Lead Coolant Test Facility Development Workshop

A workshop was held at the Idaho National Laboratory on May 25, 2005, to discuss the development of a next generation lead or lead-alloy coolant test facility. Attendees included representatives from the Generation IV lead-cooled fast reactor (LFR) program, Advanced Fuel Cycle Initiative, and several universities. Several participants gave presentations on coolant technology, existing experimental facilities for lead and lead-alloy research, the current LFR design concept, and a design by Argonne National Laboratory for an integral heavy liquid metal test facility. Discussions were focused on the critical research and development requirements for deployment of an LFR demonstration test reactor, the experimental scope of the proposed coolant test facility, a review of the Argonne National Laboratory test facility design, and a brief assessment of the necessary path forward and schedule for the initial stages of this development project. This report provides a summary of the presentations and roundtable discussions

Idaho National Laboratory Lead or Lead-Bismuth Eutectic (LBE) Test Facility - R&D Requirements, Design Criteria, Design Concept, and Concept Guidance

The Idaho National Laboratory Lead-Bismuth Eutectic Test Facility will advance the state of nuclear technology relative to heavy-metal coolants (primarily Pb and Pb-Bi), thereby allowing the U.S. to maintain the pre-eminent position in overseas markets and a future domestic market. The end results will be a better qualitative understanding and quantitative measure of the thermal physics and chemistry conditions in the molten metal systems for varied flow conditions (single and multiphase), flow regime transitions, heat input methods, pumping requirements for varied conditions and geometries, and corrosion performance. Furthering INL knowledge in these areas is crucial to sustaining a competitive global position. This fundamental heavy-metal research supports the National Energy Policy Development Group’s stated need for energy systems to support electrical generation.1 The project will also assist the Department of Energy in achieving goals outlined in the Nuclear Energy Research Advisory Committee Long Term Nuclear Technology Research and Development Plan,2 the Generation IV Roadmap for Lead Fast Reactor development, and Advanced Fuel Cycle Initiative research and development. This multi-unit Lead-Bismuth Eutectic Test Facility with its flexible and reconfigurable apparatus will maintain and extend the U.S. nuclear knowledge base, while educating young scientists and engineers. The uniqueness of the Lead-Bismuth Eutectic Test Facility is its integrated Pool Unit and Storage Unit. This combination will support large-scale investigation of structural and fuel cladding material compatibility issues with heavy-metal coolants, oxygen chemistry control, and thermal hydraulic physics properties. Its ability to reconfigure flow conditions and piping configurations to more accurately approximate prototypical reactor designs will provide a key resource for Lead Fast Reactor research and development. The other principal elements of the Lead-Bismuth Eutectic Test Facility (in addition to the Pool Unit and Storage Unit) are the Bench Scale Unit and Supporting Systems, principal of which are the O2 Sensor/Calibration System, Feed System, Transfer System, Off- Gas System, Purge and Evacuation System, Oxygen Sensor and Control System, Data Acquisition and Control System, and the Safety Systems. Parallel and/or independent corrosion studies and convective heat transfer experiments for cylindrical and annular geometries will support investigation of heat transfer phenomena into the secondary side. In addition, molten metal pumping concepts and power requirements will be measured for future design use

Materials Degradation Studies for High Temperature Steam Electrolysis Systems

Experiments are currently in progress to assess the high temperature degradation behavior of materials in solid oxide electrolysis systems. This research includes the investigation of various electrolysis cell components and balance of plant materials under both anodic and cathodic gas atmospheres at temperatures up to 850°C. Current results include corrosion data for a high temperature nickel alloy used for the air-side flow field in electrolysis cells and a commercial ferritic stainless steel used as the metallic interconnect. Three different corrosion inhibiting coatings were also tested on the steel material. The samples were tested at 850ºC for 500 h in both air and H2O/H2 atmospheres. The results of this research will be used to identify degradation mechanisms and demonstrate the suitability of candidate materials for long-term operation in electrolysis cells

Ceramographic Examinations of Irradiated AGR-1 Fuel Compacts

The AGR 1 experiment involved irradiating 72 cylindrical fuel compacts containing tri-structural isotropic (TRISO)-coated particles to a peak burnup of 19.5% fissions per initial metal atom with no in-pile failures observed out of almost 300,000 particles. Five irradiated AGR 1 fuel compacts were selected for microscopy that span a range of irradiation conditions (temperature, burnup, and fast fluence). These five compacts also included all four TRISO coating variations irradiated in the AGR experiment. The five compacts were cross-sectioned both transversely and longitudinally, mounted, ground, and polished after development of careful techniques for preserving particle structures against preparation damage. Approximately 40 to 80 particles within each cross section were exposed near enough to mid-plane for optical microscopy of kernel, buffer, and coating behavior. The microstructural analysis focused on kernel swelling and porosity, buffer densification and fracture, debonding between the buffer and inner pyrolytic carbon (IPyC) layers, and fractures in the IPyC and SiC layers. Three basic particle morphologies were established according to the extent of bonding between the buffer and IPyC layers: complete debonding along the interface (Type A), no debonding along the interface (Type B), and partial debonding (Type AB). These basic morphologies were subdivided according to whether the buffer stayed intact or fractured. The resulting six characteristic morphologies were used to classify particles within each cross section, but no spatial patterns were clearly observed in any of the cross-sectional morphology maps. Although positions of particle types appeared random within compacts, examining a total of 830 classified particles allowed other relationships among morphological types to be established

Analysis of Fission Products on the AGR-1 Capsule Components

The components of the AGR-1 irradiation capsules were analyzed to determine the retained inventory of fission products in order to determine the extent of in-pile fission product release from the fuel compacts. This includes analysis of (i) the metal capsule components, (ii) the graphite fuel holders, (iii) the graphite spacers, and (iv) the gas exit lines. The fission products most prevalent in the components were Ag-110m, Cs 134, Cs 137, Eu-154, and Sr 90, and the most common location was the metal capsule components and the graphite fuel holders. Gamma scanning of the graphite fuel holders was also performed to determine spatial distribution of Ag-110m and radiocesium. Silver was released from the fuel components in significant fractions. The total Ag-110m inventory found in the capsules ranged from 1.2×10 2 (Capsule 3) to 3.8×10 1 (Capsule 6). Ag-110m was not distributed evenly in the graphite fuel holders, but tended to concentrate at the axial ends of the graphite holders in Capsules 1 and 6 (located at the top and bottom of the test train) and near the axial center in Capsules 2, 3, and 5 (in the center of the test train). The Ag-110m further tended to be concentrated around fuel stacks 1 and 3, the two stacks facing the ATR reactor core and location of higher burnup, neutron fluence, and temperatures compared with Stack 2. Detailed correlation of silver release with fuel type and irradiation temperatures is problematic at the capsule level due to the large range of temperatures experienced by individual fuel compacts in each capsule. A comprehensive Ag 110m mass balance for the capsules was performed using measured inventories of individual compacts and the inventory on the capsule components. For most capsules, the mass balance was within 11% of the predicted inventory. The Ag-110m release from individual compacts often exhibited a very large range within a particular capsule

High Temperature Steam Electrolysis Materials Degradation: Preliminary Results of Corrosion Tests on Ceramatec Electrolysis Cell Components

Corrosion tests were performed on stainless steel and nickel alloy coupons in H2O/H2 mixtures and dry air to simulate conditions experienced in high temperature steam electrolysis systems. The stainless steel coupons were tested bare and with one of three different proprietary coatings applied. Specimens were corroded at 850°C for 500 h with weight gain data recorded at periodic intervals. Post-test characterization of the samples included surface and cross-section scanning electron microscopy, grazing incidence x-ray diffraction, and area-specific resistance measurements. The uncoated nickel alloy outperformed the ferritic stainless steel under all test conditions based on weight gain data. Parabolic rate constants for corrosion of these two uncoated alloys were consistent with values presented in the literature under similar conditions. The steel coatings reduced corrosion rates in H2O/H2 mixtures by as much as 50% compared to the untreated steel, but in most cases showed negligible corrosion improvement in air. The use of a rare-earth-based coating on stainless steel did not result in a significantly different area specific resistance values after corrosion compared to the untreated alloy. Characterization of the samples is still in progress and the findings will be revised when the complete data set is available

Ceramographic Examinations of Irradiated AGR-1 Fuel Compacts

The AGR 1 experiment involved irradiating 72 cylindrical fuel compacts containing tri-structural isotropic (TRISO)-coated particles to a peak burnup of 19.5% fissions per initial metal atom with no in-pile failures observed out of almost 300,000 particles. Six irradiated AGR 1 fuel compacts were selected for microscopy that span a range of irradiation conditions (temperature, burnup, and fast fluence). These six compacts also included all four TRISO coating variations irradiated in the AGR experiment. The six compacts were cross-sectioned both transversely and longitudinally, mounted, ground, and polished after development of careful techniques for preserving particle structures against preparation damage. From 36 to 79 particles within each cross section were exposed near enough to midplane for optical microscopy of kernel, buffer, and coating behavior. The microstructural analysis focused on kernel swelling and porosity, buffer densification and fracture, debonding between the buffer and inner pyrolytic carbon (IPyC) layers, and fractures in the IPyC and SiC layers. Three basic particle morphologies were established according to the extent of bonding between the buffer and IPyC layers: complete debonding along the interface (Type A), no debonding along the interface (Type B), and partial debonding (Type AB). These basic morphologies were subdivided according to whether the buffer stayed intact or fractured. The resulting six characteristic morphologies were used to classify particles within each cross section, but no spatial patterns were clearly observed in any of the cross-sectional morphology maps. Although positions of particle types appeared random within compacts, examining a total of 931 classified particles allowed other relationships among morphological types to be established

AGR-1 Irradiated Test Train Preliminary Inspection and Disassembly First Look

The AGR-1 irradiation experiment ended on November 6, 2009, after 620 effective full power days in the Advanced Test Reactor, achieving a peak burnup of 19.6% FIMA. The test train was shipped to the Materials and Fuels Complex in March 2010 for post-irradiation examination. The first PIE activities included non-destructive examination of the test train, followed by disassembly of the test train and individual capsules and detailed inspection of the capsule contents, including the fuel compacts and the graphite fuel holders. Dimensional measurements of the compacts, graphite holders, and steel capsules shells were performed using a custom vision measurement system (for outer diameters and lengths) and conventional bore gauges (for inner diameters). Gamma spectrometry of the intact test train gave a preliminary look at the condition of the interior components. No evidence of damage to compacts or graphite components was evident from the isotopic and gross gamma scans. Neutron radiography of the intact Capsule 2 showed a high degree of detail of interior components and confirmed the observation that there was no major damage to the capsule. Disassembly of the capsules was initiated using procedures qualified during out-of-cell mockup testing. Difficulties were encountered during capsule disassembly due to irradiation-induced changes in some of the capsule components’ properties, including embrittled niobium and molybdenum parts that were susceptible to fracture and swelling of the graphite fuel holders that affected their removal from the capsule shells. This required various improvised modifications to the disassembly procedure to avoid damage to the fuel compacts. Ultimately the capsule disassembly was successful and only one compact from Capsule 4 (out of 72 total in the test train) sustained damage during the disassembly process, along with the associated graphite holder. The compacts were generally in very good condition upon removal. Only relatively minor damage or markings were visible using high resolution photographic inspection. Compact dimensional measurements indicated diametrical shrinkage of 0.9 to 1. 4%, and length shrinkage of 0.2 to 1.1%. The shrinkage was somewhat dependent on compact location within each capsule and within the test train. Compacts exhibited a maximum diametrical shrinkage at a fast neutron fluence of approximately 3×1021 n/cm2. A multivariate statistical analysis indicates that fast neutron fluence as well as compact position in the test train influence compact shrinkage

Adaptive energy minimisation for hp-finite element methods

This article is concerned with the numerical solution of convex variational problems. More precisely, we develop an iterative minimisation technique which allows for the successive enrichment of an underlying discrete approximation space in an adaptive manner. Specifically, we outline a new approach in the context of hp-adaptive finite element methods employed for the efficient numerical solution of linear and nonlinear second-order boundary value problems. Numerical experiments are presented which highlight the practical performance of this new hp-refinement technique for both one- and two-dimensional problems

Solution of an industrially relevant coupled magneto–mechanical problem set on an axisymmetric domain

Eddy currents are generated when low frequency magnetic fields interact with conducting components and this, in turn, generates Lorentz forces, which can cause these metallic components to deform and vibrate. An important application of this magneto–mechanical coupling is in coil design for magnetic resonance imaging scanners, where such vibrations can have unwanted effects such as ghosting of images, reduction of the life span of devices and discomfort for the patient. This work is aimed at developing an accurate computational tool for better understanding these deformations by considering a benchmark problem proposed by Siemens plc (Kruip, personal communication, 2013) on an idealised axisymmetric geometry. We present a new fixed point algorithm and develop new weak variational statements, which use a stress tensor approach for force calculation and permit discretisation using H1 conforming hp-version finite elements. Numerical results are included, which show the importance of high order finite elements for predicting the eddy currents and the associated coupling in the resonance region