CURRENTCURRENT STATUSSTATUS ANDAND FUTUREFUTURE PLANPLAN OFOF FASTFAST REACTORREACTOR DEVELOPMENTDEVELOPMENT ININ INDIAINDIA
Baldev RajBaldev Raj Distinguished Scientist & Director
Indira Gandhi Centre for Atomic Research Kalpakkam
Oarai R&D Centre, Japan Atomic Energy Agency May 21, 2009 Motivation for More & Clean Energy -> Better quality of life
Increase in Demand Cost effectiveness
Energy Challenges
Reduced Emissions Public and Political acceptance
Energy defines the index of quality of life. But has to meet many challenges
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THREE STAGE NUCLEAR POWER PROGRAM
95 89 90 84 86 84 90 85 79 85 (%80 ) -----> 75 82 72 80 75 69 75 70 Capacity Factor / 71 65 67 60 A vailability 60 55
50 1995-96 1996-97 1997-98 1998-99 1999-00 2000-0102-03 2001-02 20
Stage – I PHWRs Stage II Stage – III and Beyond Fast Breeder Reactors Fast Breeder Reactors Thorium Based Reactors • 15 Operating • 3 Under construction • 40 MWth FBTR Operating • 30 kWth KAMINI Operating • Several others planned Technology Objectives realised • 300 MWe AHWR Under • Construction planned Regulatory Examination for 700 MWe units • Gestation period • 500 MWe PFBR • POWER POTENTIAL = being reduced under construction 155,000 GWe y ≅≅≅ • POWER POTENTIAL • Availability of ADS 10,000 MWe • POWER POTENTIAL: Minimum can enable early LWRs 530 GWe introduction of Thorium • 2 BWRs Operating • Participation in ITER • 2 VVERs under towards development of construction fusion technology
Kalpakkam – Unique Nuclear Site in the World housing all Three Stages & Clo sed Fuel Cycle Facilities
IGCAR – Mission Oriented Centre for Development of Science Based Techno logy for FBR Indian energy resources and Nuclear Contribution ADVANTAGES OF FAST BREEDER REACTORSADVANTAGES OF FAST BREEDER REACTORS
Energy Potential 1 kg of coal 3 kWh 1 kg of oil 4 kWh 1 kg U (natural) 50,000 kWh (if reprocessed) 3,500,000 kWh
No. of neutrons generated from fission per neutron absorbed in the fissile material
Reactor Nat.U U 235 U 233 Pu 239 (BTCE) Thermal 1.34 2.04 2.26 2.06
Fast < 1 2.20 2.35 2.75
Ø Effectively utilizes the natural uranium (nearly 80 %) Ø Consumes the depleted fuel discharged from thermal reactors Ø Breeds more fissile material (plutonium) than consumed
With a large number of thermal reactors operating and planned worldwide, the limited available natural uranium would be consumed very fast. On the other hand, with FBRs, energy supply can be ensured over a few centuries. Advantages of FBR Advantages of FBR –– contdcontd ……
FBR is important from waste management and environmental considerations. Burns actinides and long lived radioactive fission products. Generation of precious metals such as Cs, Pd etc which have many important societal applications and can be extracted from its waste (wealth from waste).
Current trends in oil prices and available uranium resources bring FBR with closed fuel cycle to focus WORLD FAST REACTOR SCENARIOWORLD FAST REACTOR SCENARIO The interest in FBR has been renewed internationally
• China, France, India, Japan, Korea, Russia, and USA have interest in FRs • France, Japan, and USA have signed an MOU to cooperate under the Global Nuclear Energy (GNEP) Partnership to demonstrate the feasibility of the sodium cooled fast reactor technology to accomplish sustainability requirements • International collaborative programmes on innovative reactors such as Generation IV & INPRO are focusing on FRs • 390 reactor years operating experience including test reactors
FBR provides ever growing challenges & opportunities in science and technology FBR PROGRAMME IN INDIAFBR PROGRAMME IN INDIA
Ø India started FBR programme with the construction of FBTR Ø FBTR is a 40 MWt (13.5 MWe) loop type reactor. The design is same as that of Rapsodie Fortissimo except for incorporation of SG and TG (agreement signed with CEA, France in 1969). Ø FBTR is in operation since 1985. Ø 500 MWe Fast Breeder Reactor Project (PFBR) through Indigenous design and construction Ø Govt. granted financial sanction for construction in Sep 2003. Ø Construction of PFBR has been undertaken by BHAVINI. Ø PFBR will be commissioned by 2010. Ø Beyond PFBR: 4 units of 500 MWe FBR (twin unit concept) similar to PFBR with improved economy and enhanced safety by 2020. Ø Subsequent reactors would be 1000 MWe units with metallic fuel l
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4 L PFBR REACTOR ASSEMBLY
01 MAIN VESSEL
02 CORE SUPPORT STRUCTURE
03 CORE CATCHER
04 GRID PLATE
05 CORE
06 INNER VESSEL
07 ROOF SLAB
08 LARGE ROTATABLE PLUG
09 SMALL ROTATABLE PLUG
10 CONTROL PLUG
11 CSRDM / DSRDM
12 TRANSFER ARM
13 IHX
14 PRIMARY SODIUM PUMP
15 SAFETY VESSEL
16 REACTOR VAULT PFBR SECONDARY SODIUM MAIN SYSTEM
Number of sodium loops : 2 Primary Pumps : 2 Nos. Secondary Pumps : 2 Nos. IHX : 4 Nos. SG Modules : 8 Nos. Turbo-Generator : 1 No. CHALLENGES IN SCIENCE AND TECHNOLOGY OF FBR
Science Engineering Technology
• Metals and their performance • Design for components at • Manufacture of large under high temperature, high temp & long life dimensioned welded thin sodium, irradiation • Design of mechanisms shell structures made of environments over the long operating in sodium and austenitic stainless steel reactor life argon cover gas space petals with close tolerances • Development of non metallic • Design to accommodate Na (~thickness) eg. Main & materials operating at high leak & Na water reactions safety vessels, inner temperatures and radiation • Seismic design of vessel, thermal baffles, etc environments (special high interconnected buildings, density concrete, elastomers, • Machining of large components and thin shells ceramics, cables, etc) dimensioned and tall with fluid structure interaction slender components with • Sodium chemistry, aerosol • ISI &repair of reactor internals stringent tolerances (grid behaviour, sodium fire and sodium water reactions • High temp. fission chamber plate, absorber rod drive and component handling • Special sensors for sodium systems) applications (detection of water leaks in steam generator, • Fabrication of large size sodium leaks, purity box structures with measurements, level detectors) controlled distortions • Thermal hydraulics and • Hard facing technology Structural mechanics (turbulences, instabilities, gas • Development of Inflatable entrainments, thermal striping, seals and large size stratifications, ratcheting, etc) bearings DESIGN OF CORE FOR HIGH BURNUPDESIGN OF CORE FOR HIGH BURNUP
Design Parameters for High Burnup
• Increasing fission gas plenum • Increasing the pellet density • Decreasing the smeared density • Annular pellet concept • High performance materials (High void swelling resistance, low Irradiation creep and improved high temperature properties POOL THERMAL HYDRAULICS POOL THERMAL HYDRAULICS
IHX • Large temperature difference (150 K) existing in IHX
CP hot pool leads to risk of thermal stratification. CP • Stratification causes sharp axial gradient in the adjoining metal wall. • Stratified layers oscillate causing high cycle
fatigue Core Core • Mitigation of stratification calls for novel thermal hydraulic design of hot pool component
• Due to large pool surface area and free surface velocity, there is risk of argon gas entrainment within hot & cold pools. • Gas entrainment can cause reactivity oscillations in case of bulk of argon bubble entering in to the core • General design guidelines is to Minimize the Free Surface Velocity to Mitigate Gas Entrainment in Hot Pool THERMAL STRIPING DESIGN THERMAL STRIPING DESIGN
Thermal striping limits on structural wall
Thermal striping values (CFD) SEISMIC DESIGN SEISMIC DESIGN
• Development of seismic design criteria • Ensuring the reactor scramability • Analysis of nuclear island connected buildings • Investigation of pump seizure (NICB) and also extract floor response spectra at • Shake table testing for validation of analysis and various component support locations qualification • Seismic analysis of reactor assembly to derive • Long term R&D: behaviour of bearing, non linear sloshing, seismic forces parametric instability of thin shells, study of cliff edge • Investigation of buckling of thin shells effects, fluid structure interaction of perforated structures
NICB model for seismic analysis FEM model of RA Buckling modes of thin vessels Drop time of absorber rods
Shake table tests on RA model Experiment TheoryTheory Experiment Theory ANALYSIS OF SHOCK STRUCTURE INTERACTION: HIGHLIGHTS
Mechanical consequences of Core Disruptive Accident (CDA)
• Complicated loading scenarios on the vessel & top shield have been realistically simulated • A series of ~65 tests have been conceived in a novel way and successfully completed at Terminal Ballistic Research Laboratory, Chandigarh over the period of 4 years • Sophisticated instrumentations were deployed to Structural integrity analysis of PFBR RA under CDA derive extensive data for investigations.
Demonstration of structural integrity by tests Validation of computer code FUSTIN CHALLENGING R&D: COMPONENT TESTING
Seismic testing of reactor assembly Simulation of complex thermal hydraulics phenomenon Prototype testing of components under actual environment (sodium & temperature)
Transfer Control & safety rod Diverse safety rod arm drive mechanism drive mechanism Components for sodium testing SODIUM FIRE AND SODIUM LEAK COLLECTION TRAYS • Sodium leak in the sodium pipelines can cause sodium fire which is the critical issue in the sodium cooled FBR design • Efficient leak detection systems • Optimisation of sodium leak collection tray design towards minimising the effects of sodium fire • Full Scale demonstration in SGTF (under operation) and Sodium Fire Test Facility (under construction)
Draining of Leaked Na into LCT
Performance Testing of LCT CFD simulation of Na draining Steam Generator Test Facility NDE: CHALLENGESNDE: CHALLENGES
Eddy Current Imaging Technique for Detection Inspection of fuel pin end plug of Voids in Sodium Bonded Metallic Fuel Pins
ISI of bimetallic SPIDER ROBOT On Mockup Steam Generator Tube (SS & CS) weld Sheet
Inservice Inspection of Main Vessel In Service Inspection of stem generator Cover gas hydrogen meter Electrochemical in-sodium hydrogen meter SENSORS FOR SODIUM APPLICATION (DEVELOPED AT IGCAR)
Polymer electrolyte based Electrochemical in-sodium Eddy Current hydrogen sensor carbon meter Flow Meter Risk Oxygen Meter Special Features
Temp. range – up tp 450ºC
Resolution – from 13 ppb
Semiconductor oxide Sensitivity –ppb to percentage based Compact hydrogen sensor Response time – from 30 s Sodium Ionisation Detector ELECTROCHEMICAL HYDROGEN METER (ECHM) FOR SODIUM CIRCUITS
Pre amplifier
45 ECHM 38 housing 30 23 Meter testing 15 8 Calibration setup Calibration pot emf / mV 0 8 15 Sodium 0.1 0.2 0.3 0.4 loop 0.04 0.05 0.06 0.07 0.08 0.09 CH / ppm Laboratory Calibration Display unit E = RT/2F ln (p (sample )/ p (ref )) H 2H 2 1/2 pH2 (sodium) related [H] Na by Sievert’s Law (pH 2) = C H / k
Performance of ECHM in FBTR east sodium circuit
Response of ECHM in SteamGenerator Test Facility INTELLIGENT WELDING – ON LINE MONITORING & PROCESS CONTROL
Digital Welding Power Source
Welding Torch IR Camera
Base Metal Weld Metal
Thermal Images of Weld Image Processing & Neuro fuzzy based Control System
• Views weld pool from arc side using infrared camera – Provides adaptive control for weld bead penetration – Acts as seam tracking device
• Thermal image of weld pool & surrounding area • Used to control welding parameters & maintain correct weld bead penetration APPLICATION OF RESULTS FROM BASIC RESEARCH APPLIED TO HARDFACING OF PFBR COMPONENTS
800 Colmonoy 5 at 300 K Colmonoy 5 at 673 K 700 Colmonoy 5 at 823 K Stellite 6 at 300 K Stellite 6 at 673 K 600 Stellite 6 at 823 K
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Estimated Vickers hardness (HV, 10 kgf) 200 0 5 10 15 20 25 30 35 40 Time of exposure (ageing) at 823 K (years) Predicted reduction in hardness with time Hardfacing of PFBR Grid Plate Normal Load : 120 N Sliding Velocity : 0.25 m/s • Ageing studies on Ni base hardfacing alloys
Near Interface (0.15 0.2 mm) Single layer confirmed no significant deterioration in hardness Double layer
0.016 with high temperature exposure . •Hardness measurement, microstructural 0.012
→ examination and wear tests confirmed significant Effect of dilution reduction in properties by dilution from base metal. 0.008 on wear loss of Hence, a minimum deposit thickness of 2 mm and the deposit Plasma Transferred Arc process were Weight Loss (g) 0.004 recommended .
0 •Hardfacing of 6 m diameter grid plate has been 0 450 900 1350 1800 carried out without cracking by Mechanized Plasma Sliding distance (m) → Transferred Arc Process Hardfacing: A Technological Challenge in Reactor Component Fabrication POST – IRRADIATION EXAMINATION FACILITY (PIE) Establishment of Leak Tight Concrete Hot Cells, Lead Cells, Glove boxes
Installation of Remote Handling and Viewing Devices MSM, Power Manipulators, In cell Cranes Hot cell Facility Periscopes, Shielding Windows, CCD Remote Examination Facilities Alpha Tight Fuel Transfer Systems Inert Gas Ventilation System In cell Equipments & Gadgets Laser Based Dismantling Machine, Metrology, Non Destructive Techniques, Metrological Equipment Tensile Testing & Laser Dismantling Machine Neutron Radiography, Metallography, Fission Gas extraction, Mechanical Testing , Electron Microscopy
Comprehensive Facilities Established for assessing the Irradiation Performance of FBTR Fuel Remote Metallography Fission Gas Extraction LIFE EXTENSION OF FBTR FUEL THROUGH PIE
(U 0.3 ,Pu 0.7 )C fuel + SS316 Cladding & Wrapper Complete closure of Fuel Clad gap with increasing burn up
Low Fission gas release ( ~15 %) and Plenum pressure (~2 MPa) in Carbide fuel pins 25GWd/t 50GWd/t Progressive increase in the Dimensions of Wrapper & Cladding
Sufficient Strength & Ductility of Cladding & Wrapper (at 80 dpa)
No Fuel pin/ Wrapper Failure in the Reactor 100GWd/t 155 GWd/t Strength Changes of SS316 Cladding with dpa 11.5% (485 C) FBTR fuel burnup enhanced through 3.5% ∆V / V % (430 C) PIE and Thermo- Mechanical analysis from 25 GWd/t to 155
Void Swelling of SS316 Clad & Wrapper GWd/t Digital Instrumentation & Control Reactor Simulator for PFBR
• About 15000 process signals are • Design basis events are modeled to provide processed by distributed digital control comprehensive training to plant operators system, developed in house with about • Integrated modeling of I&C systems for 50 000 lines of code effective simulation of plant operation • Digital design and development has • Dedicated simulator for Fuel Handling been verified & tested w.r.t software & Systems and operation hardware • 3 D animated human machine interface • Pulse Coded Safety Logic System has system has been developed been developed to ensure fail safe • Real time simulator for the fast transient operation of the plant events under development Components manufactured under technology development CONSTRUCTION OF PFBR: STATUS
Form tolerance specified for vessels : < thk Achieved : < ½ thk Insignificant weld
repair Main vessel SG
Ø Technology with strong R&D backup Ø Manufacturing technology development completed prior to start of project Ø Capability of Indian industries to manufacture high technology nuclear components demonstrated (main vessel, safety vessel, steam generator, grid plate) PFBR will be commissioned by Sept 2010 REPROCESSING OF FAST BREEDER RECTOR HIGH BURN UP FUELS
Centrifugal Extractor
Single Pin Chopper Modelling and Simulation
Design of Process Flow Sheet
CORAL facility demonstrated the successful reprocessing of mixed carbide fuels with high Pu with a burn up of 100,000 MWd/t for the first time in the world Online Monitoring
16 Stage Bank
CORAL Facility MATURITY MAPPING
Repeatability Manufacture Scale up Design Performance Integration Production evaluation Implementation Analysis Modeling Experiment Technology Integration Review Code development Pilot plant Simulation Simulation Experiment Model Simulation & Equipment Data Modeling Software Analysis Continuum Process Design criteria Synthesis Hardware Criteria Micro
Science & Technology & Science mechanics Principles Data generation Sensor Philosophy Chemistry
Reactor Design Material I & C Safety Reprocessing Physics Domains
• Judicious Mixing of step by step and concurrent • Inter woven • Multi & Interdisciplinary • Matrix management Marching from Science to Technology A Case Study : PFBR Fuel Subassembly
Potential : 10 8 kWh With int. breeding : 1.5.10 8 kWh Design Interfacing with Extracted : 10 7 kWh Reactor Physics, Power density : 416 W/ cc Technology Limited by structural materials Material Technology, • Clad 2.6 m & 0.4 mm thk Fuel cycle technology and • Tight tolerances Fine manufacturing technology Surface Finish • Wrapper 3.6 m long • Verticality 3 mm • Annular pellet
Evolution Structural Mechanics • Fuel pin Integrity Safety • Core Mechanics • Novel design features and design • Core Seismic provisions ( Radial Coolant entry & • Flow Induced Vibration multiple holes, Blockage Adaptor, • End Plug Weld Helical spacer Wire) to prevent flow blockages • Impact Analysis Science • Simulation of flow blockage & propagation and their effects • Reactor Physics • Material Characterization • Benchmark experiments Thermal Hydraulics (Physical & Chemical) • Optimum flow zoning • Fuel Chemistry • Maximise foolant mixing (Thermodynamics & Kinetics) • Flow distribution • Radiation damage • Flow characterization • Modeling & Experimental • Temperature Mapping Verification • Hot spot analysis • Post Irradiation Examination Totality of Fuel Design & Interfaces to Make the System Robust Design and Technological Challenges of Typical PFBR Components and Structures Grid Plate Steam Generator NICB
Box type structure made of top Tall component of about 25 m Nuclear island consisting of and bottom plates connected by height and has more than 500 eight inter connected buildings intermediate shell and 1758 tubes, made of modified 9 Cr 1 resting on 6 m thick common sleeves all with SS 316 LN Mo steel. base raft, is novel innovative Hard facing with colmonoy By adopting in bore welding, civil design concept introduced deposits which is its largest tube to tube sheet joint are first time in an FBR industrial utilization carried out with stringent Designed to achieve compact Tight machining and assembly acceptance standards on layout giving due considerations tolerances (<0.2 mm horizontality dimensions and weld quality for maintenance, safety. and 0.5 mm verticality) The maximum concavity Adoption of many innovative Assembly of a large number of achieved is practically zero and construction methodologies to parts (~14900) maximum weld thinning is less proceed civil construction and than the permissible < 0.2 mm mechanical component erection Top and bottom plates are concurrently perforated by removal of about 80 Welding technology has been % of the material and called for matured based on elaborate Seismic design of nuclear island innovative handling techniques . technology development calls most challenging and exercises and many trials. advanced analysis techniques Concrete mass 3.8 lakhs tonnes Fast Breeder Reactor Project
State of art concepts Incorporation of World wide FBR experiences
P latfo dem rm f ons or i trat nter ion o natio f asp nal irati ons
Convergence Synergism with Academic, R&D Consolidation & institutions and Validation Industries Cost comparison of Fast Reactors CAPITAL COST REDUCTION MEANS FOR FUTURE FBRS
4x500 MWe FBR
Twin Unit Concept with common fuel building and spent fuel storage Reduction in main vessel diameter Cost Reduction due to Investment in R&D In-Vessel purification system Reduction in height of each components supported on top shield and entire reactor assembly by improved design of top shield Use of cost optimised materials of construction Enhanced burn-up to reduce fuel cycle cost 1000 MWe FBRs Reduced construction time (7 y to 5 y) Metallic fuel Enhanced design life 40 y to 60 y Ferritic steels for core Enhanced capacity factor (75 to 85 %) UEC competitive to that of fossil power plants UEC is comparable to that of fossil power plants Vision Statement: IGCAR & BHAVINI
To be a global leader in design, construction and operation of sodium cooled fast breeder reactors and associated fuel cycle facilities
250 GWe (2052)
2.5 GWe (2020)
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e p s S Generic Challenges to Attract Bright Minds to Nuclear Engineering • Gas Entrainment in Liquids • Improved Safety with Liquid Metal • Material Modeling with Micromechanics Based Approach • Complex Thermal Hydraulics and Two Phase Flow • CFD and Power Plant Dynamics • Seismic Integrity Assessment • Advanced Civil Design with Interconnected Structures • Prediction of Ageing and Damage Mechanisms for Long and Reliable Plant Life with NDE Techniques Fuel Cycle Bulk separation processes at extremely low concentrations Single molecule spectroscopy Microstructure tailoring to achieve near zero corrosion rate Design with Enhanced Conceptualisation and Modelling Modelling to enable long life systems Development of FBR and RESEARCH associated Fuel Cycle INSTITUTE Technologies
•Construction and commissioning of FBR plant IGCAR •Construction and operation of fast reactor TODAY fuel reprocessing plant UNIVERSITY INDUSTRY •Development of enriched boron production facility •Widespread Mission Centre with interactions with University Status industry with co- responsibility with BHAVINI Global Imbalances
Consumption Per Capita - 2007 : Tonnes Oil Equivalent
Scarce Soil Fertility
World needs to agree and implement (with time frame) adequate and robust processes for equity before it becomes root cause of destruction of this beautiful and unique planet.
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CHALLENGES, APPROACHES AND TARGETS a
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