Irradiation Performance of Reduced-enrichment Fuels Tested Under the US RERTR Program PDF Download

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Considerable progress in the irradiation testing of high-density, reduced-enrichment fuels has been made during the past year. Miniplates containing UA1, U3Si2, U3Si/sub 1.5/, U3Si, U3SiCu, and, U6Fe have been irradiated. Postirradiation examinations have revealed that breakway swelling has occurred in 6.4-Mg U/m3 U3Si plates at approx. 2.8 x 1027 fissions/m3. U3Si2 plates are continuing to show satisfactory performance. The testing of full-sized fuel elements in the ORR and the SILOE reactor have continued with good results. Postirradiation examinations are confirming the satisfactory performance of these elements.

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In order to provide the technical means for reducing the enrichment of uranium used to fuel research and test reactors, the US Reduced Enrichment Research and Test Reactor (RERTR) Program has been engaged in the development and testing of higher-uranium-density fuels than had been used previously. The main characteristics to be considered in evaluating the performance of a fuel are its swelling, its blister-threshold temperature, and its metallurgical appearance. Data for the qualification of the reduced-enrichment fuels being developed by the RERTR Program are obtained from examination of minature fuel plates (miniplates) which successfully pass the irradiation screening tests and from examinations of full-sized fuel elements. This paper will summarize the miniplate data and will give the status of full-sized element irradiations. Finally, the current status of qualification of the various fuel types will be discussed and some projections of the future will be given.

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The progress of the Reduced Enrichment Research and Test Reactor (RERTR) Program is described. After a brief summary of the results which the RERTR Program, in collaboration with its many international partners, had achieved by the end of 1986, the activities, results, and new developments which occurred in 1987 are reviewed. Irradiation of the second miniplate series, concentrating on U3Si2-Al and U3Si-Al fuels, was completed and postirradiation examinations were performed on many of its miniplates. The whole-core ORR demonstration with U3Si2-Al fuel at 4.8 g U/cm3 was completed at the end of March with excellent results and with 29 elements estimated to have reached at least 40% average burnup. Good progress was made in the area of LEU usage for the production of fission 99Mo, and in the coordination of safety evaluations related to LEU conversions of US university reactors. Planned activities include testing and demonstrating advanced fuels intended to allow use of reduced enrichment uranium in very-high-performance reactors. Two candidate fuels are U3Si-Al with 19.75% enrichment and U3Si2-Al with 45% enrichment. Demonstration of these fuels will include irradiation of full-size elements and, possibly, a full-core demonstration. Achievement of the final program goals is still projected for 1990. This progress could not have been possible without the close international cooperation which has existed from the beginning, and which is essential to the ultimate success of the RERTR Program.

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In late 2003 it became evident that U-Mo aluminum fuels under development exhibited significant fuel performance problems under the irradiation conditions required for conversion of most high-powered research reactors. Solutions to the fuel performance issue have been proposed and show promise in early testing. Based on these results, a Reduced Enrichment Research and Test Reactor (RERTR) program strategy has been mapped to allow generic fuel qualification to occur prior to the end of FY10 and reactor conversion to occur prior to the end of FY14. This strategy utilizes a diversity of technologies, test conditions, and test types. Scoping studies using miniature fuel plates will be completed in the time frame of 2006-2008. Irradiation of larger specimens will occur in the Advanced Test Reactor (ATR) in the United States, the Belgian Reactor-2 (BR2) reactor in Belgium, and in the OSIRIS reactor in France in 2006-2009. These scoping irradiation tests provide a large amount of data on the performance of advanced fuel types under irradiation and allow the down selection of technology for larger scale testing during the final stages of fuel qualification. In conjunction with irradiation testing, fabrication processes must be developed and made available to commercial fabricators. The commercial fabrication infrastructure must also be upgraded to ensure a reliable low enriched uranium (LEU) fuel supply. Final qualification of fuels will occur in two phases. Phase I will obtain generic approval for use of dispersion fuels with density less than 8.5 g-U/cm3. In order to obtain this approval, a larger scale demonstration of fuel performance and fabrication technology will be necessary. Several Materials Test Reactor (MTR) plate-type fuel assemblies will be irradiated in both the High Flux Reactor (HFR) and the ATR (other options include the BR2 and Russian Research Reactor, Dmitrovgrad, Russia [MIR] reactors) in 2008-2009. Following postirradiation examination, a report detailing very-high density fuel behavior will be submitted to the U.S. Nuclear Regulatory Commission (NRC). Assuming acceptable fuel behavior, it is anticipated that NRC will issue a Safety Evaluation Report granting generic approval of the developed fuels based on the qualification report. It is anticipated that Phase I of fuel qualification will be completed prior to the end of FY10. Phase II of the fuel qualification requires development of fuels with density greater than 8.5 g-U/cm3. This fuel is required to convert the remaining few reactors that have been identified for conversion. The second phase of the fuel qualification effort includes both dispersion fuels with fuel particle volume loading on the order of 65 percent, and monolithic fuels. Phase II presents a larger set of technical unknowns and schedule uncertainties than phase I. The final step in the fuel qualification process involves insertion of lead test elements into the converting reactors. Each reactor that plans to convert using the developed high-density fuels will develop a reactor specific conversion plan based upon the reactor safety basis and operating requirements. For some reactors (FRM-II, High-Flux Isotope Reactor [HFIR], and RHF) conversion will be a one-step process. In addition to the U.S. fuel development effort, a Russian fuel development strategy has been developed. Contracts with Russian Federation institutes in support of fuel development for Russian are in place.

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The US Reduced Enrichment Research and Test Reactor (RERTR) Program was established in 1978 to provide the technical means to operate research and test reactors with low enrichment uranium (LEU) fuels without significant penalty in experiment performance, operation costs, component modifications, or safety characteristics. This paper discusses relevant developments in fuel developments. 9 refs., 1 tab.

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Progress in the development and irradiation testing of high-density fuels for use with low-enriched uranium in research and test reactors is reported. Swelling and blister-threshold temperature data obtained from the examination of miniature fuel plates containing UAl(subscript x), U3O, U3Si2, or U3Si dispersed in an aluminum matrix are presented. Combined with the results of metallurgical examinations, these data show that these four fuel types will perform adequately to full burnup of the 235U contained in the low-enriched fuel. The exothermic reaction of the uranium-silicide fuels with aluminum has been found to occur at about the same temperature as the melting of the aluminum matrix and cladding and to be essentially quenched by the melting endotherm. A new series of miniature fuel plate irradiations is also discussed.

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The irradiation and postirradiation examination of high-density, reduced-enrichment miniplates and full-sized elements are continuing under the RERTR Program. The emphasis is currently being placed on determining uranium-density/fission-density limits for the highest-density silicide fuels. One whole core demonstration is nearing completion in the FNR, and another, using U3Si2 fuel, is scheduled to begin in the ORR during the next year. This paper will summarize the progress made during the past year.

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An irradiation test facility, which provides a test bed for irradiating a variety of miniature fuel plates (miniplates) for the Reduced Enrichment Research and Test Reactors (RERTR) program, has been placed into operation. These tests screen various candidate fuel materials on their suitability for replacing the highly enriched uranium fuel materials currently used by the world's test and research reactors with a lower enrichment fuel material, without significantly degrading reactor operating characteristics and power levels. The use of low uranium enrichment of about 20% 235U in place of highly enriched fuel for these reactors would reduce the potential for 235U diversion. The irradiation test facility, designated as HFED, is operating in core position E-7 in the Oak Ridge Research Reactor (ORR), a 30-MW water-moderated reactor. The miniplates will achieve burnups of up to approx. 2.2 x 1027 fissions/m3 of fuel.

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The progress of the Reduced Enrichment Research and Test Reactor (RERTR) Program since its inception in 1978 is described. A brief summary of the results which the RERTR Program had achieved by the end of 1996 in collaboration with its many international partners is followed by a detailed review of the major events, findings, and activities of 1997. Significant progress has been made during the past year. In the area of U.S. acceptance of spent fuel from foreign research reactors, several shipments have taken place and additional are being planned. Intense fuel development activities are in progress, including procurement of equipment, screening of candidate materials, and production of microplates. Irradiation of the first series of microplates began in August 1997 in the Advanced Test Reactor, in Idaho. Progress has been made in the Russian RERTR program, which aims to develop and demonstrate within five years the technical means needed to convert Russian-supplied research reactors to LEU fuels. The study of an alternative LEU core for the FRM-II design has been extended to address, with favorable results, controversial performance issues which were raised at last year's meeting. Progress was also made on several aspects of producing molybdenum-99 from fission targets utilizing LEU instead of HEU. Various types of targets and processes are being pursued, with FDA approval of an LEU process projected to occur within two years. The feasibility of LEU Fuel conversion for three important DOE research reactors (BMRR, HFBR, and HFIR) has been evaluated by the RERTR program. In spite of the many momentous events which have occurred during the intervening years, and the excellent progress achieved, the most important challenges that the RERTR program faces today are not very different in type from those that were faced during the first RERTR meeting. Now, as then, the most important task is to develop new LEU fuels satisfying requirements which cannot be satisfied by any existing fuel. These new advanced fuels will enable conversion of the reactors which cannot be converted today, ensure better efficiency and performance for all research reactors, and allow the design of more powerful new advanced LEU reactors. As in the past, the success of the RERTR program will depend on free exchange of ideas and information, and on the international friendship and cooperation that have been a trademark of the RERTR program since its inception.

Author: Mitchell K. Meyer
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Irradiation testing of U-Mo based fuels is the central component of the Reduced Enrichment for Research and Test Reactors (RERTR) program fuel qualification plan. Several RERTR tests have recently been completed or are planned for irradiation in the Advanced Test Reactor (ATR) located at the Idaho National Laboratory in Idaho Falls, ID. Four mini-plate experiments in various stages of completion are described in detail, including the irradiation test design, objectives, and irradiation conditions. Observations made during and after the in-reactor RERTR-7A experiment breach are summarized. The irradiation experiment design and planned irradiation conditions for full-size plate test are described. Progress toward element testing will be reviewed.