Fuel performance simulation of iron-chrome-aluminum (FeCrAl) cladding during steady-state LWR operation

Highlights: • FeCrAl alloy cladding has been simulated using BISON, a finite-element fuel performance code. • Modifications to fuel enrichment and fuel rod geometry are needed to offset the neutronic penalty. • Several scoping analyses show the expected behavior for a variety of fuel and cladding creep parameters. • Fuel creep was assessed and modified to assess its role in the stress evolution of FeCrAl cladding. • Using the modified fuel creep model, manageable hoop stresses develop in the cladding from PCMI. - Abstract: Alternative cladding materials have been proposed to replace the currently used zirconium (Zr)-based alloys, in order to improve the accident tolerance of light water reactor (LWR) fuel. Of these materials, there is a particular focus on iron-chromium-aluminum (FeCrAl) alloys that exhibit much slower oxidation kinetics in high-temperature steam than Zr-alloys. This behavior should decrease the energy release due to oxidation and allow the cladding to remain integral longer in the presence of high temperature steam, making accident mitigation more likely. Within the development of these alloys, suitability for normal operation must also be demonstrated. This article is focused on modeling the integral thermo-mechanical performance of FeCrAl clad UO₂ fuel during normal reactor operation. Finite element analysis has been performed to assess commercially available FeCrAl alloys (namely Alkrothal 720 and APMT) as a candidate fuel cladding replacement for Zr-alloys, using the MOOSE-based fuel performance code BISON. These simulations identify the effects of the mechanical-stress and irradiation responses of FeCrAl and provide a comparison with Zr-alloys. In comparing these cladding materials, fuel rods have been simulated for normal reactor operation and simple steady-state operation. Normal reactor operating conditions target the cladding performance over the rod lifetime (∼4 cycles) for the highest-power rod in the highest-power fuel assembly under reactor power maneuvering. These power histories and axial temperature profiles input into BISON were generated from a neutronics study on full-core reactivity equivalence for FeCrAl using the 3D full core simulator NESTLE. The fuel rod designs and operating conditions used here are based on the Peach Bottom BWR with representative GE-12/14 fuel geometries, and design consideration was given to minimize the neutronic penalty of the FeCrAl cladding by changing fuel enrichment and cladding thickness. Individual sensitivity analyses of the fuel and cladding creep responses were also performed, which indicated the influence of compliance for each material, separately, on the stress state of the fuel cladding. These parametric analyses are performed using steady-state operating conditions such as a simple axial power profile, a constant cladding surface temperature, and a constant fuel power history.