For long-term storage, spent nuclear fuel (SNF) is placed in dry storage cask systems, commonly consisting of welded stainless steel containers enclosed in ventilated cement or steel overpacks. At near-marine sites, failure by chloride-induced stress corrosion cracking (SCC) due to deliquescence of deposited salt aerosols is a major concern. This paper presents a preliminary probabilistic performance assessment model to assess canister penetration by SCC. The model first determines whether conditions for salt deliquescence are present at any given location on the canister surface, using an abstracted waste package thermal model and site-specific weather data (ambient temperature and absolute humidity). As the canister cools and aqueous conditions become possible, corrosion is assumed to initiate and is modeled as pitting (initiation and growth). With increasing penetration, pits convert to SCC and a crack growth model is implemented. The SCC growth model includes rate dependencies on temperature and crack tip stress intensity factor. The amount of penetration represents the summed effect of corrosion during time steps when aqueous conditions are predicted to occur. Model results and sensitivity analyses provide information on the impact of model assumptions and parameter values on predicted storage canister performance, and provide guidance for further research to reduce uncertainties.
This progress report describes work being done at Sandia National Laboratories (SNL) to assess the localized corrosion performance of container/cask materials used in the interim storage of used nuclear fuel. The work involves both characterization of the potential physical and chemical environment on the surface of the storage canisters and how it might evolve through time, and testing to evaluate performance of the canister materials under anticipated storage conditions. To evaluate the potential environment on the surface of the canisters, SNL is working with the Electric Power Research Institute (EPRI) to collect and analyze dust samples from the surface of in-service SNF storage canisters. In FY 13, SNL analyzed samples from the Calvert Cliffs Independent Spent Fuel Storage Installation (ISFSI); here, results are presented for samples collected from two additional near-marine ISFSI sites, Hope Creek NJ, and Diablo Canyon CA. The Hope Creek site is located on the shores of the Delaware River within the tidal zone; the water is brackish and wave action is normally minor. The Diablo Canyon site is located on a rocky Pacific Ocean shoreline with breaking waves. Two types of samples were collected: SaltSmart™ samples, which leach the soluble salts from a known surface area of the canister, and dry pad samples, which collected a surface salt and dust using a swipe method with a mildly abrasive ScotchBrite™ pad. The dry samples were used to characterize the mineralogy and texture of the soluble and insoluble components in the dust via microanalytical techniques, including mapping X-ray Fluorescence spectroscopy and Scanning Electron Microscopy. For both Hope Creek and Diablo Canyon canisters, dust loadings were much higher on the flat upper surfaces of the canisters than on the vertical sides. Maximum dust sizes collected at both sites were slightly larger than 20 μm, but Phragmites grass seeds ~1 mm in size, were observed on the tops of the Hope Creek canisters. At both sites, the surface dust could be divided into fractions generated by manufacturing processes and by natural processes. The fraction from manufacturing processes consisted of variably-oxidized angular and spherical particles of stainless steel and iron, generated by machining and welding/cutting processes, respectively. Dust from natural sources consisted largely of detrital quartz and aluminosilicates (feldspars and clays) at both sites. At Hope Creek, soluble salts were dominated by sulfates and nitrates, mostly of calcium. Chloride was a trace component and the only chloride mineral observed by SEM was NaCl. Chloride surface loads measured by the Saltsmart™ sensors were very low, less than 60 mg m–2 on the canister top, and less than 10 mg m–2 on the canister sides. At Diablo Canyon, sea-salt aggregates of NaCl and Mg-SO4, with minor K and Ca, were abundant in the dust, in some cases dominating the observed dust assemblage. Measured Saltsmart™ chloride surface loads were very low (<5 mg m–2); however, high canister surface temperatures damaged the Saltsmart™ sensors, and, in view of the SEM observations of abundant sea-salts on the package surfaces, the measured surface loads may not be valid. Moreover, the more heavily-loaded canister tops at Diablo Canyon were not sampled with the Saltsmart™ sensors. The observed low surface loads do not preclude chloride-induced stress corrosion cracking (CISCC) at either site, because (1) the measured data may not be valid for the Diablo Canyon canisters; (2) the surface coverage was not complete (for instance, the 45º offset between the outlet and inlet vents means that near-inlet areas, likely to have heavier dust and salt loads, were not sampled); and (3) CISCC has been experimentally been observed at salt loads as low as 5-8 mg/m2. Experimental efforts at SNL to assess corrosion of interim storage canister materials include three tasks in FY14. First, a full-diameter canister mockup, made using materials and techniques identical to those used to make interim storage canisters, was designed and ordered from Ranor Inc., a cask vendor for Areva/TN. The mockup will be delivered prior to the end of FY14, and will be used for evaluating weld residual stresses and degrees of sensitization for typical interim storage canister welds. Following weld characterization, the mockup will be sectioned and provided to participating organizations for corrosion testing purposes. A test plan is being developed for these efforts. In a second task, experimental work was carried out to evaluate crevice corrosion of 304SS in the presence of limited reactants, as would be present on a dustcovered storage canister. This work tests the theory that limited salt loads will limit corrosion penetration over time, and is a continuation of work carried out in FY13. Laser confocal microscopy was utilized to assess the volume and depth of corrosion pits formed during the crevice corrosion tests. Results indicate that for the duration of the current experiments (100 days), no stifling of corrosion occurred due to limitations in the amount of reactants present at three different salt loadings. Finally, work has been carried out this year perfecting an instrument for depositing sea-salts onto metal surfaces for atmospheric corrosion testing purposes. The system uses an X-Y plotter system with a commercial airbrush, and deposition is monitored with a quartz crystal microbalance. The system is capable of depositing very even salt loadings, even at very low total deposition rates.
After an exposition of the materials used in DPCs and the factors controlling material corrosion in disposal environments, a survey is given of the corrosion rates, mechanisms, and products for commonly used stainless steels. Research needs are then identified for predicting stability of DPC materials in disposal environments. Stainless steel corrosion rates may be low enough to sustain DPC basket structural integrity for performance periods of as long as 10,000 years, especially in reducing conditions. Uncertainties include basket component design, disposal environment conditions, and the in-package chemical environment including any localized effects from radiolysis. Prospective disposal overpack materials exist for most disposal environments, including both corrosion allowance and corrosion resistant materials. Whereas the behavior of corrosion allowance materials is understood for a wide range of corrosion environments, demonstrating corrosion resistance could be more technically challenging and require environment-specific testing. A preliminary screening of the existing inventory of DPCs and other types of canisters is described, according to the type of closure, whether they can be readily transported, and what types of materials are used in basket construction.
This document identifies materials and material mitigation processes that might be used in new designs for standardized canisters for storage, transportation, and disposal of spent nuclear fuel. It also addresses potential corrosion issues with existing dual-purpose canisters (DPCs) that could be addressed in new canister designs. The major potential corrosion risk during storage is stress corrosion cracking of the weld regions on the 304 SS/316 SS canister shell due to deliquescence of chloride salts on the surface. Two approaches are proposed to alleviate this potential risk. First, the existing canister materials (304 and 316 SS) could be used, but the welds mitigated to relieve residual stresses and/or sensitization. Alternatively, more corrosion-resistant steels such as super-austenitic or duplex stainless steels, could be used. Experimental testing is needed to verify that these alternatives would successfully reduce the risk of stress corrosion cracking during fuel storage. For disposal in a geologic repository, the canister will be enclosed in a corrosion-resistant or corrosion-allowance overpack that will provide barrier capability and mechanical strength. The canister shell will no longer have a barrier function and its containment integrity can be ignored. The basket and neutron absorbers within the canister have the important role of limiting the possibility of post-closure criticality. The time period for corrosion is much longer in the post-closure period, and one major unanswered question is whether the basket materials will corrode slowly enough to maintain structural integrity for at least 10,000 years. Whereas there is extensive literature on stainless steels, this evaluation recommends testing of 304 and 316 SS, and more corrosion-resistant steels such as super-austenitic, duplex, and super-duplex stainless steels, at repository-relevant physical and chemical conditions. Both general and localized corrosion testing methods would be used to establish corrosion rates and component lifetimes. Finally, it is unlikely that the aluminum-based neutron absorber materials that are commonly used in existing DPCs would survive for 10,000 years in disposal environments, because the aluminum will act as a sacrificial anode for the steel. We recommend additional testing of borated and Gd-bearing stainless steels, to establish general and localized corrosion resistance in repository-relevant environmental conditions.
This progress report describes work being done at Sandia National Laboratories (SNL) to assess the localized corrosion performance of container/cask materials used in the interim storage of used nuclear fuel. The work involves both characterization of the potential physical and chemical environment on the surface of the storage canisters and how it might evolve through time, and testing to evaluate performance of the canister materials under anticipated storage conditions.
Results reported here continue to support the FY13 conclusion that direct disposal of DPCs is technically feasible, at least for some DPCs, and for some disposal concepts (geologic host media). Much of the work performed has reached a point where site-specific information would be needed for further resolution. Several activities in FY14 have focused on clay/shale media because of potential complications resulting from low thermal conductivity, limited temperature tolerance, and the need to construct hundreds of kilometers of emplacement drifts that will remain stable for at least 50 years. Technologies for rapid excavation and liner installation have significantly advanced in the past 20 years. Tunnel boring machines are the clear choice for large-scale excavation. The first TBM excavations, including some constructed in clay or shale media, are now approaching 50 years of service. Open-type TBMs are a good choice but the repository host formation would need to have sufficient compressive strength for the excavation face to be self-supporting. One way to improve the strength-stress relationship is to reduce the repository depth in soft formations (e.g., 300 m depth). The fastest construction appears to be possible using TBMs with a single-pass liner made of pre-fabricated concrete segments. Major projects have been constructed with prefabricated segmented liner systems, and with cast-in-place concrete liners. Cost comparisons show that differences in project management and financing may be larger cost factors than the choice of liner systems. Costs for large-scale excavation and construction in clay/shale media vary widely but can probably be limited to $10,000 per linear meter, which is similar to previous estimates for repository construction. Concepts for disposal of DPC-based waste packages in clay/shale media are associated with thermal management challenges because of the relatively low thermal conductivity and limited temperature tolerance. Peak temperature limits of 100°C or lower for clay-rich materials have been selected by some international programs, but a limit above 100°C could help to shorten the duration of surface decay storage and repository ventilation. The effects of locally higher peak temperatures on repository performance need to be evaluated (in addition to the effects at lower temperatures). This report describes a modeling approach that couples the TOUGH2 and FLAC3D codes to represent thermally driven THM processes, as a demonstration of the types of models needed.
Potentially corrosive environments may form on the surface of spent nuclear fuel dry storage canisters by deliquescence of deposited dusts. To assess this, samples of dust were collected from in-service dry storage canisters at two near-marine sites, the Hope Creek and Diablo Canyon storage installations, and have been characterized with respect to mineralogy, chemistry, and texture. At both sites, terrestrially-derived silicate minerals, including quartz, feldspars, micas, and clays, comprise the largest fraction of the dust. Also significant at both sites were particles of iron and iron-chromium metal and oxides generated by the manufacturing process. Soluble salt phases were minor component of the Hope Creek dusts, and were compositionally similar to inland salt aerosols, rich in calcium, sulfate, and nitrate. At Diablo Canyon, however, sea-salt aerosols, occurring as aggregates of NaCl and Mg-sulfate, were a major component of the dust samples. The seasalt aerosols commonly occurred as hollow spheres, which may have formed by evaporation of suspended aerosol seawater droplets, possibly while rising through the heated annulus between the canister and the overpack. The differences in salt composition and abundance for the two sites are attributed to differences in proximity to the open ocean and wave action. The Diablo Canyon facility is on the shores of the Pacific Ocean, while the Hope Creek facility is on the shores of the Delaware River, several miles from the open ocean.
Report RWEV-REP-001, Analysis of Postclosure Groundwater Impacts for a Geologic Repository for the Disposal of Spent Nuclear Fuel and High Level Radioactive Waste at Yucca Mountain, Nye County, Nevada was issued by the DOE in 2009 and is currently being updated. Sandia National Laboratories (SNL) provided support for the original document, performing calculations and extracting data from the Yucca Mountain Performance Assessment Model that were used as inputs to the contaminant transport and dose calculations by Jason Associates Corporation, the primary developers of the DOE report. The inputs from SNL were documented in LSA-AR-037, Inputs to Jason Associates Corporation in Support of the Postclosure Repository Supplemental Environmental Impact Statement. To support the updating of the original Groundwater Impacts document, SNL has reviewed the inputs provided in LSA-AR-037 to verify that they are current and appropriate for use. The results of that assessment are documented here.
A primary concern with dry storage of spent nuclear fuel is chloride-induced stress corrosion cracking, caused by deliquescence of salts deposited on the stainless steel canisters. However, limited access through the ventilated overpacks and high surface radiation fields impede direct examination of cask surfaces for CISCC, or sampling of surface deposits. Predictive models for CISCC must be able to predict the occurrence of a corrosive chemical environment (a chloride-rich brine formed by dust deliquescence) at specific locations (e.g. weld zones) on the canister surface. The presence of a deliquescent brine is controlled by the relative humidity (RH), which is a function of absolute humidity and cask surface temperature. This requires a thermal model that includes the canister and overpack design, canister-specific waste heat load, and passive cooling by ventilation. Brine compositions vary with initially-deposited salt assemblage, reactions with atmospheric gases, temperature, and the relative rates of salt deposition and reaction; predicting brine composition requires site-specific compositional data for atmospheric aerosols and acid gases. Aerosol particle transport through the overpack and deposition onto the canister must also be assessed. Initial field data show complex variability in the amount and composition of deposited salts as a function of canister surface location.