ORNL-5018 Program Plan for Development of Molten-Salt Breeder Reactors L.E. McNeese and Staff of the Molten-Salt Reactor Program DECEMBER 1974 OAK RIDGE NATIONAL LABORATORY Oak Ridge, Tennessee 37830 operated by UNION CARBIDE CORPORATION for the U.S. ATOMIC ENERGY COMMISSION Contents 1 Program Plan Overview 23 1.1 Introduction and Summary . 23 1.2 Status of Technology and Planned Development Activities . 24 1.2.1 Development of structural metal for primary and secondary circuits . 25 1.2.2 Fuel processing . 26 1.2.3 Fuel processing materials development . 27 1.2.4 Chemical research and development . 29 1.2.5 Analytical research and development . 30 1.2.6 Reactor safety . 31 1.2.7 Reactor design and analysis . 32 1.2.8 Graphite development . 34 1.2.9 Reactor technology development . 35 1.2.10 Maintenance . 36 1.2.11 Instrumentation and controls development . 38 1.2.12 Molten-Salt Test Reactor mockup . 38 1.2.13 Molten-Salt Test Reactor . 39 1.2.14 Molten-Salt Demonstration Reactor . 39 1.3 Key Program Milestones . 39 1.4 Estimated Fund Requirements . 40 1.5 References for Section 1 . 46 2 Development of Structural Metal for Primary and Secondary Circuits 47 2.1 Introduction . 47 2.1.1 Objective . 47 2.1.2 Scope . 48 2.2 Program Budget and Schedule . 50 2.2.1 Schedule and key program milestones . 50 2.2.2 Funding . 51 2.3 Material Requirements, Background, and Status of Development . 52 2.3.1 Material requirements . 52 2.3.2 Background . 52 2.3.3 Status of development . 56 1 2.4 Task Group 1.1 Determination of Alloy Composition . 62 2.4.1 Objective . 62 2.4.2 Schedule . 62 2.4.3 Funding . 64 2.4.4 Facilities . 64 2.4.5 Task 1.1.1 Procurement of test materials . 64 2.4.6 Task 1.1.2 Basic studies on interaction of tellurium with Hastelloy N . 67 2.4.7 Task 1.1.3 Effects of fission products on mechanical properties . 67 2.4.8 Task 1.1.4 Thermal convection corrosion tests . 68 2.4.9 Task 1.1.5 Forced convection corrosion tests . 69 2.4.10 Task 1.1.6 In-reactor fueled capsule tests . 70 2.4.11 Task 1.1.7 Irradiation embrittlement of Hastelloy N . 72 2.5 Task Group 1.2 Procurement of Commercial Heats . 73 2.5.1 Objective . 74 2.5.2 Schedule . 74 2.5.3 Funding . 74 2.5.4 Task 1.2.1 Specifications . 75 2.5.5 Task 1.2.2 Bidding and vendor selection . 75 2.5.6 Task 1.2.3 Surveillance of fabrication . 75 2.5.7 Task 1.2.4 Receipt and cataloging of material . 75 2.6 Task Group 1.3 Evaluation of Commercial Heats . 75 2.6.1 Objective . 76 2.6.2 Schedule . 76 2.6.3 Funding . 76 2.6.4 Facilities . 77 2.6.5 Task 1.3.1 Weldability . 77 2.6.6 Task 1.3.2 Mechanical property tests . 79 2.6.7 Task 1.3.3 Physical property measurements . 80 2.6.8 Task 1.3.4 Thermal convection corrosion tests . 81 2.6.9 Task 1.3.5 Forced convection corrosion tests . 81 2.6.10 Task 1.3.6 In-reactor fueled capsule tests . 82 2.7 Task Group 1.4 Development of Analytical Design Methods—ASME Code Case Submission . 82 2.7.1 Objective . 83 2.7.2 Schedule . 83 2.7.3 Funding . 83 2.7.4 Facilities . 83 2.7.5 Task 1.4.1 Data analysis . 84 2.7.6 Task 1.4.2 Development of design methods . 84 2.7.7 Task 1.4.3 Submission of code case . 84 2.8 Task Group 1.5 Long-Term Materials Tests . 85 2.8.1 Objective . 85 2 2.8.2 Schedule . 85 2.8.3 Funding . 85 2.8.4 Facilities . 86 2.8.5 Task 1.5.1 Mechanical property tests . 86 2.8.6 Task 1.5.2 Forced circulation loops . 86 2.8.7 Task 1.5.3 In-reactor fueled capsule tests . 87 2.9 Task Group 1.6 Material Optimization . 87 2.9.1 Objective . 87 2.9.2 Schedule . 87 2.9.3 Funding . 87 2.9.4 Facilities . 88 2.9.5 Task 1.6.1 Further Hastelloy N improvement . 88 2.9.6 Task 1.6.2 Consideration of other materials . 88 2.10 References for Section 2 . 89 3 Fuel Processing 92 3.1 Introduction . 92 3.1.1 Objective . 92 3.1.2 Scope . 92 3.2 Program Budget and Schedule . 95 3.2.1 Schedule and key program milestones . 95 3.2.2 Budget . 95 3.3 Requirements, Background, and Status of Development . 95 3.3.1 Processing requirements . 95 3.3.2 Background . 97 3.3.3 Status of development . 103 3.4 Task Group 2.1 Flowsheet Analysis and Development . 108 3.4.1 Objective . 108 3.4.2 Schedule . 108 3.4.3 Funding . 108 3.4.4 Task 2.1.1 Heat balances . 108 3.4.5 Task 2.1.2 Mass balances . 109 3.4.6 Task 2.1.3 Parametric and optimization studies . 109 3.4.7 Task 2.1.4 Waste characterization . 109 3.4.8 Task 2.1.5 Processing plant conceptual design and cost estimate . 109 3.4.9 Task 2.1.6 Processing system control . 110 3.4.10 Task 2.1.7 Resource requirements and utilization . 110 3.4.11 Task 2.1.8 Alternate process development . 111 3.5 Task Group 2.2 Continuous Fluorinator Development . 111 3.5.1 Objective . 111 3.5.2 Schedule . 111 3.5.3 Funding . 112 3 3.5.4 Facilities . 112 3.5.5 Task 2.2.1 Non-radioactive heat generation studies . ..