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.


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 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.


Design Study for a Low-Enriched Uranium Core for the High Flux Isotope Reactor, Annual Report for FY 2008

Design Study for a Low-Enriched Uranium Core for the High Flux Isotope Reactor, Annual Report for FY 2008

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Published: 2009

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This report documents progress made during FY 2008 in studies of converting the High Flux Isotope Reactor (HFIR) from highly 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. Scoping experiments with various manufacturing methods for forming the LEU alloy profile are presented.


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.


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.


Low-Enriched Uranium Fuel Conversion Activities for the High Flux Isotope Reactor, Annual Report for FY 2011

Low-Enriched Uranium Fuel Conversion Activities for the High Flux Isotope Reactor, Annual Report for FY 2011

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Published: 2012

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This report describes progress made during FY11 in ORNL activities to support 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 (UMo) alloy. With both radial and axial contouring 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 levels achieved with HEU fuel. Studies are continuing to demonstrate that the fuel thermal safety margins can be preserved following conversion. Studies are also continuing to update other aspects of the reactor steady state operation and accident response for the effects of fuel conversion. Technical input has been provided to Oregon State University in support of their hydraulic testing program. The HFIR conversion schedule was revised and provided to the GTRI program. In addition to HFIR conversion activities, technical support was provided directly to the Fuel Fabrication Capability program manager.


Reactor Physics Methods and Preconceptual Core Design Analyses for Conversion of the Advanced Test Reactor to Low-Enriched Uranium Fuel Annual Report for Fiscal Year 2012

Reactor Physics Methods and Preconceptual Core Design Analyses for Conversion of the Advanced Test Reactor to Low-Enriched Uranium Fuel Annual Report for Fiscal Year 2012

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Published: 2012

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Under the current long-term DOE policy and planning scenario, both the ATR and the ATRC will be reconfigured at an appropriate time within the next several years to operate with low-enriched uranium (LEU) fuel. This will be accomplished under the auspices of the Reduced Enrichment Research and Test Reactor (RERTR) Program, administered by the DOE National Nuclear Security Administration (NNSA). At a minimum, the internal design and composition of the fuel element plates and support structure will change, to accommodate the need for low enrichment in a manner that maintains total core excess reactivity at a suitable level for anticipated operational needs throughout each cycle while respecting all control and shutdown margin requirements and power distribution limits. The complete engineering design and optimization of LEU cores for the ATR and the ATRC will require significant multi-year efforts in the areas of fuel design, development and testing, as well as a complete re-analysis of the relevant reactor physics parameters for a core composed of LEU fuel, with possible control system modifications. Ultimately, revalidation of the computational physics parameters per applicable national and international standards against data from experimental measurements for prototypes of the new ATR and ATRC core designs will also be required for Safety Analysis Report (SAR) changes to support routine operations with LEU. This report is focused on reactor physics analyses conducted during Fiscal Year (FY) 2012 to support the initial development of several potential preconceptual fuel element designs that are suitable candidates for further study and refinement during FY-2013 and beyond. In a separate, but related, effort in the general area of computational support for ATR operations, the Idaho National Laboratory (INL) is conducting a focused multiyear effort to introduce modern high-fidelity computational reactor physics software and associated validation protocols to replace several obsolete components of the current analytical tool set used for ATR neutronics support. This aggressive computational and experimental campaign will have a broad strategic impact on the operation of the ATR, both in terms of improved computational efficiency and accuracy for support of ongoing DOE programs as well as in terms of national and international recognition of the ATR National Scientific User Facility (NSUF). It will also greatly facilitate the LEU conversion effort, since the upgraded computational capabilities are now at a stage where they can be, and in fact have been, used for the required physics analysis from the beginning. In this context, extensive scoping neutronics analyses were completed for six preconceptual candidate LEU fuel element designs for the ATR (and for its companion critical facility, ATRC). Of these, four exhibited neutronics performance in what is believed to be an acceptable range. However, there are currently some concerns with regard to fabricability and mechanical performance that have emerged for one of the four latter concepts. Thus three concepts have been selected for more comprehensive conceptual design analysis during the upcoming fiscal year.


Assumptions and Criteria for Performing a Feasability Study of the Conversion of the High Flux Isotope Reactor Core to Use Low-Enriched Uranium Fuel

Assumptions and Criteria for Performing a Feasability Study of the Conversion of the High Flux Isotope Reactor Core to Use Low-Enriched Uranium Fuel

Author: R. J. Ellis

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Published: 2006

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A computational study will be initiated during fiscal year 2006 to examine the feasibility of converting the High Flux Isotope Reactor from highly enriched uranium fuel to low-enriched uranium. The study will be limited to steady-state, nominal operation, reactor physics and thermal-hydraulic analyses of a uranium-molybdenum alloy that would be substituted for the current fuel powder--U{sub 3}O{sub 8} mixed with aluminum. The purposes of this document are to (1) define the scope of studies to be conducted, (2) define the methodologies to be used to conduct the studies, (3) define the assumptions that serve as input to the methodologies, (4) provide an efficient means for communication with the Department of Energy and American research reactor operators, and (5) expedite review and commentary by those parties.