John T. Maki

Key differences in the fabrication, irradiation and high temperature accident testing of US and German TRISO-coated particle fuel, and their implications on fuel performance

Historically, the irradiation performance of TRISO-coated gas reactor particle fuel in Germany has been superior to that in the US. German fuel generally has displayed gas release values during irradiation three orders of magnitude lower than US fuel. Thus, we have critically examined the TRISO-coated fuel fabrication processes in the US and Germany and the associated irradiation database with a goal of understanding why the German fuel behaves acceptably, why the US fuel has not faired as well, and what process/production parameters impart the reliable performance to this fuel form. The postirradiation examination results are also reviewed to identify failure mechanisms that may be the cause of the poorer US irradiation performance. This comparison will help determine the roles that particle fuel process/product attributes and irradiation conditions (burnup, fast neutron fluence, temperature, degree of acceleration) have on the behavior of the fuel during irradiation and provide a more quantitative linkage between acceptable processing parameters, as-fabricated fuel properties and subsequent in-reactor performance.

Consideration of the effects on fuel particle behavior from shrinkage cracks in the inner pyrocarbon layer

The fundamental design for a gas-cooled pebble bed reactor relies on an understanding of the behavior of coated particle fuel. The coating layers surrounding the fuel kernels in these spherical particles consist of pyrolytic carbon layers and a silicon carbide (SiC) layer. These coating layers act as a pressure vessel that retains fission product gases. A small percentage of fuel particles may fail during irradiation in the mode of a traditional pressure vessel failure. Fuel performance models used to predict particle behavior have traditionally been one-dimensional models that focus on this failure mechanism. Results of irradiation experiments, however, show that many more fuel particles fail than would be predicted by this mechanism alone. Post-irradiation examinations indicate that multi-dimensional effects, such as the presence of shrinkage cracks in the inner pyrolytic carbon layer (IPyC), contribute to these unexplained failures. Results of a study performed to evaluate the significance of cracking in the IPyC layer on behavior of a fuel particle are presented herein, which indicate that shrinkage cracks could contribute significantly to fuel particle failures.

Statistical approach and benchmarking for modeling of multi-dimensional behavior in TRISO-coated fuel particles

The fundamental design for a gas-cooled reactor relies on the behavior of the coated particle fuel. The coating layers, termed the TRISO coating, act as a mini-pressure vessel that retains fission products. Results of US irradiation experiments show that many more fuel particles have failed than can be attributed to one-dimensional pressure vessel failures alone. Post-irradiation examinations indicate that multi-dimensional effects, such as the presence of irradiation-induced shrinkage cracks in the inner pyrolytic carbon layer, contribute to these failures. To address these effects, the methods of prior one-dimensional models are expanded to capture the stress intensification associated with multi-dimensional behavior. An approximation of the stress levels enables the treatment of statistical variations in numerous design parameters and Monte Carlo sampling over a large number of particles. The approach is shown to make reasonable predictions when used to calculate failure probabilities for irradiation experiments of the New Production – Modular High Temperature Gas Cooled Reactor Program.

Key Differences in the Fabrication, Irradiation, and Safety Testing of U.S. and German TRISO-coated Particle Fuel and Their Implications on Fuel Performance

High temperature gas reactor technology is achieving a renaissance around the world. This technology relies on high quality production and performance of coated particle fuel. Historically, the irradiation performance of TRISO-coated gas reactor particle fuel in Germany has been superior to that in the United States. German fuel generally displayed in-pile gas release values that were three orders of magnitude lower than U.S. fuel. Thus, we have critically examined the TRISO-coated fuel fabrication processes in the U.S. and Germany and the associated irradiation database with a goal of understanding why the German fuel behaves acceptably, why the U.S. fuel has not faired as well, and what process/ production parameters impart the reliable performance to this fuel form. The postirradiation examination results are also reviewed to identify failure mechanisms that may be the cause of the poorer U.S. irradiation performance. This comparison will help determine the roles that particle fuel process/product attributes and irradiation conditions (burnup, fast neutron fluence, temperature, and degree of acceleration) have on the behavior of the fuel during irradiation and provide a more quantitative linkage between acceptable processing parameters, as-fabricated fuel properties and subsequent in-reactor performance.

Mission and Status of the First Two Next Generation Nuclear Plant Fuel Irradiation Experiments in the Advanced Test Reactor

The United States Department of Energy’s Next Generation Nuclear Plant (NGNP) Advanced Gas Reactor (AGR) Fuel Development and Qualification Program will be irradiating up to nine low enriched uranium (LEU) tri-isotopic (TRISO) particle fuel (in compact form) experiments in the Advanced Test Reactor (ATR) located at the Idaho National Laboratory (INL). The ATR has a long history of irradiation testing in support of reactor development and the INL has been designated as the United States Department of Energy’s lead laboratory for nuclear energy development. These irradiations and fuel development are being accomplished to support development of the next generation reactors in the United States, and the irradiations will be completed over the next five to six years to support demonstration and qualification of new TRISO coated particle fuel for use in high temperature gas reactors. The goals of the irradiation 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. The experiments, which will each consist of multiple separate capsules, will be irradiated in an inert sweep gas atmosphere with individual on-line temperature monitoring and control of each capsule. The sweep gas will also have on-line fission product monitoring on its effluent to track performance of the fuel in each individual capsule during irradiation. The first experiment (designated AGR-1) started irradiation in December 2006 and completed a very successful irradiation in early November 2009. The second experiment (AGR-2) is currently being fabricated and assembled for insertion in the ATR in the early to mid calendar 2010. The design of test trains, the support systems and the fission product monitoring system used to monitor and control the experiment during irradiation will be discussed. In addition, the purpose and differences between the first two experiments will be compared, and updated information on the design and status of AGR-2 is provided. The preliminary irradiation results for the AGR-1 experiment are also presented.Copyright

TRISO-Coated Particle Fuel Performance

Tristructural isotropic (TRISO)-coated particle fuel is used in all current and planned high-temperature gas-cooled reactors (HTGRs). The robustness of this fuel, coupled with the high heat capacity of graphite, has led to the development of modular HTGRs with a high degree of passive safety. In this chapter, the irradiation and accident performance of modern TRISO-coated particle fuel around the world are reviewed. For all HTGRs, TRISO-coated particle fuel forms the heart of the concept. Such fuels have been studied extensively over the past four decades around the world, for example, in countries including the United Kingdom, Germany, Japan, the United States, Russia, China, and more recently, South Africa.

NP-MHTGR Fuel Development Program Results

In August 1988, the Secretary of Energy announced a strategy to acquire New Production Reactor capacity for producing tritium. The strategy involved construction of a New Production Modular High Temperature Gas-Cooled Reactor (NP-MHTGR) where the Idaho National Engineering and Environmental Laboratory (INEEL) was selected as the Management and Operations contractor for the project. Immediately after the announcement in August 1988, tritium target particle development began with the INEEL selected as the lead laboratory. Fuel particle development was initially not considered to be on a critical path for the project, therefore, the fuel development program was to run concurrently with the design effort of the NP-MHTGR.

Thermal Predictions of the AGR-3/4 Experiment With Time Varying Gas Gaps

A thermal analysis was performed for the Advanced Gas Reactor test experiment (AGR-3/4) with time varying gas gaps. The experiment was irradiated at the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL). Several fuel irradiation experiments are planned for the AGR Fuel Development and Qualification Program which supports the development of the Very-High-Temperature gas-cooled Reactor (VHTR) under the Next-Generation Nuclear Plant (NGNP) project.AGR-3/4 combines two tests in a series of planned AGR experiments to test tri-structural-isotropic (TRISO)-coated, low-enriched uranium oxy-carbide fuel. The AGR-3/4 test was designed primarily to assess fission product transport through various graphite materials. The AGR-3/4 test irradiation in the ATR started in December 2011 and finished in April 2014. Forty-eight (48) TRISO fueled compacts were inserted into twelve separate capsules for the experiment (four compacts per capsule).The purpose of this analysis was to calculate the temperatures of each compact and graphite layer to obtain daily average temperatures using time (fast neutron fluence) varying gas gaps and to compare with experimentally measured thermocouple data. Previous experimental data was used for the graphite shrinkage versus fast neutron fluence. Heat rates were input from a detailed physics analysis using the Monte Carlo N-Particle (MCNP) code for each day during the experiment. Individual heat rates for each non-fuel component were input as well. A steady-state thermal analysis was performed for each daily calculation. A finite element model was created for each capsule using the commercial finite element heat transfer and stress analysis package ABAQUS. The fission and neutron gamma heat rates were calculated with the nuclear physics code MCNP. ATR outer shim control cylinders and neck shim rods along with driver fuel power and fuel depletion were incorporated into the daily physics heat rate calculations. Compact and graphite thermal conductivity were input as a function of temperature and neutron fluence with the field variable option in ABAQUS. Surface-to-surface radiation heat transfer along with conduction heat transfer through the gas mixture of helium-neon (used for temperature control) was used in these models. Model results are compared to thermocouple data taken during the experiment.Copyright

Thermal Predictions of the AGR-3/4 Experiment Using PIE-Measured Time Varying Gas Gaps

A thermal analysis was performed for the Advanced Gas Reactor test experiment (AGR-3/4) with Post Irradiation Examination (PIE) measured time varying gas gaps. The experiment was irradiated at the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL). Several fuel irradiation experiments are planned for the AGR Fuel Development and Qualification Program which supports the development of the Very-High-Temperature gas-cooled Reactor (VHTR) under the Next-Generation Nuclear Plant (NGNP) project.AGR-3/4 combines two tests in a series of planned AGR experiments to test tri-structural-isotropic (TRISO)-coated, low-enriched uranium oxy-carbide fuel. The AGR-3/4 test was designed primarily to assess fission product transport through various graphite materials. The AGR-3/4 test irradiation in the ATR started in December 2011 and finished in April 2014. Forty-eight (48) TRISO fueled compacts were inserted into twelve separate capsules for the experiment (four compacts per capsule).The purpose of this analysis was to calculate the temperatures of each compact and graphite layer to obtain daily average temperatures using PIE-measured time (fast neutron fluence) varying gas gaps and to compare with experimentally measured thermocouple data. PIE-measured experimental data was used for the graphite shrinkage versus fast neutron fluence. Heat rates were input from a detailed physics analysis using the Monte Carlo N-Particle (MCNP) code for each day during the experiment. Individual heat rates for each non-fuel component were input as well. A steady-state thermal analysis was performed for each daily calculation. A finite element model was created for each capsule using the commercial finite element heat transfer and stress analysis package ABAQUS. The fission and neutron gamma heat rates were calculated with the nuclear physics code MCNP. ATR outer shim control cylinders and neck shim rods along with driver fuel power and fuel depletion were incorporated into the daily physics heat rate calculations. Compact and graphite thermal conductivity were input as a function of temperature and fast neutron fluence with the field variable option in ABAQUS. Surface-to-surface radiation heat transfer along with conduction heat transfer through the gas mixture of helium-neon (used for temperature control) was used in these models. Model results are compared to thermocouple data taken during the experiment.Copyright

Thermal Predictions of the AGR-3/4 Experiment

A thermal analysis was performed for the Advanced Gas Reactor test experiment number three/four (AGR-3/4) irradiated at the Advanced Test Reactor (ATR) at the Idaho National Laboratory (INL). Several fuel irradiation experiments are planned for the AGR Fuel Development and Qualification Program which supports the development of the Very-High-Temperature gas-cooled Reactor (VHTR) under the Next-Generation Nuclear Plant (NGNP) project.AGR-3/4 combines two tests in a series of planned AGR experiments to test tristructural-isotropic (TRISO)-coated, low-enriched uranium oxycarbide fuel. The AGR-3/4 test was designed primarily to assess fission product transport through various graphite materials. The AGR-3/4 test was inserted in the ATR beginning in 2011 and is currently still in the reactor. Forty-eight (48) TRISO fueled compacts were inserted into twelve separate capsules for the experiment.The purpose of this analysis was to calculate the temperatures of each compact and graphite layer to obtain daily average temperatures and to compare with experimentally measured thermocouple data. Heat rates were input from a detailed physics analysis using the MCNP code for each day during the experiment. Individual heat rates for each non-fuel component were input as well. A steady-state thermal analysis was performed for each daily calculation. A finite element model was created for this analysis using the commercial finite element heat transfer and stress analysis package ABAQUS. The fission and neutron gamma heat rates were calculated with the nuclear physics code MCNP. ATR outer shim control cylinders and neck shim rods along with driver fuel power and fuel depletion were incorporated into the daily physics heat rate calculations. Compact and graphite thermal conductivity were input as a function of temperature and neutron fluence with the field variable option in ABAQUS. Surface-to-surface radiation heat transfer along with conduction heat transfer through the gas mixture of helium-neon (used for temperature control) was used in these models. The kinetic theory of gases was used to correlate the thermal conductivity of the gas mixture. Model results are compared to thermocouple data taken during the experiment. Future thermal analysis models will consider control temperature gas gaps and fuel compact–graphite holder gas gaps varying from the original fabrication dimensions as a function of fast neutron fluence.Copyright