MOLTEN METAL FUEL BUFFER IN FISSION REACTOR AND METHOD OF MANUFACTURE

Abstract

Fission reactor has a cladding encasing a heat generating source including a fissionable nuclear fuel composition. The heat generating source is offset from the surface of the cladding and molten metal is located within the void space formed by the offset. As a liquid, the molten metal will flow and occupy any contiguous network of void space within the fuel cavity and provides thermal transfer contact between the heat generating source and the cladding. The cladding separates the heat generating source and the molten metal from the primary coolant volume.

Claims

1. A fission reactor, comprising: a heat generating source including a fissionable nuclear fuel composition; a primary coolant volume through which a primary coolant is flowable during operation of the fission reactor; a cladding encasing the heat generating source, wherein the cladding has a first side oriented toward the heat generating source and a second side oriented toward the primary coolant volume and wherein at least a portion of the cladding separates the heat generating source from the primary coolant volume; and a molten metal in thermal transfer contact with the heat generating source and the first side of the cladding.

2. The fission reactor according to claim 1, including a space between the heat generating source and the first side of the cladding, wherein the molten metal occupies at least a portion of the space.

3. The fission reactor according to claim 2, wherein the space is located at a portion of the periphery of the heat generating source.

4. The fission reactor according to claim 2, wherein the space is located at the entire periphery of the heat generating source.

5. The fission reactor according to claim 2, wherein the space is located at a portion of the periphery of the heat generating source and wherein at least a portion of the heat generating source is in thermal transfer contact with the cladding

6. The fission reactor according to claim 5, wherein the cladding separates the molten metal from the primary coolant.

7. The fission reactor according to claim 6, wherein the primary coolant volume has a shape of a tube.

8. The fission reactor according to claim 7, wherein an exterior surface of the tube is part of the first side of the cladding and an interior surface of the tube is part of the second side of the cladding.

9. The fission reactor according to claim 8, wherein a longitudinal axis of the primary coolant volume is parallel to a longitudinal axis of the fission reactor.

10. The fission reactor according to claim 9, wherein, in an axial cross-section relative to the longitudinal axis of the fission reactor, the tube has a shape of a circle or a hexagon.

11. The fission reactor according to claim 9, wherein a longitudinal axis of the primary coolant volume is parallel to a longitudinal axis of the fission reactor, and wherein, in an axial cross-section relative to the longitudinal axis of the fission reactor, the cladding encasing the heat generating source has a shape of a cross-section of a hyperboloid of one sheet, a cross-section of a circle, a cross-section of a hexagon, or an annular cross-section.

12. The fission reactor according to claim 11, wherein, in an axial cross-section relative to the longitudinal axis of the fission reactor, the tube has a shape of a circle or a hexagon.

13. The fission reactor according to claim 6, wherein the cladding encasing the heat generating source has a shape of a tube.

14. The fission reactor according to claim 13, wherein an exterior surface of the tube is part of the first side of the cladding and an interior surface of the tube is part of the second side of the cladding.

15. The fission reactor according to claim 14, wherein a longitudinal axis of the tube of cladding encasing the heat generating source is parallel to a longitudinal axis of the fission reactor.

16. The fission reactor according to claim 5, wherein the molten metal is sodium (Na), sodium-potassium (NaK), potassium (K), iron (Fe), copper (Cu), lead-bismuth (PbBi), tin-lead (SnPb), or tin (Sn).

17. The fission reactor according to claim 16, wherein the heat generating source, the cladding, and the molten metal are an integral, unitary structure.

18. The fission reactor according to claim 1, wherein the cladding separates the molten metal from the primary coolant.

19. The fission reactor according to claim 1, wherein the primary coolant volume has a shape of a tube.

20. The fission reactor according to claim 1, wherein the cladding encasing the heat generating source has a shape of a tube.

21. The fission reactor according to claim 20, wherein an exterior surface of the tube is part of the first side of the cladding and an interior surface of the tube is part of the second side of the cladding.

22. The fission reactor according to claim 21, wherein a longitudinal axis of the tube of cladding encasing the heat generating source is parallel to a longitudinal axis of the fission reactor.

23. The fission reactor according to claim 1, wherein the molten metal is sodium (Na), sodium-potassium (NaK), potassium (K), iron (Fe), copper (Cu), lead-bismuth (PbBi), tin-lead (SnPb), or tin (Sn).

24. The fission reactor according to claim 1, wherein the heat generating source, the cladding, and the molten metal are an integral, unitary structure.

25. A method of manufacturing a fuel cavity of a fission reactor, the method comprising: manufacturing a cladding structure defining an initial fuel cavity having an opening; loading molten metal and a heat generating source including the fissionable nuclear fuel composition into the initial fuel cavity via the opening while maintaining an expansion volume; and sealing the opening to form an assembled fuel cavity, wherein the cladding has a first side oriented toward the heat generating source and a second side oriented toward a primary coolant volume of the fission reactor, wherein the cladding separates the molten metal from the primary coolant volume, and wherein, at an operating temperature, the molten metal is in thermal transfer contact with the heat generating source and the first side of the cladding.

26. A method of manufacturing a fuel cavity of a fission reactor, the method comprising: manufacturing a cladding structure and a heat generating source including a fissionable nuclear fuel composition with an additive manufacturing process, wherein the cladding structure defines an initial fuel cavity and the heat generating source is located with the initial fuel cavity; loading molten metal into the initial fuel cavity while maintaining an expansion volume; and sealing the loaded initial fuel cavity with an additive manufacturing process to form an assembled fuel cavity, wherein the cladding has a first side oriented toward the heat generating source and a second side oriented toward a primary coolant volume of the fission reactor, wherein the cladding separates the molten metal from the primary coolant volume, and wherein, at an operating temperature, the molten metal is in thermal transfer contact with the heat generating source and the first side of the cladding.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The foregoing summary, as well as the following detailed description of the embodiments, can be better understood when read in conjunction with the appended drawings. It should be understood that the embodiments depicted are not limited to the precise arrangements and instrumentalities shown.

[0016] FIG. 1A shows a conventional fuel assembly with fuel elements comprising rods of fissionable nuclear fuel and non-fuel tubes and in which primary coolant flows through the assembly and around individual tubes.

[0017] FIG. 1B illustrates, in a magnified schematic, an example of the flow of primary coolant in a portion of a conventional fuel assembly.

[0018] FIG. 2 shows a perspective, radial cross-sectional and axial cut-away view of a portion of an alternative core design in which the cladding forms a primary coolant volume through which the primary coolant flows during operation of the fission reactor.

[0019] FIGS. 3A-3C schematically illustrate, for an example fission reactor in which the primary coolant flows through the assembly and around the cladding containing the heat generating source, fuel rod cross sections with different variants of the void space in which the molten metal is located to improve thermal coupling.

[0020] FIGS. 4A and 4B schematically illustrate, for an example fission reactor in which the primary coolant flows through a primary coolant volume formed by the cladding, a portion of an example variant of the void space in which the molten metal is located in an alternative nuclear core, such as, for example, that shown and described herein.

DETAILED DESCRIPTION

[0021] Embodiments of disclosed fission reactors comprise a heat generating source including a fissionable nuclear fuel composition, a primary coolant volume through which a primary coolant is flowable during operation of the fission reactor, and cladding encasing the heat generating source having a first side oriented toward the heat generating source and a second side oriented toward the primary coolant volume. The cladding encasing the heat generating source defines a fuel cavity in which the fissionable nuclear fuel composition is located. The fuel cavity is a closed volume and the cladding (or at least a portion of the cladding) separates the heat generating source from the primary coolant volume.

[0022] Disclosed embodiments of the fission reactor further include a molten metal in thermal transfer contact with the heat generating source and the first side of the cladding. The molten metal occupies at least a portion of a void space between the heat generating source and the first side of the cladding. However, the molten metal may navigate towards the center of the heat generating source in the event of cracking or degradation. Considering that a lack of contact, i.e., an offset or void space, between the heat generating source and the first side of the cladding would cause a reduction in thermal conductivity, the presence of molten metal in the void space provides thermal transfer contact between the heat generating source and the first side of the cladding.

[0023] Providing thermal transfer contact between the heat generating source and the first side of the cladding with a molten metal in the void space formed by the offset can be adapted to any of various geometric arrangements of fission reactors. In one example, the fission reactor operates with primary coolant that flows through the assembly and around the cladding containing the heat generating source. In such fission reactors, there are different variants of the void space between the heat generating source and the cladding in which the molten metal is located. FIGS. 3A-3C show example embodiments of these variants.

[0024] In some embodiments, the void space is formed as a result of offsetting the heat generating source from the cladding. FIG. 3A is a schematic of an axial cross-section of a fuel element, i.e., a cross-section in a plane perpendicular to the longitudinal axis of the fuel element, and illustrates an example of such an offset and the resulting void space. In FIG. 3A, the heat generating source 100, which includes a fissionable nuclear fuel composition, is encased within a cladding 102. Offsetting occurs where the dimensions/volume of the heat generating source 100 are less than the dimensions/volume of the inner surface 104 of the cladding 102, which creates a void space 106 between an outer surface 108 of the heat generating source 100 and a surface of the cladding 102 oriented toward the heat generating source 100, e.g., the inner surface 104 of the cladding 102.

[0025] The void space 106 mitigates stresses that can arise due to differences in the coefficient of thermal expansion (CTE) between the materials in any one structure as well as between materials in different, but in-contact structures, including the cladding material and the fissionable nuclear fuel composition by forming space for growth without intimate contact. Additionally, the void space 106 accommodates any manufacturing variations in the dimensions of components and reduces fine tolerance requirements. Also, the void space 106 provides a volume to contain or accommodate any reaction products, such as fission gas formation and associated swelling of the heat generating source 100.

[0026] Depending on the size of the offset, i.e., the differential between the outer surface 108 of the heat generating source 100 and the inner surface 104 of the cladding 102, the void space 106 is either larger or smaller, and the void space can vary from being present at the entire periphery of the heat generating surface (such as shown in FIG. 3A) to being present at a portion of the periphery of the heat generating source (such as shown in FIG. 3B). When a void space 106 is present at the entire periphery of the heat generating source 100 (such as shown in FIG. 3A), the heat generating source 100 is not attached to, or otherwise in contact with, the cladding 102 and effectively floats in the fuel cavity. When a void space 106 is present only at a portion of the periphery of the heat generating source 100 (such as shown in FIG. 3B), at least a portion of the heat generating source 100 can be in thermal transfer contact with the cladding 102. An example of such thermal transfer contact between the heat generating source 100 and the cladding 102 is illustrated in region 110 in FIG. 3B.

[0027] In further embodiments, the void space 106 can be a result of a defect, such as a chip, a pit, or a flat or convexity/concavity in the surface, in one or more of the heat generating source 100 or the cladding 102. FIG. 3C illustrates examples of such a void space 106 within the surface of the heat generating source 100 (analogous defects can be present within the inner surface 104 of the cladding 102). Furthermore, in operation, the heat generating source 100 can crack 112, for example, due to fission gas formation and natural fuel degradation. Molten metal can penetrate such a crack 112 and can improve the thermal transfer between the sides of the heat generating source 100 separated by the crack 112 as well as with the cladding 102. As a liquid, the molten metal will flow and occupy any contiguous network of void space within the fuel cavity, preventing intra-fuel peak temperature phenomena. Other purposeful cavities or voids, for example that are associated with the structure of the fuel having an open structure, such as a gyroid or lattes, could also be occupied by the molten material.

[0028] Any one or more of the above variants can be present in combination and the molten metal can bridge any of the thermal gaps from void spaces between the metal cladding and the fissionable nuclear fuel composition as well as any thermal gaps, such as cracks, arising in the fissionable nuclear fuel composition itself.

[0029] In another example, the fission reactor includes fuel assemblies or a fissionable nuclear fuel composition that is arranged between and around the primary coolant volume though which the primary coolant flows during operation of the fission reactor. Primary coolant flow path 54 in FIG. 2 is an example of such a primary coolant volume. In such fission reactors, there are different variants of the void space between the heat generating source and the cladding in which the molten metal is located. FIGS. 4A-4B show an example embodiment of this variant.

[0030] In some embodiments, the void space is formed as a result of offsetting the heat generating source from the cladding to account for manufacturing tolerance and assembly fit-up. FIG. 4A is schematic perspective view of a portion of a fission reactor illustrating fuel elements 150 (which contain the fissionable nuclear fuel composition) or more simply the fissionable nuclear fuel composition itself, arranged within a cladding structure 152 that defines a primary coolant volume 154 through which a primary coolant flows during operation (by enclosing a volume in which primary coolant flows), defines a fuel cavity (by enclosing a volume encasing the heat generating source), as well as forms a barrier between the fuel elements or fissionable nuclear fuel composition 150 and the primary coolant (when present in the primary coolant volume 154). FIG. 4B (which is a magnified portion of region 160 of FIG. 4A) is a schematic of an axial cross-section, i.e., a cross-section in a plane perpendicular to the longitudinal axis of the fuel element, and illustrates an example of a fuel element and encasing cladding and associated primary coolant volume and illustrating an example of an offset and the resulting void space. As shown in FIGS. 4A and 4B, the fuel assemblies or the fissionable nuclear fuel composition 150, i.e., the heat generating source, are arranged between and around the primary coolant volume 154. The heat generating source is encased within the cladding 152 and the primary coolant (such as water) flows through the primary coolant volume 154 to provide both a moderator for the fission reaction (depending on the reactor type) and a heat extraction medium for heat generated by a fission reaction in fuel elements or fissionable nuclear fuel composition 150. i.e., the heat generating source.

[0031] As seen in FIG. 4B, a void space 156 is formed at the periphery of the heat generating source as a result of offsetting the fuel assemblies or the fissionable nuclear fuel composition 150, i.e., the heat generating source, from the cladding 152. Offsetting occurs where the dimensions/volume of the fuel assemblies or the fissionable nuclear fuel composition 150, i.e., the heat generating source, are less than the dimensions/volume of a surface 158 of the cladding 152 oriented toward the heat generating source, which creates a void space 156 between a surface of the fuel assemblies or the fissionable nuclear fuel composition 150, i.e., the heat generating source, and a surface of the cladding 152 oriented toward the heating source, e.g., the outer surface 158 of the cladding 152.

[0032] The void space 156 mitigates stresses that can arise due to differences in the coefficient of thermal expansion (CTE) between the materials in any one structure as well as between materials in different, but in-contact structures, including the cladding material and the fissionable nuclear fuel composition by forming space for growth without intimate contact. Additionally, the void space 156 accommodates any manufacturing variations in the dimensions of components and reduces fine tolerance requirements. Also, the void space 156 provides a volume to contain or accommodate any reaction products, such as fission gas formation and associated swelling of the fuel assemblies or the fissionable nuclear fuel composition 150, i.e., the heat generating source.

[0033] Depending on the size of the offset, i.e., the differential between the outer surface of the fuel assemblies or the fissionable nuclear fuel composition 150, i.e., the heat generating source, and the surface 158 of the cladding 152 oriented toward the heating source, the void space 156 is either larger or smaller, and the void space can vary from being present at the entire periphery of the heat generating surface (such as shown in FIG. 4B) to being present at a portion of the periphery of the heat generating source. When a void space 156 is present at the entire periphery of the heat generating source (such as shown in FIG. 4B), the heat generating source is not attached to, or otherwise in contact with, the cladding and effectively floats in the fuel cavity. When a void space 156 is present only at a portion of the periphery of the heat generating source, at least a portion of the fuel assemblies or the fissionable nuclear fuel composition 150, i.e., the heat generating source, can be in thermal transfer contact with the cladding 152.

[0034] Similar to the embodiments in FIGS. 3A-3C, the embodiment in FIGS. 4A-4B can have one or more void spaces 156 that are a result of a defect, such as a chip, a pit, or a flat or convexity/concavity in the surface, in one or more of the fuel assemblies or the fissionable nuclear fuel composition 150, i.e., the heat generating source, or the cladding 152. Furthermore, in operation, the fuel assemblies or the fissionable nuclear fuel composition 150, i.e., the heat generating source, can crack, for example, due to fission gas formation or natural degradation. Molten metal can penetrate such a crack and can improve the thermal transfer between the sides of the heat generating source separated by the crack and cracks, as well as with the cladding 152. As a liquid, the molten metal will flow and occupy any contiguous network of void space within the fuel cavity.

[0035] The offset in the various embodiments disclosed herein can be any suitable size. In some embodiments, the offset is 0.005 to 0.01 inches (0.127 to 0.254 mm). In terms of volume, the volume of the heat generating source is 2% to 10% smaller, alternatively, 5% to 8% smaller, than the volume of the fuel cavity, which provides for a void space within the fuel cavity that can accommodate the molten metal. For example, on a volume basis relative to the volume of the fuel cavity, the heat generating source can occupy 92% to 93% of the volume of the fuel cavity and the molten metal can occupy 5% of the volume of the fuel cavity. The balance of the volume of the fuel cavity is left empty to allow for an expansion volume to accommodate (a) thermal expansion of the cladding forming the fuel cavity, the heat generating source, and the molten metal, and (b) fission gas release. The differences in the coefficient of thermal expansion for the various materials as well as the anticipated fission gas release and the effects at operational temperatures can be used to calculate the volume of molten metal required at room temperature assembly.

[0036] A suitable fissionable nuclear fuel composition applicable to the disclosed fission reactor and to be included in the heat generating source includes uranium oxide that is less than 20% enriched, uranium with 10 wt. % molybdenum (U-10Mo), uranium nitride (UN), and other stable fissionable fuel compounds. Burnable poisons may also be included. Typically, the fissionable nuclear fuel composition is in the form of a ceramic material.

[0037] Suitable molten metals for inclusion in the disclosed fission reactor and to be included in the fuel cavity include sodium (Na), sodium-potassium (NaK), potassium (K), iron (Fe), copper (Cu), lead-bismuth (PbBi), tin-lead (SnPb), and tin (Sn). Different metals and alloys can be suitably used depending on the cladding/fuel combination.

[0038] When either the fuel cavity (such as in FIGS. 3A-C) or the primary coolant volume (such as in FIGS. 4A-B) are embodied in the shape of a tube, the tube is generally oriented within the fission reactor with a longitudinal axis is parallel to a longitudinal axis of the fission reactor. Further, the tube can have any suitable cross-sectional shape (in an axial cross-section relative to the longitudinal axis of the fission reactor), although typically the cladding forming the walls of the tube has a shape of a circle or a hexagon. Example shapes of the cladding encasing the heat generating source include the shape of a cross-section of a hyperboloid of one sheet, the shape of a cross-section of a circle, the shape of cross-section of a hexagon, or the shape of an annular cross-section.

[0039] The molten metal fuel buffers disclosed herein can be manufactured by any suitable process. In a first manufacturing process, the cladding structure defining the fuel cavity is manufactured by metallurgical processes. The cladding structure is initially manufactured to a point where an opening remains in the fuel cavity, i.e., an initial fuel cavity such as a tube having side walls and one closed end. The initial fuel cavity is then loaded with the molten metal and the heat generating source, including the fissionable nuclear fuel composition. For example, a volume of molten metal is placed into the initial fuel cavity (e.g., via the open end of the tube) followed by the heat generating source (or vice versa). If liquid under the manufacturing conditions, the molten metal can be poured into the initial fuel cavity; if solid under the manufacturing conditions, suitable shaped piece(s) of the molten metal can be placed into the initial fuel cavity (suitable shaped to conform to the fuel cavity geometry and the heat generating source geometry). As previously noted, an expansion volume remains unoccupied. Once the initial fuel cavity is loaded, an end cap is placed over the opening and is sealed, for example, by welding or by a hot isostatic pressing (HIP) process, to form the assembled fuel cavity.

[0040] In a second manufacturing process, features of the fission reactor are manufactured as an integral, unitary structure using, for example, an additive manufacturing process. An example of a suitable additive manufacturing process utilizes 3-D printing of a metal alloy, such as a molybdenum-containing metal alloy, Zircaloy-4 or Hastelloy X, to form the noted cladding structural features. In other embodiments, the fissionable nuclear fuel composition and/or the molten metal can be included within the integral, unitary structure when suitable multi-material, additive manufacturing processes with multiple metals within the feedstock are employed. If the molten metal is not included in the additive manufacturing process, the additive manufacturing process can be paused, a volume of molten metal placed into the fuel cavity (either in liquid or solid form) and the additive manufacturing process continued to complete the structure of the closed, assembled fuel cavity. Other alloys that can be used when suitable multi-material, additive manufacturing processes with multiple metals within the feedstock are employed include: steel alloys, zirconium alloys, and Molybdenum-Tungsten alloys (for the shell of the reactor core); beryllium alloys (for the reflector); and stainless steel (for the containment housing).

[0041] Additive manufacturing techniques for the manufacture of the integral and unitary structure for the fission reactors and assembled fuel cavities disclosed herein can include the additional steps of: (a) predictive and causal analytics, (b) in-situ monitoring combined with machine vision and accelerated processing during the layer-by-layer fabrication of the structure, (c) automated analysis combined with a machine learning component, and (d) virtual inspection of a digital representation of the as-built structure. In addition, additive manufacturing technology can create complex geometries and, when coupled with in-situ sensors, machine vision imagery, and artificial intelligence, allows for tuning of the manufacturing quality as the components are built on a layer-by-layer additive basis (often, these layers are on the scale of 50 microns) and provides predictive quality assurance for the manufacture of such reactors and structures.

[0042] It is contemplated that various supporting and ancillary equipment can be incorporated into the disclosed fission reactor. For example, at least one of a moderator, such as a zirconium hydride neutron moderator, a control rod, such as iridium control rod, and a scientific instrument, such as a temperature sensor or radiation detector, can be incorporated into the fission reactor. Additionally, the control rods can also incorporate a neutron poison which absorbs neutrons and can be used to regulate the criticality of nuclear reactors. The neutron poison can absorb enough neutrons to shut down the fission reactor (e.g., when the control rods are completely inserted into the reactor space) or can be axially positioned to maintain criticality of the fission reactor (e.g., when the control rods are withdrawn from the reactor core a distance to allow a continuous fission chain reaction). Any suitable number of control rods and moderators can be used and suitably distributed throughout the reactor space in order to obtain one or more of a desired flux profile, power distribution, and operating profile. In exemplary embodiments, the control rods are threaded, which contribute to save axial space, maximizes control rod diameter, and allows for direct roller nut contact for reliable SCRAM operation. All or a subset of control rods can be individually controlled by independent motors to provide discrete reactivity control and/or for power shaping.

[0043] The disclosed arrangementsin which the molten metal enclosed in the fuel cavity is separated from the primary coolant and bridges thermal gaps in the heat transfer path from heat generating source to claddingpertains to any configuration in which a heat generating source including a fissionable nuclear fuel composition, whether a fuel element or the fissionable nuclear fuel composition per se, is surrounded by cladding. Although generally described herein in connection with a pressurized water reactor (PWR reactors) and with water as a primary coolant, the structures and methods disclosed herein can also be applicable to other reactor systems. This includes boiling water reactors (BWR reactors), deuterium oxide (heavy water) moderator reactors such as CANDU reactors, light water reactors (LWR reactors), pebble bed reactors (PBR reactors), nuclear thermal propulsion reactors (NTP reactors), both commercial and research reactors, and utilize other primary coolants, such as helium, hydrogen, methane, carbon dioxide, molten salts, and liquid metals. Any fuel-to-clad configuration in these various reactors may produce better nuclear core safety and performance characteristics if the molten metal fuel buffer technique disclosed herein is utilized.

[0044] Fission reactors disclosed herein can be used in suitable applications including, but not limited to, terrestrial power sources, remote power or off-grid applications, space power, space propulsion, isotope production, directed energy applications, commercial power applications, and desalination.

[0045] While reference has been made to specific embodiments, it is apparent that other embodiments and variations can be devised by others skilled in the art without departing from their spirit and scope. The appended claims are intended to be construed to include all such embodiments and equivalent variations.