Nuclear Engineering Commons^™

Design And Evaluation Of Processes For Fuel Fabrication, Georg F. Mauer

Fuels Campaign (TRP)

The goal of this research project is to provide technical support to process designers working on the development of the fuel cycles for transmutation applications. Detailed process models are developed to better define the impact of fuel choice on the transmuter fuel cycle, including relative process losses, waste generation, and plant capital cost. These process models provide insight regarding required plant size and number of plants needed to mesh with the fuel recycling line. They also determine requirements for automation.

Manufacturing models for large-scale production in a hot cell environment are also developed. Combined, these two models allow the assessment …

Design And Evaluation Of Processes For Transmuter Fuel Fabrication, Georg F. Mauer

Fuels Campaign (TRP)

• Project Objective: examine autonomous robotic fuel fabrication processes with regard to hot cell and equipment design, operations, and costs.

• Fabrication processes for different fuel types differ in terms of equipment types, throughput, and cost.

• Design options are restricted by the requirement to employ only radiation-hardened machinery and components

• Benefit to Department of Energy: decision support for the selection of the most suitable manufacturing process.

Design And Evaluation Of Processes For Fuel Fabrication: Quarterly Progress Report #5, Georg F. Mauer

Fuels Campaign (TRP)

The fifth quarter of the project covered the following:

· Literature Search: The process of evaluating the pertinent literature continued.

· Mr. Richard Silva continued the development of a simulation model with a Waelischmiller hot cell robot. Rich will continue to develop detailed 3-D process simulation models as his M.Sc. thesis project.

· Dr. Mauer presented a paper at the ANS Winter annual meeting in Washington, D.C. titled: “Design and Evaluation of Processes for Transmuter Fuel Fabrication.”

· Concepts and Methods for Vision-Based Hot Cell Supervision and control (Ph.D. Student Jae-Kyu Lee )

· Dr. Mauer presented a paper at …

Design And Evaluation Of Processes For Fuel Fabrication: Quarterly Progress Report #4, Georg F. Mauer

Fuels Campaign (TRP)

The fourth quarter of the project covered the following:

• Literature Search: The process of evaluating the pertinent literature continued. Results are summarized.

• Mr. Richard Silva developed a simulation model with a Waelischmiller hot cell robot. Rich will continue to develop detailed 3-D process simulation models as his M.Sc. thesis project.

• Dr. Mauer visited CEA Cadarache and CEA Marcoule in France, the institute for transuranics in Karlsruhe, and the Framatome manufacturing plant in Lingen, Germany.

• Concepts and Methods for Vision-Based Hot Cell Supervision and control (Ph.D. Student Jae-Kyu Lee )

Design And Evaluation Of Processes For Fuel Fabrication: Year 1 Final Report, Georg F. Mauer

Fuels Campaign (TRP)

The project objective is the design and evaluation of manufacturing processes for transmuter fuel fabrication. The large-scale deployment of remote fabrication and refabrication processes will be required for all transmutation scenarios. Current program emphasis is on a five-year effort to determine the feasibility of transmutation as a technology to limit the need for repository storage of spent commercial fuel. The evaluation of the fabrication processes will create a decision support data base to document design, operations, and costs. Fabrication processes required for different fuel types differ in terms of equipment types, throughput, and cost. The year 1 project was focused …

Design And Evaluation Of Processes For Fuel Fabrication: Year 1 Final Report, Georg F. Mauer

Fuels Campaign (TRP)

The project objective is the design and evaluation of manufacturing processes for transmuter fuel fabrication. The large-scale deployment of remote fabrication and refabrication processes will be required for all transmutation scenarios. Current program emphasis is on a five-year effort to determine the feasibility of transmutation as a technology to limit the need for repository storage of spent commercial fuel. The evaluation of the fabrication processes will create a decision support data base to document design, operations, and costs. Fabrication processes required for different fuel types differ in terms of equipment types, throughput, and cost. The year 1 project was focused …

Design And Analysis For Melt Casting Metallic Fuel Pins Incorporating Volatile Actinides: Quarterly Progress Report 5/16/02- 8/15/02, Yitung Chen, Randy Clarksean, Darrell Pepper

Fuels Campaign (TRP)

An important aspect of the Advanced Accelerator Applications (AAA) program is the development of a casting process by which volatile actinide element (i.e., americium) can be incorporated into metallic alloy fuel pins. The traditional metal fuel casting process uses an inductively heated crucible.

This process works well for the fabrication of metal fuel pins traditionally composed of alloys of uranium and plutonium, but does not work well when highly volatile actinides are included in the melt. The problem occurs both during the extended time period required to superheat the alloy melt as well as when the chamber must be evacuated. …

Phase I: Design And Analysis Of A Process For Melt Casting Metallic Fuel Pins Incorporating Volatile Actinides, Yitung Chen, Randy Clarksean, Darrell Pepper

Fuels Campaign (TRP)

The proposed research would be conducted in 3 phases. Each of the phases would be carried out over a one-year period. Phase I includes model development, analysis, and the selection of a new casting furnace design. The work discussed in this report was completed as Phase I. Phase II of the program will lead to more modeling and validation to evaluate the proposed furnace concept. Phase III would be a joint effort between UNLV and Argonne National Laboratory (ANL) to demonstrate the acceptable use of the new furnace in a simulated remote environment.

The Phase III work would include the …

Development Of A Model For Induction Heating, Randy Clarksean, Yitung Chen

Fuels Campaign (TRP)

There are two coupled equations that must be solved in order to determine the power deposition. The numerical solution of these equations is needed in order to apply a source term within the energy equations. These equations have previously solved in FIDAP. That implementation used modified versions of the momentum and energy equations to provide a mechanism for the solution of two coupled equations. Currently, we want to solve for the induction heating field in addition to the flow field and the energy equation. In order to do this, a mechanism has to be defined within FIDAP to solve these …

Design And Evaluation Of Processes For Fuel Fabrication, Georg F. Mauer

Fuels Campaign (TRP)

The objective of this project is the design and evaluation of manufacturing processes for transmuter fuel fabrication. The large-scale deployment of remote fabrication and refabrication processes will be required for all transmutation scenarios. Current program emphasis is on a five-year effort to determine the feasibility of transmutation as a technology to limit the need for repository storage of spent commercial fuel. The evaluation of the fabrication processes will create a decision support data base to document design, operations, and costs. Fabrication processes required for different fuel types differ in terms of equipment types, throughput, and cost. Differential cost Implications of …

Design And Evaluation Of Processes For Fuel Fabrication: Quarterly Progress Report #3, Georg F. Mauer

Fuels Campaign (TRP)

The third quarter of the project covered the following:

• Literature Search: The process of evaluating the pertinent literature continued. Results are summarized.

• Mr. Richard Silva, developed an initial work cell simulation with two robots. Rich will continue to develop detailed 3-D process simulation models as his M.Sc. thesis project. Rich is employed with Bechtel at the Yucca Mountain project.

• The equipment detail and estimates were refined based on the literature survey results for different manufacturing plant design options.

• Concepts and Methods for Vision-Based Hot Cell Supervision and control (Ph.D. Student Jae-Kyu Lee )

Design And Analysis Of A Process For Melt Casting Metallic Fuel Pins Incorporating Volatile Actinides, Yitung Chen, Darrell Pepper, Randy Clarksean

Fuels Campaign (TRP)

UNLV has developed and will continue to develop process models for the analysis of melt casting processes. This work will continue to be performed under the guidance of Argonne National Laboratory (ANL) engineers to ensure that their knowledge and experience benefits the project. The research to be conducted during the second year will center on performing detailed analyses on a conceptual design of an inductively heated skull-crucible casting furnace. Processing conditions will be analyzed, basic models utilized, and detailed heat and mass transfer models will be developed to analyze the most promising processes. The goal of this second year is …

Design And Evaluation Of Processes For Fuel Fabrication: Quarterly Progress Report #2, Georg F. Mauer

Fuels Campaign (TRP)

The second quarter of the project covered the following:

• Project review with Dr. Mitchell Meyer, ANL West: A project review of the transmuter fuels project was conducted during the January 2002 AAA meeting in Las Vegas.

• A second graduate student, Mr. Richard Silva, began working on the project. Rich will develop detailed 3-D process simulation models as his M.Sc. thesis project. Rich is employed with Bechtel at the Yucca Mountain project.

• AAA Seminar Presentation by Mr. Jae-Kyu Lee and G. Mauer. Title: Transmuter Fuel Fabrication Processes.

• More equipment detail and estimates were developed for different manufacturing …

Design And Analysis For Melt Casting Metallic Fuel Pins Incorporating Volatile Actinides: Quarterly Progress Report 11/16/01- 2/15/02, Yitung Chen, Randy Clarksean, Darrell Pepper

Fuels Campaign (TRP)

An important aspect of the Advanced Accelerator Applications (AAA) program is the development of a casting process by which volatile actinide element (i.e., americium) can be incorporated into metallic alloy fuel pins. The traditional metal fuel casting process uses an inductively heated crucible.

This process works well for the fabrication of metal fuel pins traditionally composed of alloys of uranium and plutonium, but does not work well when highly volatile actinides are included in the melt. The problem occurs both during the extended time period required to superheat the alloy melt as well as when the chamber must be evacuated. …

Design And Analysis Of A Process For Melt Casting Metallic Fuel Pins Incorporating Volatile Actinides, Yitung Chen, Darrell Pepper, Randy Clarksean

Fuels Campaign (TRP)

The Transmutation Research Program requires the incorporation of non-fertile actinides into the fuel matrix for the transmuter blanket. One of three currently proposed candidate matrices for the transmuter blanket is a metallic alloy fuel matrix. Metallic fuels are an outstanding candidate for a transmutation fuel due to excellent irradiation performance and ease of fabrication. However, including a volatile constituent during fabrication of these fuel pins presents a challenge. High vapor pressure actinides, particularly americium, are susceptible to rapid vaporization and transport using traditional metal fuel casting processes. As a result, only a fraction of the desired charge is incorporated into …

Design And Evaluation Of Processes For Fuel Fabrication, Georg F. Mauer

Fuels Campaign (TRP)

One of the primary concerns in selecting a fuel matrix for actinide-bearing fuels, such as those for transmutation systems, is fuel fabrication. Fuel fabrication technologies for the fabrication and re-fabrication processes must meet several technical considerations, such as minimizing secondary radioactive waste streams, economic viability, reasonable capital outlay, and must be easy to maintain over the transmuter core life cycle. Additionally, the fuel type chosen must be easily manufactured in a remote environment. The volatile behavior of americium during thermal processing further complicates these goals. Currently, the national program is investigating a number of candidate fuel matrices: metallic, ceramic, dispersion, …

Design And Evaluation Of Processes For Fuel Fabrication: Quarterly Progress Report #1, Georg F. Mauer

Fuels Campaign (TRP)

The first three months of the project covered the following:

• Literature review: A comprehensive study of the pertinent publications pertaining to transmuter fuels composition and manufacturing processes was conducted.

• Visit at ANL West in Idaho Falls, ID: Dr. Mauer visited the ANL West facility and met with his National Laboratory Collaborator, Dr. Mitchell K. Meyer, Group Leader, Fabrication Development on October 14 and 15, 2001.

• Student Paper Presentation at the ANS Annual Meeting by Ph.D. student Mr. Jae-Kyu Lee. Title: Transmuter Fuel Fabrication Processes.

Design And Analysis For Melt Casting Metallic Fuel Pins Incorporating Volatile Actinides: Quarterly Progress Report 8/16/01- 11/15/01, Yitung Chen, Randy Clarksean, Darrell Pepper

Fuels Campaign (TRP)

An important aspect of the Advanced Accelerator Applications (AAA) program is the development of a casting process by which volatile actinide element (i.e., americium) can be incorporated into metallic alloy fuel pins. The traditional metal fuel casting process uses an inductively heated crucible. The process involves evacuation of the furnace. The evacuation of the furnace also evacuates quartz rods used as fuel pin molds. Once evacuated the open ends of the molds are lowered into the melt; the casting furnace is then rapidly pressurized, forcing the molten metal up into the evacuated molds where solidification occurs.

This process works well …

Design And Analysis For Melt Casting Metallic Fuel Pins Incorporating Volatile Actinides: Quarterly Report 5/15/01-8/15/01, Yitung Chen, Darrell Pepper, Randy Clarksean

Fuels Campaign (TRP)

No abstract provided.

Design And Evaluation Of Processes For Fuel Fabrication, Georg F. Mauer

Fuels Campaign (TRP)

The objective of this project is the design and evaluation of manufacturing processes for transmuter fuel fabrication. A detailed design description for the manufacturing of each candidate fuel type would support the informed selection of fuel for a transmutation system. We will collect pertinent manufacturing and process-related information and create an information database that will document the design, operations, and cost implications of various fuel choices. Fabrication processes for different fuel types will likely differ in terms of equipment types, throughput, and cost.

Year 1 of the project will be devoted to the analysis and assessment of the multiple steps …

Design And Analysis For Melt Casting Metallic Fuel Pins Incorporating Volatile Actinides, Yitung Chen, Darrell Pepper, Randy Clarksean

Fuels Campaign (TRP)

UNLV investigators will evaluate and select a process for the melt casting of metallic fuel pins that contain volatile actinides. This work will be performed with the guidance of Argonne National Laboratory (ANL) engineers to insure that their knowledge and experience benefits the project. The research to be conducted during year one will center on selecting, evaluating, and modeling potential alternatives to the traditional injection casting process used at ANL. Processing conditions will be analyzed, basic models utilized, and detailed heat and mass transfer models will be developed to analyze the most promising processes. The goal of the first year …