The Role of COMSOL Toward a Low-Enriched Uranium Fuel Design for the High Flux Isotope Reactor
The Role of COMSOL Toward a Low-Enriched Uranium Fuel Design for the High Flux Isotope Reactor

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Published: 2009

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Design and safety analyses are underway to convert the High Flux Isotope Reactor (HFIR) at the Oak Ridge National Laboratory (ORNL) from a high-enriched uranium (HEU) fuel to a low-enriched uranium (LEU) fuel. The primary constraint for the project is that the overall fuel plate dimensions and the current neutron flux performance must remain unchanged. This allows minimal impact on the facility and cost for the conversion, and provides transparency to the HFIR customer base and research projects that depend on the facility for isotopes and neutron flux. As a consequence, the LEU design demands more accuracy and less margin in the analysis efforts than the original design. Several technical disciplines are required to complete this conversion including nuclear reactor physics, heat transfer, fluid dynamics, structural mechanics, fuel fabrication, and engineering design. The role of COMSOL is to provide the fully-coupled 3D multi-physics analysis for heat transfer, turbulent flow, and structural mechanics of the fuel plates and flow channels. A goal is for COMSOL to simulate the entire fuel element array of fuel plates (171 inner, 369 outer). This paper describes the progress that has been made toward development of benchmark validation models of the existing HEU inner-element fuel plates.

Research and Development of Multiphysics Models in Support of the Conversion of the High Flux Isotope Reactor to Low Enriched Uranium Fuel
Research and Development of Multiphysics Models in Support of the Conversion of the High Flux Isotope Reactor to Low Enriched Uranium Fuel

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Published: 2015

Total Pages: 227

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ABSTRACT The findings presented in this report are results of a five year effort lead by the RRD Division of the ORNL, which is focused on research and development toward the conversion of the High Flux Isotope Reactor (HFIR) fuel from high-enriched uranium (HEU) to low-enriched uranium (LEU). This report focuses on the tasks accomplished by the University of Tennessee Knoxville (UTK) team from the Department of Mechanical, Aerospace, and Biomedical Engineering (MABE) that provided expert support in multiphysics modeling of complex problems associated with the LEU conversion of the HFIR reactor. The COMSOL software was used as the main computational modeling tool, whereas Solidworks was also used in support of computer-aided-design (CAD) modeling of the proposed LEU fuel design. The UTK research has been governed by a statement of work (SOW), which was updated annually to clearly define the specific tasks reported herein. Ph.D. student Isaac T. Bodey has focused on heat transfer and fluid flow modeling issues and has been aided by his major professor Dr. Rao V. Arimilli. Ph.D. student Franklin G. Curtis has been focusing on modeling the fluid-structure interaction (FSI) phenomena caused by the mechanical forces acting on the fuel plates, which in turn affect the fluid flow in between the fuel plates, and ultimately the heat transfer, is also affected by the FSI changes. Franklin Curtis has been aided by his major professor Dr. Kivanc Ekici. M.Sc. student Adam R. Travis has focused two major areas of research: (1) on accurate CAD modeling of the proposed LEU plate design, and (2) reduction of the model complexity and dimensionality through interdimensional coupling of the fluid flow and heat transfer for the HFIR plate geometry. Adam Travis is also aided by his major professor, Dr. Kivanc Ekici. We must note that the UTK team, and particularly the graduate students, have been in very close collaboration with Dr. James D. Freels (ORNL technical monitor and mentor) and have benefited greatly from his leadership and expertise in COMSOL modeling of complex physical phenomena. Both UTK and ORNL teams have used COMSOL releases 3.4 through 5.0 inclusive (with particular emphasis on 3.5a, 4.3a, 4.3b, and 4.4) for most of the work described in this report, except where stated otherwise. Just as in the performance of the research, each of the respective sections has been originally authored by respective authors. Therefore, the reader will observe a contrast in writing style throughout this document.

Low-Enriched Uranium Fuel Design with Two-Dimensional Grading for the High Flux Isotope Reactor
Low-Enriched Uranium Fuel Design with Two-Dimensional Grading for the High Flux Isotope Reactor

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Published: 2011

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An engineering design study of the conversion of the High Flux Isotope Reactor (HFIR) from high-enriched uranium (HEU) to low-enriched uranium (LEU) fuel is ongoing at Oak Ridge National Laboratory. The computational models developed during fiscal year 2010 to search for an LEU fuel design that would meet the requirements for the conversion and the results obtained with these models are documented and discussed in this report. Estimates of relevant reactor performance parameters for the LEU fuel core are presented and compared with the corresponding data for the currently operating HEU fuel core. The results obtained indicate that the LEU fuel design would maintain the current performance of the HFIR with respect to the neutron flux to the central target region, reflector, and beam tube locations under the assumption that the operating power for the reactor fueled with LEU can be increased from the current value of 85 MW to 100 MW.

Reference (Axially Graded) Low Enriched Uranium Fuel Design for the High Flux Isotope Reactor (HFIR).
Reference (Axially Graded) Low Enriched Uranium Fuel Design for the High Flux Isotope Reactor (HFIR).

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Published: 2010

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During the past five years, staff at the Oak Ridge National Laboratory (ORNL) have studied the issue of whether the HFIR could be converted to low enriched uranium (LEU) fuel without degrading the performance of the reactor. Using state-of-the-art reactor physics methods and behind-the-state-of-the-art thermal hydraulics methods, the staff have developed fuel plate designs (HFIR uses two types of fuel plates) that are believed to meet physics and thermal hydraulic criteria provided the reactor power is increased from 85 to 100 MW. The paper will present a defense of the results by explaining the design and validation process. A discussion of the requirements for showing applicability of analyses to approval for loading the fuel to HFIR lead test core irradiation currently scheduled for 2016 will be provided. Finally, the potential benefits of upgrading thermal hydraulics methods will be discussed.

Design Study for a Low-Enriched Uranium Core for the High Flux Isotope Reactor, Annual Report for FY 2006
Design Study for a Low-Enriched Uranium Core for the High Flux Isotope Reactor, Annual Report for FY 2006

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Published: 2006

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Neutronics and thermal-hydraulics studies show that, for equivalent operating power [85 MW(t)], a low-enriched uranium (LEU) fuel cycle based on uranium-10 wt % molybdenum (U-10Mo) metal foil with radially, "continuously graded" fuel meat thickness results in a 15% reduction in peak thermal flux in the beryllium reflector of the High Flux Isotope Reactor (HFIR) as compared to the current highly enriched uranium (HEU) cycle. The uranium-235 content of the LEU core is almost twice the amount of the HEU core when the length of the fuel cycle is kept the same for both fuels. Because the uranium-238 content of an LEU core is a factor of 4 greater than the uranium-235 content, the LEU HFIR core would weigh 30% more than the HEU core. A minimum U-10Mo foil thickness of 84 [mu]m is required to compensate for power peaking in the LEU core although this value could be increased significantly without much penalty. The maximum U-10Mo foil thickness is 457[mu]m. Annual plutonium production from fueling the HFIR with LEU is predicted to be 2 kg. For dispersion fuels, the operating power for HFIR would be reduced considerably below 85 MW due to thermal considerations and due to the requirement of a 26-d fuel cycle. If an acceptable fuel can be developed, it is estimated that $140 M would be required to implement the conversion of the HFIR site at Oak Ridge National Laboratory from an HEU fuel cycle to an LEU fuel cycle. To complete the conversion by fiscal year 2014 would require that all fuel development and qualification be completed by the end of fiscal year 2009. Technological development areas that could increase the operating power of HFIR are identified as areas for study in the future.

Design Study for a Low-enriched Uranium Core for the High Flux Isotope Reactor, Annual Report for FY 2007
Design Study for a Low-enriched Uranium Core for the High Flux Isotope Reactor, Annual Report for FY 2007

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Published: 2007

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This report documents progress made during fiscal year 2007 in studies of converting the High Flux Isotope Reactor (HFIR) from highly enriched uranium (HEU) fuel to low enriched uranium fuel (LEU). Conversion from HEU to LEU will require a change in fuel form from uranium oxide to a uranium-molybdenum alloy. A high volume fraction U/Mo-in-Al fuel could attain the same neutron flux performance as with the current, HEU fuel but materials considerations appear to preclude production and irradiation of such a fuel. A diffusion barrier would be required if Al is to be retained as the interstitial medium and the additional volume required for this barrier would degrade performance. Attaining the high volume fraction (55 wt. %) of U/Mo assumed in the computational study while maintaining the current fuel plate acceptance level at the fuel manufacturer is unlikely, i.e. no increase in the percentage of plates rejected for non-compliance with the fuel specification. Substitution of a zirconium alloy for Al would significantly increase the weight of the fuel element, the cost of the fuel element, and introduce an as-yet untried manufacturing process. A monolithic U-10Mo foil is the choice of LEU fuel for HFIR. Preliminary calculations indicate that with a modest increase in reactor power, the flux performance of the reactor can be maintained at the current level. A linearly-graded, radial fuel thickness profile is preferred to the arched profile currently used in HEU fuel because the LEU fuel media is a metal alloy foil rather than a powder. Developments in analysis capability and nuclear data processing techniques are underway with the goal of verifying the preliminary calculations of LEU flux performance. A conceptual study of the operational cost of an LEU fuel fabrication facility yielded the conclusion that the annual fuel cost to the HFIR would increase significantly from the current, HEU fuel cycle. Though manufacturing can be accomplished with existing technology, several engineering proof-of-principle tests would be required. The RERTR program is currently conducting a series of generic fuel qualification tests at the Advanced Test Reactor. A review of these tests and a review of the safety basis for the current, HEU fuel cycle led to the identification of a set of HFIR-specific fuel qualification tests. Much additional study is required to formulate a HFIR-specific fuel qualification plan from this set. However, one such test - creating a graded fuel profile across a flat foil - has been initiated with promising results.

PREPARING THE HIGH FLUX ISOTOPE REACTOR FOR CONVERSION TO LOW ENRICHED URANIUM FUEL? EXTENDING CYCLE BURNUP.
PREPARING THE HIGH FLUX ISOTOPE REACTOR FOR CONVERSION TO LOW ENRICHED URANIUM FUEL? EXTENDING CYCLE BURNUP.

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Published: 2009

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Reactor performance studies have been completed for conceptual plate designs and show that maintaining reactor performance while converting HFIR from high enriched to low enriched uranium (20 wt % 235U) fuel requires extending the end-of-life burnup value for HFIR fuel from the current nominal value of 2200 MWD to 2600 MWD. The current fuel fabrication procedure is discussed and changes that would be required to this procedure are identified. Design and safety related analyses that are required for the certification of a new fuel are identified. Qualification tests and comments regarding the regulatory approval process are provided along with a conceptual schedule.

DESIGN STUDY FOR A LOW-ENRICHED URANIUM CORE FOR THE HIGH FLUX ISOTOPE REACTOR, ANNUAL REPORT FOR FY 2010
DESIGN STUDY FOR A LOW-ENRICHED URANIUM CORE FOR THE HIGH FLUX ISOTOPE REACTOR, ANNUAL REPORT FOR FY 2010

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Published: 2011

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This report documents progress made during FY 2010 in studies of converting the High Flux Isotope Reactor (HFIR) from high enriched uranium (HEU) fuel to low enriched uranium (LEU) fuel. Conversion from HEU to LEU will require a change in fuel form from uranium oxide to a uranium-molybdenum alloy. With axial and radial grading of the fuel foil and an increase in reactor power to 100 MW, calculations indicate that the HFIR can be operated with LEU fuel with no degradation in performance to users from the current level. Studies are reported of support to a thermal hydraulic test loop design, the implementation of finite element, thermal hydraulic analysis capability, and infrastructure tasks at HFIR to upgrade the facility for operation at 100 MW. A discussion of difficulties with preparing a fuel specification for the uranium-molybdenum alloy is provided. Continuing development in the definition of the fuel fabrication process is described.

Development of CFD Models to Support LEU Conversion of ORNL S High Flux Isotope Reactor
Development of CFD Models to Support LEU Conversion of ORNL S High Flux Isotope Reactor

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Published: 2012

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The US Department of Energy s National Nuclear Security Administration (NNSA) is participating in the Global Threat Reduction Initiative to reduce and protect vulnerable nuclear and radiological materials located at civilian sites worldwide. As an integral part of one of NNSA s subprograms, Reduced Enrichment for Research and Test Reactors, HFIR is being converted from the present HEU core to a low enriched uranium (LEU) core with less than 20% of U-235 by weight. Because of HFIR s importance for condensed matter research in the United States, its conversion to a high-density, U-Mo-based, LEU fuel should not significantly impact its existing performance. Furthermore, cost and availability considerations suggest making only minimal changes to the overall HFIR facility. Therefore, the goal of this conversion program is only to substitute LEU for the fuel type in the existing fuel plate design, retaining the same number of fuel plates, with the same physical dimensions, as in the current HFIR HEU core. Because LEU-specific testing and experiments will be limited, COMSOL Multiphysics was chosen to provide the needed simulation capability to validate against the HEU design data and previous calculations, and predict the performance of the proposed LEU fuel for design and safety analyses. To achieve it, advanced COMSOL-based multiphysics simulations, including computational fluid dynamics (CFD), are being developed to capture the turbulent flows and associated heat transfer in fine detail and to improve predictive accuracy [2].

Design Study for a Low-Enriched Uranium Core for the High Flux Isotope Reactor, Annual Report for FY 2009
Design Study for a Low-Enriched Uranium Core for the High Flux Isotope Reactor, Annual Report for FY 2009

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Published: 2010

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This report documents progress made during FY 2009 in studies of converting the High Flux Isotope Reactor (HFIR) from high enriched uranium (HEU) fuel to low enriched uranium (LEU) fuel. Conversion from HEU to LEU will require a change in fuel form from uranium oxide to a uranium-molybdenum alloy. With axial and radial grading of the fuel foil and an increase in reactor power to 100 MW, calculations indicate that the HFIR can be operated with LEU fuel with no degradation in reactor performance from the current level. Results of selected benchmark studies imply that calculations of LEU performance are accurate. Studies are reported of the application of a silicon coating to surrogates for spheres of uranium-molybdenum alloy. A discussion of difficulties with preparing a fuel specification for the uranium-molybdenum alloy is provided. A description of the progress in developing a finite element thermal hydraulics model of the LEU core is provided.