSTI2025

A simplified approach for creep damage and remaining life calculation for materials surveillance in advanced reactors

High temperature reactor materials will experience a combination of mechanical degradation caused by creep and fatigue and environmental degradation caused by neutron irradiation and, in some cases, exposure to corrosive coolants. A materials surveillance program is one option for ensuring the safe, reliable operation of key reactor components under these conditions. Such a program would monitor the degradation in key material properties over time, using this data to predict how changes in the material properties affect components performance. This could then be used to make plant operational decisions and support eventual plant license extensions. Past work de-scribes such a material surveillance program based on passively actuated mechanical test articles that impose creep-fatigue type loading on test materials driven only by changes in temperature, for example those experienced by components under standard operating cycles. This report focuses on two aspects of the proposed material surveillance program: how to design the test articles to mimic the mechanical response of the corresponding component and how to use ex-situ test data to deter-mine the amount of damaged experienced by the test article (and hence the corresponding compo-nent) in service. Specifically, this report derives and validated simplified methods for both tasks, replacing earlier, more complicated approaches based on simulating the test article response and finding the best specimen design or current damage via complex numerical optimization. The sim-plified methods for each task developed here can be implemented in spreadsheet software and are simple enough for practical use in future operating plants. This report derives the methods (one for sizing and two options for damage inference), verifies the simplified approaches versus more so-phisticated methods, and compares the results of applying the simplified methods to previous re-sults using the complex numerical optimization approach. The report also provides a worked sam-pled problem applying the simplified techniques to a realistic high temperature reactor component.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗