US swaps nuclear rods for high-precision control drums in next-gen reactor design

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US swaps nuclear rods for high-precision control drums in next-gen reactor design
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The MARVEL microreactor utilizes a novel 'tunable' reactivity system to provide carbon-free heat and power for remote locations.

Engineers at the Idaho National Laboratory have reached a critical milestone in the development of the MARVEL microreactor. They have successfully assembled and tested a novel Reactivity Control System that replaces traditional, bulky nuclear control rods with high-precision rotating drums.

“The control drum and control rod have the same basic functions — one translates, one rotates,” said Anthony Crawford, a researcher in INL’s mechatronics group. “But control drums are more challenging because of their inertia, bearings, penetrations and rotational dynamics. That’s why industry doesn’t always use them.”From rods to drumsFor over half a century, nuclear plants have regulated power by moving vertical “control rods” in and out of the reactor core. While reliable, these systems require significant vertical space. However, this is a feature the MARVEL reactor can not afford to have.Standing just 15 feet tall and 4 feet wide, which is roughly the size of two stacked telephone booths, MARVEL is designed for portability and rapid deployment. To maintain this “Lego-like” footprint, researchers swapped the traditional vertical rods for four rotating control drums.“Microreactors—particularly MARVEL—need more compact solutions,” added Crawford.“In MARVEL, the control drums are the heart of how we control the reactor during operation.”Addressing the challengesUnlike rods that slide, these drums sit on the periphery of the core and feature two distinct sides. The drums utilize reflective material to bounce neutrons back into the core to increase power, as well as absorber material that soaks up neutrons to slow or stop the reaction. By rotating these drums, operators can fine-tune the reactor’s output with extreme precision.For emergency “scrams” , the system is designed to release a clutch, allowing springs to snap the drums into the “absorber” position instantly.The transition from paper to hardware wasn’t without its “mechanical drama.” During prototyping, the team discovered that real-world friction was higher than CAD models predicted, which prevented the drums from snapping shut fast enough during a scram.The solution required a complete mechanical overhaul, including larger gearheads and redesigned dampers. The team also had to account for “backlash”—a pause in mechanical engagement similar to the “slop” in an old car’s steering wheel. In a nuclear environment, even a one-degree deviation matters.A modular futureCurrently, all five actuators have been assembled and installed on a test stand for integrated qualification. This system is built to NQA-1 standards, the gold-label benchmark for nuclear quality.Once operational, MARVEL won’t just provide 85 kilowatts of power; it will serve as a testbed for remote electricity for isolated communities, carbon-free heat for industrial processes, and hydrogen and chemical production.“The RCS parameters evolve with the reactor,” Crawford concluded, emphasizing that the system is “tunable” to account for fuel burnup and material swelling over time.“With tunability, we can adapt quickly — a capability that is applicable not just for MARVEL, but for other reactor designs too.”

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