U.S. patent application number 14/790888 was filed with the patent office on 2015-10-29 for fully ceramic nuclear fuel and related methods.
The applicant listed for this patent is Logos Technologies LLC, UT-BATELLE, LLC. Invention is credited to Yutai KATOH, Lance Lewis SNEAD, Francesco VENNERI.
Application Number | 20150310948 14/790888 |
Document ID | / |
Family ID | 45532003 |
Filed Date | 2015-10-29 |
United States Patent
Application |
20150310948 |
Kind Code |
A1 |
VENNERI; Francesco ; et
al. |
October 29, 2015 |
FULLY CERAMIC NUCLEAR FUEL AND RELATED METHODS
Abstract
Various embodiments of a nuclear fuel for use in various types
of nuclear reactors and/or waste disposal systems are disclosed.
One exemplary embodiment of a nuclear fuel may include a fuel
element having a plurality of tristructural-isotropic fuel
particles embedded in a silicon carbide matrix. An exemplary method
of manufacturing a nuclear fuel is also disclosed. The method may
include providing a plurality of tristructural-isotropic fuel
particles, mixing the plurality of tristructural-isotropic fuel
particles with silicon carbide powder to form a precursor mixture,
and compacting the precursor mixture at a predetermined pressure
and temperature.
Inventors: |
VENNERI; Francesco; (Los
Alamos, NM) ; KATOH; Yutai; (Oak Ridge, TN) ;
SNEAD; Lance Lewis; (Knoxville, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Logos Technologies LLC
UT-BATELLE, LLC |
Fairfax
Oak Ridge |
VA
TN |
US
US |
|
|
Family ID: |
45532003 |
Appl. No.: |
14/790888 |
Filed: |
July 2, 2015 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12959115 |
Dec 2, 2010 |
|
|
|
14790888 |
|
|
|
|
Current U.S.
Class: |
264/.5 |
Current CPC
Class: |
Y02E 30/30 20130101;
Y02E 30/38 20130101; G21C 3/626 20130101; G21C 21/04 20130101; G21C
3/20 20130101; G21C 3/62 20130101; G21C 21/02 20130101 |
International
Class: |
G21C 21/02 20060101
G21C021/02; G21C 3/62 20060101 G21C003/62 |
Goverment Interests
STATEMENT OF FEDERALLY SPONSORED RESEARCH
[0001] The United States Government has certain rights in this
invention pursuant to Contract No. DE-AC05-00OR22725 between the
United States Department of Energy and UT-Battelle, LLC.
Claims
1-19. (canceled)
20. A method of manufacturing a nuclear fuel, comprising: providing
a plurality of tristructural-isotropic fuel particles; mixing the
plurality of tristructural-isotropic fuel particles with silicon
carbide powder to form a precursor mixture; and compacting the
precursor mixture at a predetermined pressure and temperature.
21. The method of claim 20, wherein the predetermined pressure is
at about 10 MPa.
22. The method of claim 20, wherein the predetermined temperature
is at about 1850.degree. C.
23. The method of claim 20, wherein compacting comprises placing
the precursor mixture in a mold having a predetermined shape and
pressing the mixture to stress.
24. The method of claim 20, wherein the SiC powder has an average
particle size of less than 11 .mu.m.
25. The method of claim 20, wherein the SiC powder has an average
specific surface area greater than 20 m.sup.2/g.
26. The method of claim 20, further comprising adding sintering
additives to the precursor mixture.
27. The method of claim 26, wherein the sintering additives
comprise at least one of alumina and rare earth oxides.
28. The method of claim 26, wherein the sintering additives
comprises about 6 to 10 weight % of the precursor mixture.
29. The method of claim 20, wherein the tristructural-isotropic
fuel particles are formed by coating fuel kernels with at least one
ceramic layer.
30. The method of claim 20, wherein the plurality of
tristructural-isotropic fuel particles comprise transuranic waste
extracted from a spent fuel of a light water reactor.
Description
FIELD OF THE INVENTION
[0002] The present invention relates generally to nuclear
technologies. More specifically, particular embodiments of the
invention relate to nuclear fuels, and related methods, for use in
various types of nuclear reactors and/or waste disposal
systems.
DESCRIPTION OF RELATED ART
[0003] Despite nuclear power has provided a reliable, safe source
of electricity in the United States for more than 40 years, no new
nuclear power plant has been built in the United States since 1978,
mainly because of concerns over, among others, inherent dangers
associated with nuclear reactors, nuclear waste storage and
disposal, and costs. Yet, to meet the increasing demands for power
as well as environmental friendliness, nuclear power is destined to
make a comeback in the United States since nuclear power is
currently the only environment-friendly, large-scale, and reliable
source of energy. The degree of use and acceptance of nuclear
power, however, will primarily depend on whether the nuclear
industry finds acceptable ways to reduce nuclear wastes (including
the growing amount of spent fuel stored in existing nuclear power
plants) and to make nuclear power economically more
competitive.
[0004] One of the proposed concepts for reducing the nuclear wastes
is to increase discharge burnup of nuclear fuel. By increasing the
fraction of fission per initial heavy metal atom (FIMA) in the
nuclear fuel, the overall spent fuel volume and long-lived
radioactive isotope inventories can be significantly reduced.
Moreover, extracting more energy per unit mass of fuel naturally
translates into lengthened fuel cycle, reduced fuel consumption
and, hence, reduced overall fuel cost.
[0005] Higher burnup of fuel, however, may pose a challenge on the
performance and overall integrity of the fuel. For example, the
vast majority of nuclear fuel used today are uranium dioxide
(UO.sub.2) pellets stacked inside a sealed cladding tube of
zirconium alloy to make a fuel rod. For such a monolithic UO.sub.2
fuel with zircalloy cladding, increasing burnup generally results
in: increased corrosion of the cladding material due to higher
neutron fluence and/or extended in-core residence; higher fuel rod
internal pressures due to higher fission product gas release from
the UO.sub.2 fuel; poor thermal conductivity and strength of the
UO.sub.2 fuel; and/or higher swelling of the UO.sub.2 fuel due to
fission gas formation and damages to the lattice of the fuel
pellets. Since this type of fuel generally has a single containment
(i.e., cladding tube) against fission product release to the
coolant, the material deterioration is the most critical barrier to
increasing burnup of nuclear fuel.
[0006] Recently, micro-encapsulated tristructural-isotropic (TRISO)
fuel particles compacted within a graphite matrix have been
proposed for the next generation gas-cooled reactors. A TRISO fuel
particle comprises a kernel of fissile/fertile material coated with
several isotropic layers of pyrolytic carbon (PyC) and silicon
carbide (SiC). These TRISO particles are combined with a graphite
matrix material and pressed into a specific shape. While the TRISO
fuel forms offer better fission product retention at higher
temperatures and burnups than metallic fuel forms, they also
provide only one containment shell (i.e., SiC layer) against
fission product release to the coolant, and some fission products
may migrate out of the kernel and through the outer layers and
escape into the graphite matrix and coolant.
[0007] Thus, there exists a need for an improved nuclear fuel that
provides enhanced fission product retention mechanisms and/or
permits higher fuel burnup without compromising the integrity and
stability of the fuel.
[0008] There also exists a need for a more efficient and/or safer
low enrichment uranium (LEU) fuel for existing reactors, which
would prevent fission products from being dispersed into the
coolant under any accident conditions.
SUMMARY OF THE INVENTION
[0009] Although the present invention may obviate one or more of
the above-mentioned needs, it should be understood that some
aspects of the invention might not necessarily obviate one or more
of those needs.
[0010] In the following description, certain aspects and
embodiments will become evident. It should be understood that these
aspects and embodiments are merely exemplary and the invention, in
its broadest sense, could be practiced without having one or more
features of these aspects and embodiments.
[0011] To attain the advantages and in accordance with the purpose
of the invention, as embodied and broadly described herein, one
aspect of the invention may provide a nuclear fuel comprising a
fuel element comprising a plurality of tristructural-isotropic fuel
particles embedded in a silicon carbide matrix.
[0012] In some exemplary embodiments, each of the
tristructural-isotropic fuel particles may comprise a fuel kernel
disposed substantially at the center and a ceramic layer
surrounding the fuel kernel. In another exemplary embodiment, the
fuel element may have a shape of a cylindrical pellet. In still
another exemplary embodiment, the silicon carbide matrix may have a
density substantially equal to the theoretical density.
[0013] According to one exemplary embodiment, the nuclear fuel may
further include: a tubular enclosure defining an interior space,
wherein an outer surface of the tubular enclosure is configured to
contact a coolant of a nuclear reactor; and a plurality of fuel
element disposed in the interior space. The tubular enclosure may
be a metallic cladding tube.
[0014] According to another exemplary embodiment, the nuclear fuel
may further comprise a graphite block having one or more holes,
wherein the fuel element is disposed inside the one or more
holes.
[0015] In still another exemplary embodiment, the plurality of
tristructural-isotropic fuel particles may comprise transuranic
elements extracted from a spent fuel of a light water reactor or
from a nuclear weapon.
[0016] Another exemplary aspect of the present invention may
provide a method of manufacturing a nuclear fuel. The method may
comprise: providing a plurality of tristructural-isotropic fuel
particles; mixing the plurality of tristructural-isotropic fuel
particles with silicon carbide powder to form a precursor mixture;
and compacting the precursor mixture at a predetermined pressure
and temperature.
[0017] In one exemplary embodiment, the predetermined pressure may
be at about 10 MPa. The predetermined temperature may be at about
1850.degree. C.
[0018] According to another exemplary embodiment, compacting may
comprise placing the precursor mixture in a mold having a
predetermined shape and pressing the mixture to stress.
[0019] In some exemplary embodiments, the SiC powder may have an
average particle size of less than 1 .mu.m. According to another
exemplary embodiment, the SiC powder may have an average specific
surface area greater than 20 m.sup.2/g.
[0020] In various exemplary embodiments, the method may further
comprise adding sintering additives to the precursor mixture. The
sintering additives may comprise at least one of alumina and rare
earth oxides. The sintering additives may comprise about 6 to 10
weight % of the precursor mixture.
[0021] According to one exemplary embodiment, the
tristructural-isotropic fuel particles may be formed by coating
fuel kernels with at least one ceramic layer.
[0022] In another exemplary embodiment, the plurality of
tristructural-isotropic fuel particles may comprise transuranic
waste extracted from a spent fuel of a light water reactor.
[0023] Additional objects and advantages of the invention will be
set forth in part in the description which follows, and in part
will be obvious from the description, or may be learned by practice
of the invention. The objects and advantages of the invention will
be realized and attained by means of the elements and combinations
particularly pointed out in the appended claims.
[0024] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention, as
claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate several
embodiments of the invention and together with the description,
serve to explain the principles of the invention.
[0026] FIG. 1 is a schematic illustration of various constituents
of a fuel element, according to one exemplary embodiment of the
invention.
[0027] FIG. 2 is a partial cross-sectional, microscopic view of the
fuel element shown in FIG. 1.
[0028] FIG. 3 is a graph illustrating a temperature profile of the
fuel element of FIG. 1 as compared to a conventional UO.sub.2 fuel
element.
[0029] FIG. 4 is a schematic illustration of an exemplary
application of the fuel element, consistent with the present
invention.
[0030] FIG. 5 is a schematic illustration of another exemplary
application of the fuel element, consistent with present
invention.
DESCRIPTION OF THE EMBODIMENTS
[0031] Reference will now be made in detail to the exemplary
embodiments consistent with the present invention, examples of
which are illustrated in the accompanying drawings. Wherever
possible, the same reference characters will be used throughout the
drawings to refer to the same or like parts.
[0032] FIGS. 1-3 illustrate an exemplary nuclear fuel element
consistent with various aspects of the present invention. While the
invention will be described in connection with particular reactor
types (e.g., light water reactors and gas-cooled reactors),
embodiments of the invention may be used, or modified for use, in
any other types of nuclear reactors, such as heavy water reactors,
liquid metal reactors, and thermoionic nuclear converters.
Moreover, certain aspects of the invention may be applied to, or
used in connection with, reprocessing of spent nuclear fuel for
refueling, storage, or permanent disposal.
[0033] Referring to FIG. 1, a fuel element 10, according to one
exemplary embodiment, may comprise a plurality of
micro-encapsulated fuel particles 20 embedded in a silicon carbide
(SiC) matrix 15. The fuel element 10 may be formed by compressing a
mixture of the fuel particles 20 and a SiC-based matrix precursor
material in a mold. The mold may have any desired shape for the
fuel element 10. In one exemplary embodiment, the SiC-based matrix
precursor material may comprise SiC powder mixed with sintering
additives and may be in a form of powder-based slurry, ceramic
slurry for tape casting, or any other mixture type known in the
art. Because the SiC matrix 15 is a ceramic material, the fuel
element 10 is sometimes referred to as a fully ceramic
micro-encapsulated fuel element.
[0034] While the fuel element 10 of FIG. 1 has a shape of a
cylindrical pellet, particularly suitable for use in a conventional
light water reactor, the fuel element may have a variety of other
shapes, such as, for example, a sphere or an elongated rod,
depending on the type and/or operational characteristics of the
nuclear reactor in which the fuel element is intended to be used.
The fabrication process and the resulting properties and
characteristics of the fuel element 10 will be described in more
detail later.
[0035] The fuel particles 20 dispersed in the SiC matrix 15 may be
tristructural-isotropic (TRISO) fuel particles. The term "TRISO
fuel particle," as used herein, may refer to any type of micro fuel
particle comprising a fuel kernel and one or more layers of
isotropic materials surrounding the fuel kernel. By way of example
only, the fuel particle 20 may have a diameter of about 1
millimeter.
[0036] As shown in FIG. 1, the fuel particle 20 may comprise a fuel
kernel 25 at its center. The fuel kernel 25 may comprise fissile
and/or fertile materials (e.g., uranium, plutonium, thorium, etc.)
in an oxide, carbide, or oxycarbide form. In one exemplary
embodiment, the fuel kernel 25 may comprise low enriched uranium
(LEU) of any suitable enrichment level.
[0037] When the fuel element 10 is used for waste mitigation and/or
disposal purposes, the fuel kernel 25 may alternatively or
additionally comprise transuranics (TRU) and/or fission products
extracted or otherwise reprocessed from spent fuels.
[0038] For example, the fuel element 10 may be used for destruction
of transuranic waste generated from, for example, light water
reactors or decommissioned nuclear weapons. For that purpose, the
fuel element 10 may include fuel kernels 25 formed of transuranic
elements extracted from a spent fuel of a light water reactor
and/or a core of a nuclear weapon. According to one exemplary
embodiment, the fuel element 10 thus formed may be used as fuel for
a light water reactor to destroy the transuranic waste while, at
the same time, generating power from it.
[0039] The fuel kernel 25 may be coated with four distinct layers:
(1) a porous carbon buffer layer 22; (2) an inner pyrolytic carbon
(PyC) layer 24; (3) the ceramic layer 26; and (4) an outer PyC
layer 28.
[0040] The porous carbon buffer layer 22 surrounds the fuel kernel
25 and serves as a reservoir for accommodating buildup of fission
gases diffusing out of the fuel kernel 25 and any mechanical
deformation that the fuel kernel 25 may undergo during the fuel
cycle.
[0041] The inner PyC layer 24 may be formed of relatively dense PyC
and seals the carbon buffer layer 22.
[0042] The ceramic layer 26 may be formed of a SiC material and
serve as a primary fission product barrier and a pressure vessel
for the fuel kernel 25, retaining gaseous and metallic fission
products therein. The ceramic layer 26 also provides overall
structural integrity of the fuel particle 20.
[0043] In some exemplary embodiments, the SiC layer 26 may be
replaced or supplemented with zirconium carbine (ZrC) or any other
suitable material having similar properties as those of SiC and/or
ZrC.
[0044] The outer PyC layer 28 protects the SiC layer 26 from
chemical attack during operation and acts as an additional
diffusion boundary to the fission products. The outer PyC layer 28
may also serve as a substrate for bonding to the surrounding matrix
material.
[0045] The configuration and/or composition of the fuel particle
are not limited to the embodiments described above. Instead, it
should be understood that a fuel particle consistent with the
present disclosure may include one or more additional layers, or
omit one or more layers, depending on the desired properties of the
fuel particle. For example, the fuel particle 20 may be overcoated
with the SiC matrix material (i.e., SiC layer) prior to being mixed
and compressed with the SiC powder.
[0046] An exemplary method of fabricating the fuel element 10,
according to another aspect of the present invention, will be
described herein.
[0047] To form the fuel particles 20, according to one exemplary
embodiment, the material for the fuel kernel 25 may be dissolved in
a nitric acid to form a solution (e.g., uranyl nitrate). The
solution is then dropped through a small nozzle or orifice to form
droplets or microspheres. The dropped microspheres are then gelled
and calcined at high temperature to produce the fuel kernels 25.
The fuel kernels 25 may then be run through a suitable coating
chamber, such as a CVD furnace, in which desired layers are
sequentially coated onto the fuel kernels 25 with high precision.
It should be understood that any other fabrication method known in
the art may be additionally or alternatively used to form the fuel
kernels 25.
[0048] Once the fuel particles 20 are prepared, the fuel particles
20 are mixed with SiC powder, which comprises the precursor for the
SiC matrix 15. Prior to the mixing, the fuel particles 20 may be
coated with a suitable surface protection material. The SiC powder
may have an average size of less than 1 .mu.m and/or a specific
surface area greater than 20 m.sup.2/g. By way of example only, the
size of the SiC powder may range from about 15 nm to about 51 nm
with the mean particle size being about 35 nm.
[0049] During or prior to mixing, sintering additives, such as, for
example, alumina and rare earth oxides, may be added to the SiC
powder and/or coated onto the SiC powder surface. In one exemplary
embodiment, the amount of additives may range from about 6 weight %
to 10 weight %. When mixing with the fuel particles 20, the
SiC-based precursor material containing the SiC powder may be in a
variety of physical states (e.g., powder, liquid, slurry, etc.)
depending on the mixing and/or fabrication method used.
[0050] The SiC-based precursor mixed with the fuel particles 20 may
then be pressed to stress at a predetermined pressure and
temperature to form the fuel element 10. According to one exemplary
embodiment, the sintering pressure and temperature during the press
may be less than about 30 MPa and 1900.degree. C., respectively.
Preferably, the sintering pressure and temperature may be about 10
MPa and 1850.degree. C., respectively. The duration of the press
may be less than or equal to about one hour, but it may take more
than one hour.
[0051] The small size or large specific surface area of the SiC
powder, with the limited mass fraction of the sintering additives,
may enable the formation of highly crystalline, near-full density,
SiC matrix at conditions sufficient to ensure the integrity of the
fuel particles 20. The SiC matrix provides an additional barrier to
fission products that may be released during normal operation and
accident temperatures and contaminate the coolant of the reactor.
The SiC matrix also helps containing fission products after
disposal.
[0052] For example, FIG. 2 shows a microscopic, partial
cross-sectional view of the fuel element 10 fabricated with a
method consistent with the present invention. As can be seen from
the figure, the fuel element 10 has very clean interfaces between
the fuel particles 20 and the SiC matrix 15. Further, the SiC
matrix 15 has a very low porosity (e.g., only about 3.about.4%
closed microporosity), forming a gas-impermeable barrier that acts
as a secondary barrier to fission products/actinides diffusion and
other radioactivity releases from the fuel particles 20.
[0053] In addition, the SiC matrix 15 has very low permeability to
helium (e.g., in the order of about 10.sup.-10 to 10.sup.-11
m.sup.2/s), which is substantially lower than that of graphite and
makes it particularly suitable for a gas cooled reactor that uses
helium as a coolant. Low permeability of the SiC matrix 15 may also
ensure retention of fission product gas.
[0054] FIG. 3 illustrates a temperature gradient inside the fuel
element 10 at an operating condition, with a comparison to a
conventional UO.sub.2 fuel element. As shown in the figure, the
fuel element 10 consistent with the present invention may have
substantially higher thermal conductivity than that of the UO.sub.2
fuel element. Higher thermal conductivity has many beneficial
effects.
[0055] For example, higher thermal conductivity may permit
operating the nuclear reactor at higher temperature. Operating a
reactor at higher temperature may increase the efficiency and the
power density, which may permit reduction of the reactor size.
Higher thermal conductivity may also permit higher burnup of the
fuel element while maintaining the overall fuel integrity.
Moreover, as briefly mentioned above, higher burnup may not only
reduce the overall waste volume but also limit possible nuclear
proliferation and diversion opportunities. Further, the fuel with
high thermal conductivity may undergo less severe temperature
transients during an accident condition, such as a loss of coolant
accident (LOCA). In a light water reactor operating conditions,
migration of fission products (including gases) outside the TRISO
fuel particles and the SiC matrix is not expected to occur.
[0056] Further, the SiC matrix 15 has higher fracture strength,
higher irradiation resistance, and lower irradiation swelling than
graphite or UO.sub.2. Combination of better irradiation performance
and better thermal conductivity may result in better mechanical
performance as compared to graphite or UO.sub.2 fuel element. The
resulting matrix 15 is considered a near-stoichiometric,
radiation-resistant, form of SiC, allowing the fuel element 10 to
be repository-stable for direct disposal even after substantial
burnup (e.g., 60.about.99% burnup).
[0057] Now, with reference to FIGS. 4 and 5, exemplary applications
of the fuel element 10, according to various aspects of the present
invention, are described.
[0058] In one exemplary embodiment, one or more fuel elements 10
may be enclosed in a metallic cladding tube 35 or any other
suitable enclosure to form a fuel rod 30, as shown in FIG. 4. When
the fuel elements 10 are enclosed inside the cladding tube 35 or an
enclosure, the cladding tube 35 or the enclosure may provide an
additional barrier (i.e., in addition to the pressure-bearing
ceramic coating around the fuel kernel 25 and the fully ceramic SiC
matrix 15) to fission products and actinide transport from the fuel
particles 20. One or more fuel rods 30 may then be placed in a fuel
bundle 40 for use in, for example, a light water reactor. Thus,
according to one exemplary aspect, the fuel element 10 consistent
with the present invention may be used in a conventional light
water reactor, as replacement fuel for conventional UO.sub.2 fuel
pellets, which may provide enhanced thermal conductivity and
irradiation stability, as well as added barriers to fission product
and actinide transport.
[0059] According to another aspect of the present invention, the
fuel element 100 may be provided as an elongated rod, as shown in
FIG. 5. The fuel element 100 may be placed in a hole 135 drilled in
a graphite prism or block for use in a gas-cooled reactor. As
mentioned above, the fully ceramic fuel element 100, consistent
with the present invention, may exhibit higher fracture strength,
higher irradiation resistance, and lower irradiation swelling than
the conventional graphite matrix-based fuel.
[0060] Other embodiments of the invention will be apparent to those
skilled in the art from consideration of the specification and
practice of the invention disclosed herein. It is intended that the
specification and examples be considered as exemplary only, with a
true scope and spirit of the invention being indicated by the
following claims.
* * * * *