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New Fuel Assemblies for Advanced Nuclear Technologies

Lead Research Organisation: University of Manchester
Department Name: Mechanical & Aerospace Engineering

Abstract

Meeting the growing energy demand from an increasing population, whilst addressing the depletion of fossil fuels and reducing greenhouse gases is the one of the grandest scale challenges of the 21st century. Currently, around 15% of the world's electricity is generated by nuclear fission energy, the largest supply by any non-greenhouse gas emitting resource and it will be critical to the country's energy mix if the UK is to meet its goal of net zero carbon emissions by 2050 as evidenced by the construction the UKs first nuclear power plant in two decades at Hinkley point C. However, new materials are being developed to improve the intrinsic safety of current nuclear reactors and for deployment in future nuclear power plant technologies.

The fuel materials to be studied in this project include uranium silicide, nitride and boride and cladding materials, silicon carbide, zirconium carbide and zirconium nitride will be studied to asses their feasibility for use in current and next generation nuclear power plants by using ion beam irradiation to mimic the conditions of a nuclear reactor and performed an in-depth characterisation of the materials post irradiation. These novel fuel materials are strong candidates to replace current uranium oxide fuel assemblies due to their much higher thermal conductivity, which will reduce fuel temperatures and buy vital time in an accident scenario, such as Fukushima like accident. The cladding materials also have much higher melting temperature than the currently used Zr alloy in water cooled reactors and so would delay or even mitigate meltdown scenarios. If these materials can prove themselves in current nuclear reactors for these reasons, they will also be promising for deployment in next generation nuclear power plants which will operate at much higher temperatures and under more extreme radiation damage.

Radiation damage from neutron bombardment causes atomic displacement which leads to defects in materials that can evolve as a function of temperature. In addition to this build-up of defects, gases (such as hydrogen and helium) can accumulate from transmutation reactions. These gases interact with the defects formed and can further degrade the mechanical and thermophysical properties. Research into the effects of radiation damage on the properties of these advanced non-oxide ceramics are in their infancy and will need to be better understood before the materials can be developed further and eventually deployed.

This project will use facilities at the Nuclear Fuel Centre for Excellence and the Dalton Cumbria Facility (DCF) based withing the Henry Royce Institute to manufacture, irradiate and perform micro and nano-structural characterisation of the materials post irradiation. Thermal analysis of the materials will then be performed at project partners at the University of Oxford and The Massachusetts Institute of Technology (MIT) will answer the key question - what effect does radiation damage have on the superior thermal conductivity of these materials and do they fall to levels below which developing these new materials becomes uneconomical? Finally, from the highly detailed understanding of the effect of radiation damage on their micro and nano-structure, can we reverse engineer these materials

Publications

10 25 50
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Harrison R (2021) Spark plasma sintering of (U,Ce)O2 as a MOx nuclear fuel surrogate in Journal of Nuclear Materials

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Townsend LT (2021) Sulfidation of magnetite with incorporated uranium. in Chemosphere

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Harrison R (2022) Development and comparison of field assisted sintering techniques to densify CeO2 ceramics in Journal of the European Ceramic Society

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Worth R (2022) Oxidation of U3Si2: The role of exothermic energy in Journal of Nuclear Materials

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Foster C (2022) Hydrotalcite Colloidal Stability and Interactions with Uranium(VI) at Neutral to Alkaline pH. in Langmuir : the ACS journal of surfaces and colloids

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Harrison R (2025) Flash sintering of UO2 pellets for nuclear fuel and wasteform applications in Journal of the European Ceramic Society

 
Description Silicon carbide (SiC) is a potential nuclear fuel cladding material and fusion armour material and as such will experience extreme conditions such as radiation damage. The thermal conductivity of SiC decreases dramatically at low irradiation doses in neutron environments, however, analysis of the mechanisms of this degradation and thus understanding of how to negate it are challenging due to the limited access to neutron irradiated samples and facilities to handle them. In this work we have used ion irradiation to mimic the radiation damage process which limits characterisation to the first few microns of the sample and renders classical bulk techniques inappropriate. We have therefore used advanced techniques to study the ion damaged thin surface layer and achieved parity with neutron samples - validating the use of these techniques as a way of emulating these processes. Furthermore, we can then perform details analysis of the samples and reveal that regardless of starting microstructure, once point defects are formed from radiation damage these become the dominant cause of decrease in thermal conductivity of SiC, which may have significant impact on manufacturing specifications.

We have also completed the measurements on uranium nitride, a novel nuclear fuel material showing that ion irradiation and gas atom implantation can mimic the processes. Detailed characterisation and heat treatments has revealed predictive tools to correlate radiation damage and materials characteristics to their thermal properties.
Exploitation Route the ion irradiation and characterisation techniques have been validated. This will generate a significant interest in the radiation damage/ceramics community as a screening tool for novel materials and composites. Furthermore, we have shown that regardless of starting material quality, all samples under radiation damage ultimately have the same thermal conductivity once irradiated which may have significant impact on the manufacturing specification of the materials.
Sectors Energy

Manufacturing

including Industrial Biotechology

 
Description The validation of the techniques has resulted in industrial partner collaboration with UKAEA to examine this a tool to develop silicon carbide materials for fusion related aspects, to drive towards fusion energy deployment to meet net-zero targets.
First Year Of Impact 2023
Sector Energy,Environment,Manufacturing, including Industrial Biotechology
Impact Types Societal

Economic

 
Description Best practice on Radiation Damage Workshop
Geographic Reach Europe 
Policy Influence Type Influenced training of practitioners or researchers
Impact 2 day workshop held at the Henry Royce Institute based on disseminating best practice on the planning, execution and characterisation of ion beam irradiation experiments attended by >80 delegated from PhD student, PDRAs, early career researchers and industry. Talks were from UoM, NNL, UKAEA, Sheffield University and University of Huddersfield. The success lead to the workshop becoming an annual event and the PI, RWH being asked to join an international committee for the OECD on best practice for characterisation techniques
 
Description Consultancy for national defence programme
Geographic Reach National 
Policy Influence Type Contribution to a national consultation/review
 
Description Contribution to international working group on best practice of microscopy of nuclear fuels
Geographic Reach Europe 
Policy Influence Type Influenced training of practitioners or researchers
Impact Development of practice and guidance report which has been rolled out to European industrial and academic institutes working in the field of nuclear materials research
 
Description Managing the UK Pu disposition
Geographic Reach National 
Policy Influence Type Contribution to a national consultation/review
URL https://www.dalton.manchester.ac.uk/managing-uk-plutonium-stockpile/
 
Description ESA Flash sintering RTGs
Amount £150,081 (GBP)
Organisation National Nuclear Laboratory 
Sector Public
Country United Kingdom
Start 08/2022 
End 08/2023
 
Description Microscopy of CuCrZr alloys for fusion applications
Amount £85,000 (GBP)
Organisation Culham Centre for Fusion Energy 
Sector Academic/University
Country United Kingdom
Start 03/2025 
End 07/2025
 
Description PDRA in actinide materials electron microscopy
Amount £525,000 (GBP)
Organisation Atomic Weapons Establishment 
Sector Private
Country United Kingdom
Start 03/2026 
End 03/2028
 
Description PhD studentship studying electronic structure of actinide materials
Amount £75,000 (GBP)
Organisation Atomic Weapons Establishment 
Sector Private
Country United Kingdom
Start 09/2025 
End 09/2029
 
Description Plutonium Ceramics Academic Hub
Amount £5,000,000 (GBP)
Organisation Nuclear Decommissioning Authority NDA 
Sector Public
Country United Kingdom
Start 11/2024 
End 10/2029
 
Description Bangor University 
Organisation Bangor University
Country United Kingdom 
Sector Academic/University 
PI Contribution UoM provide empirical data to Bangor University for modelling as well as access to research project materials results etc.
Collaborator Contribution Bangor provide academic time to NuFAN steering group committee and in-kind modelling simualtion
Impact Collaborative meetings at steering group but no common outputs to date yet.
Start Year 2022
 
Description MIT 
Organisation Massachusetts Institute of Technology
Country United States 
Sector Academic/University 
PI Contribution Access to ion irradiated materials and secondments of PI to MIT in ~2024 to undertake experiments on ion irradiated uranium materials
Collaborator Contribution Attendance at steering group committees and feedback on projects results to date and planning of experiments on thermal measurements to be undertaken at MIT ~2024 on uranium active samples
Impact Attendance at steering group committees and feedback on projects results to date and planning of experiments on thermal measurements to be undertaken at MIT ~2024 on uranium active samples. No outputs to date
Start Year 2022
 
Description NNL 
Organisation National Nuclear Laboratory
Country United Kingdom 
Sector Public 
PI Contribution Access to research data and results from the project to date
Collaborator Contribution Attendance at steering group committees and feedback on projects results to date
Impact Attendance at steering group committees and feedback on projects results to date
Start Year 2022
 
Description UKAEA 
Organisation UK Atomic Energy Authority
Country United Kingdom 
Sector Public 
PI Contribution Match funding of a PhD studentship in irradiation effects in SiC materials for nuclear fusion applications
Collaborator Contribution Match funding of a PhD studentship in irradiation effects in SiC materials for nuclear fusion applications
Impact No outputs yet, PhD student due to be in place Sep 2024
Start Year 2024
 
Description University of Oxford 
Organisation University of Oxford
Country United Kingdom 
Sector Academic/University 
PI Contribution Research partnership to examine the surface measurements of ion beam irradiation induced changes in thermal properties and validation against neutron irradiated data.
Collaborator Contribution Undertaken work to develop PDRA at UoM and make measurements of samples
Impact No outputs or outcomes yet from partnership
Start Year 2023
 
Description Westinghouse 
Organisation Westinghouse
Country United States 
Sector Private 
PI Contribution Supervision of EPSRC ICASE PhD studentship on radiation damage effects in uranium nitride
Collaborator Contribution Westinghouse have allocated a EPSRC funded ICASE studentship to the PI for further work on the irradiation behaviour of uranium nitride nuclear fuels
Impact The main outcome of this collaboration is the allocation a EPSRC funded ICASE studentship to the PI for further work on the irradiation behaviour of uranium nitride nuclear fuels the PhD student will be in place Sept 2024
Start Year 2023
 
Description Ion beam workshop 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact The event was a 2 day workshop on best practice on the use of ion beams for irradiation damage in materials and characterisation techniques hosted by the PI in the Henry Royce Hub building (UK centre for advanced materials) at UoM. The workshop brought together speakers from industry NNL, UKAEA and academia, UoM, University of Sheffield and Huddersfield. There was 80 attendees to the workshop from a range of backgrounds, both industry and academic and career stages, PhD, Post-doctoral, early career and established. The event also sparked lots of discussion and feedback was every positive on the best practice that was developed at the workshop and resulted in the publication of several how to guides on the Royce website which will provide a ongoing resource for users going forwards.
Year(s) Of Engagement Activity 2023
URL https://www.royce.ac.uk/events/royce-training-ion-beam-irradiation-and-characterisation-best-practic...
 
Description NuMAT conference presentation 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact Presented results at the nuclear materials research conference (NuMAT) in Ghent, Belgium 2022
Year(s) Of Engagement Activity 2022
 
Description Nuclear for Net Zero 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Public/other audiences
Results and Impact Presented a talk at a Pint of Science 2023 event called fuelling the future, on the use of nuclear power for net-zero to around 50 members of the public within a pub in manchester, this was followed by questions/debate on the issues and discussion about public attitude towards nuclear power and was generally very positively perceived.
Year(s) Of Engagement Activity 2023
URL https://pintofscience.co.uk/event/fuelling-our-future
 
Description Outreach at Sale high school Manchester 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact 200 year 6 six students attended an assembly on careers in STEM where the PI presented with another engineer from Industry on engineering challenges to address Net-Zero. This consisted of a presentation of videos, activities and other engagement actives to get the students to understand where our energy comes from and the consequences of such sources as well as discuss what it is to be an engineer/scientist. The event was organised via the STEM ambassador scheme and the teacher who organised the event reported a high amount of engagement after the day with students discussing more about the range of careers available in STEM subjects.
Year(s) Of Engagement Activity 2023
 
Description Presentation at NuFuel conference 2023 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Presented research of grant to audience at the 2023 nuclear fuel conference hosted in south of France. The outcomes of the presentation lead to two engagements with CEA in France and invitation for a site visit and collaboration on a EU working group for characterisation techniques for the OECD and the 2nd with KIT in Sweden on collaboration on uranium nitride samples.
Year(s) Of Engagement Activity 2023
 
Description Presentation at NuMAT conference 2024 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Presentation at of work funded through Fellowship at the Nuclear Materials conference 2024 hosted in Singapore
Year(s) Of Engagement Activity 2024
 
Description Uranium Science 2023 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Uranium Science conference 2023 was hosted at the Henry Royce Institute, R. Harrison was lead organiser - event was attended by >100 people from international audiences made up of early, mid and late career stages as well as PhD students covering topics of uranium science, fuel development, environmental, forensic and fundamental chemistry
Year(s) Of Engagement Activity 2023
URL https://www.royce.ac.uk/events/uranium-science-conference-2023/