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Under accidental conditions for high temperature gas-cooled reactors (HTGR), the SiC layer in tri-structural-isotropic (TRISO) fuel particles can be exposed to water vapor. In this study, oxidation behaviors of surrogate TRISO fuel particles were investigated in a He-20 vol% water vapor mixed atmosphere at temperatures up to 1600 °C. The growth of the crystalline oxide passivation layer with cracks and pores followed a parabolic law with time, where the maximum was 2.3 μm at 1600 °C. The oxide layer and the SiC surface under the oxide became flattened with increasing temperature, as a function of the silica viscosity and the diffusion path of water vapor. Volatilization of the oxide layer was analyzed using a mechanistic model that an inert gas in oxidizing atmospheres could influence the magnitude of volatilization. The fracture load and strength of the oxidized and thinned SiC layer were numerically estimated to decrease from 2.27 to 1.69 N and from 317 to 299 MPa, respectively, with the SiC thickness decrease from 35 to 32 μm. This prediction indicates that the oxidized SiC layer should retain fission products. Additionally, the mechanical integrity of each layer in the TRISO fuel particle after oxidation was evaluated. The results in this work provide important data for the safety analysis of accidental scenarios in HTGRs.

This document demonstrates completion of the goals described in the technical narrative of the FOA project titled: ”Modeling and Simulation Development Pathways to Accelerating KP-FHR Licensing” regarding fission product transport in the Kairos-proposed fuel pebble by INL and Kairos Power. Showcased in this report are code developments and simulations in BISON that extend the state of the art in computation and understanding of fission product transport in a TRISO fuel particle and pebble. These enhancements lay the foundation for making predictions of fission product transport that can be used as input in the fuel licensing process. This was achieved by installing existing fuel material models originally used in PARFUME, developing a new failure probability method that is efficient and multi-dimensional, employing material homogenization, and expanding verification and validation simulations to demonstrate the efficacy of the work. All this work is leveraged to spotlight the main deliverable; a three-dimensional model and corresponding demonstration simulation of a pebble, which will serve as the starting point for models used to predict fission product release.

This ECAR documents the as-run Jim Sterbentz’s MCNP ORIGEN Coupled Utility Program (JMOCUP) physics depletion calculation and the calculated results for the AGR-5/6/7 irradiation experiment in the Advanced Test Reactor (ATR). AGR 5/6/7 was irradiated for nine power cycles in the northeast flux trap. The depletion calculations were performed to provide input data for a variety of other engineering analyses supporting the AGR-5/6/7 experiment along with post-irradiation characterization of the tri-structural isotropic (TRISO) particle fuel compacts. Detailed full-core MCNP models and Oak Ridge Isotope Generation (ORIGEN2) radionuclide generation models were specifically developed as part of the JMOCUP Monte Carlo depletion calculations. The MCNP ORIGEN2 computer codes were coupled using the well-established JMOCUP utility modules to couple the two codes and run the depletion calculations. The physics calculations were performed in support of the Advanced Gas Reactor (AGR) program.

We report that coated particle fuel concepts date back some 60 years, and have evolved significantly from the relatively primitive pyrocarbon-coated kernels envisioned by the first pioneers. Improvements in particle design, coating layer properties, and kernel composition have produced the modern tristructural isotropic (TRISO) particle, capable of low statistical coating failure fractions and good fission product retention under extremely severe conditions, including temperatures of 1600 °C for hundreds of hours. The fuel constitutes one of the key enabling technologies for high-temperature gas-cooled reactors, allowing coolant outlet temperatures approaching 1000 °C and contributing to enhanced reactor safety due to the hardiness of the particles. TRISO fuel development has taken place in a number of countries worldwide, and several fuel qualification programs are currently in progress. Here, we discuss the unique history of particle fuel development and some key technology advances, concluding with some of the latest progress in UO₂ and UCO TRISO fuel qualification.

Highlights of Advanced Gas Reactor (AGR) activities during January through March 2019.

Microstructural characterization of the SiC layer was carried out on neutron irradiated, tristructural isotropic (TRISO) particles from the Advanced Gas Reactor (AGR)-2 experiment. The SiC grain boundary distribution in each particle was characterized with precession electron diffraction in the transmission electron microscope. Generally, the distributions in the AGR-2 TRISO particles (fabricated at the pilot scale by an industrial vendor) were similar to the Variant 3, AGR-1 TRISO particles made on a laboratory-scale at Oak Ridge National Laboratory. Slightly more random, high-angle grain boundaries in conjunction with slightly less low-angle grain boundaries were found in the AGR-2 TRISO particles compared to AGR-1 TRISO particles. Plotting the Ag-110m retention exhibited by both Variant 3 AGR-1 and AGR-2 irradiated TRISO particles against various grain boundary types revealed Ag retention correlate with the random, high-angle and twin grain boundary fraction in the center area of the SiC layer. Observations associated with localized areas of precipitation also will be reported in this paper.

Mechanisms by which fission products migrate across the coating layers of tristructural isotropic (TRISO) coated particles, designed for next generation nuclear reactors, remain poorly understood despite numerous research activities. In this study, a crack across the buffer layer and the inner pyrolytic carbon (IPyC) layer was identified using X-ray tomography in a TRISO coated particle with ~30% Cs and ~85% Ag release. Detailed scanning transmission electron microscopy (STEM) coupled with energy dispersive X-ray spectroscopy (EDS) were performed on focused ion beam prepared lamellae from different locations close to and far away from the crack to study the distribution and composition of fission products across the IPyC and SiC layers in the areas examined. Pure carbon areas were found in areas in the SiC layer close to the crack tip. Precipitates present in these carbon areas consist mostly of Pd2Si, PdSi or Pd, with Ag and/or Cd frequently identified in these precipitates. Cs was found in nano-cracks and some precipitates in the carbon areas in the SiC layer. Areas in the SiC layer close to the crack tip with localized accumulation of Pd were corroded by Pd, forming pure carbon areas and palladium silicide. Such localized corroded areas provide pathways for Ag, Cd and Cs migration.

Here, detailed electron microscopy studies were performed to investigate the distribution and composition of fission products in the SiC layer of a tristructural isotropic coated particle exhibiting localized corrosion. Previous studies on this particle indicated that pure carbon areas in the SiC layer, resulting from localized corrosion of SiC by Pd, provide pathways for Ag, Cd and Cs migration. This study reveals the presence of Ag- and/or Cd-containing precipitates in un-corroded SiC areas. Ag/Cd may exist by themselves or coexist with Pd. Ag/Cd mainly transport along SiC grain boundaries. An Ag-Pd-Cd precipitate was identified at a stacking fault inside a SiC grain, suggesting that intragranular transport of Ag/Cd is possible. Ce is present with Pd or Pd-U in some precipitates >50 nm. U and Ce frequently coexist with each other, whereas Ag/Cd usually does not coexist with U or Ce. No Cs was detected in any precipitates in the areas examined.

The AGR-1 irradiation experiment was performed as the first test of tristructural isotropic (TRISO) fuel in the US Advanced Gas Reactor Fuel Development and Qualification Program. The experiment consisted of 72 right cylinder fuel compacts containing approximately 3×105 coated fuel particles with uranium oxide/uranium carbide (UCO) fuel kernels. The fuel was irradiated in the Advanced Test Reactor for a total of 620 effective full power days. Fuel burnup ranged from 11.3 to 19.6% fissions per initial metal atom and time average, volume average irradiation temperatures of the individual compacts ranged from 955 to 1136°C. This paper focuses on key results from the irradiation and post-irradiation examination, which revealed a robust fuel with excellent performance characteristics under the conditions tested and have significantly improved the understanding of UCO coated particle fuel irradiation behavior within the US program. The fuel exhibited a very low incidence of TRISO coating failure during irradiation and post-irradiation safety testing at temperatures up to 1800°C. Advanced PIE methods have allowed particles with SiC coating failure to be isolated and meticulously examined, which has elucidated the specific causes of SiC failure in these specimens. The level of fission product release from the fuel during irradiation and post-irradiation safety testing has been studied in detail. Results indicated very low release of krypton and cesium through intact SiC and modest release of europium and strontium, while also confirming the potential for significant silver release through the coatings depending on irradiation conditions. Focused study of fission products within the coating layers of irradiated particles down to nanometer length scales has provided new insights into fission product transport through the coating layers and the role various fission products may have on coating integrity. The broader implications of these results and the application of lessons learned from AGR-1 to fuel fabrication and post-irradiation examination for subsequent fuel irradiation experiments as part of the US fuel program is also discussed.

Tristructural isotropic (TRISO) coated particle fuel is a promising fuel form for advanced reactor concepts such as high temperature gas-cooled reactors (HTGR) and is being developed domestically under the US Department of Energy’s Nuclear Reactor Technologies Initiative in support of Advanced Reactor Technologies. The fuel development and qualification plan includes a series of fuel irradiations to demonstrate fuel performance from the laboratory to commercial scale. The first irradiation campaign, AGR-1, included four separate TRISO fuel variants composed of multiple, laboratory-scale coater batches. The second irradiation campaign, AGR-2, included TRISO fuel particles fabricated by BWX Technologies with a larger coater representative of an industrial-scale system. The SiC layers of as-fabricated particles from the AGR-1 and AGR-2 irradiation campaigns have been investigated by electron backscatter diffraction (EBSD) to provide key information about the microstructural features relevant to fuel performance. The results of a comprehensive study of multiple particles from all constituent batches are reported. The observations indicate that there were microstructural differences between variants and among constituent batches in a single variant. Finally, insights on the influence of microstructure on the effective diffusivity of key fission products in the SiC layer are also discussed.