Implicit in any engineering design is an underlying optimization problem, although the exact objective function to be optimized is rarely stated explicitly. Nuclear systems optimization is as old as the discipline of nuclear engineering. Advanced manufacturing in the nuclear industry has opened the door for the re-examination of optimization in a way in which it was not possible before, namely, determining the optimal geometry for a given objective function. A trivial example is the sphere as the shape that minimizes the volume (or mass) of bare fissile material in a critical configuration. However, the problem becomes less trivial under even the simplest of multiphysics considerations. In this work, we develop the solution methodology for finding the minimum volume geometric configurations under the multiphysics constraints of 1,500 pcm excess reactivity and maximum fuel temperature of 618°C under forced-flow cooling conditions. Constraining the solution geometry only to right cylinders, surprisingly yields two disjoint solution regions. Flat, wide (disk-like) cylinders and tall, narrow (rod-like) cylinders both satisfy the constraints and yield very similar minimal volumes. However, the ultimate pursuit of this work is truly arbitrary geometry.
Early cycle activities under the Transformational Challenge Reactor (TCR) program focused on analyzing and maturing four reactor core design concepts: two fast-spectrum systems and two thermal-spectrum systems. A rapid, iterative approach has been implemented through which designs can be modified and analyzed and subcomponents can be manufactured in parallel over time frames of weeks rather than months or years. To meet key program initiatives (e.g., timeline, material use), several constraints—including fissile material availability (less than 250 kg of HALEU), component availabilities, materials compatibility, and additive manufacturing capabilities—were factored into the design effort, yielding small (less than one cubic meter in volume) cores with near-term viability. The fast-spectrum designs did not meet the fissile material constraint, so the thermal-spectrum systems became the primary design focus. Since significant progress has been made on advanced moderator materials (YHx) under the TCR program, gas-cooled thermal-spectrum systems using less than 250 kg of HALEU that occupy less than 1 m3 are now feasible. The designs for two of these systems have been evolved and matured. In both thermal-spectrum design concepts, bidirectional coolant flow is used. Coolant flows down through YHx moderator elements and is reversed in a bottom manifold and core support structure, and then flows up though or around the fuel elements. The main difference between the two thermal-spectrum design concepts is the fuel elements—one uses traditional UO2 ceramic fuel, and the other uses UN-bearing TRISO fuel particles embedded inside a SiC matrix. Core neutronics and thermal performance for these systems are assessed and summarized herein.
The authors developed an artificial intelligence (AI)-based algorithm for the design and optimization of a nuclear reactor core based on a flexible geometry and demonstrated a 3× improvement in the selected performance metric: temperature peaking factor. The rapid development of advanced, and specifically, additive manufacturing (3-D printing) and its introduction into advanced nuclear core design through the Transformational Challenge Reactor program have presented the opportunity to explore the arbitrary geometry design of nuclear-heated structures. The primary challenge is that the arbitrary geometry design space is vast and requires the computational evaluation of many candidate designs, and the multiphysics simulation of nuclear systems is very time-intensive. Therefore, the authors developed a machine learning-based multiphysics emulator and evaluated thousands of candidate geometries on Summit, Oak Ridge National Laboratory’s leadership class supercomputer. The results presented in this work demonstrate temperature distribution smoothing in a nuclear reactor core through the manipulation of the geometry, which is traditionally achieved in light water reactors through variable assembly loading in the axial direction and fuel shuffling during refueling in the radial direction. The conclusions discuss the future implications for nuclear systems design with arbitrary geometry and the potential for AI-based autonomous design algorithms.
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