Fuel Sphere Manufacture. Presented by: David Boyes STL Nuclear IAEA - October 2015
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1 Fuel Sphere Manufacture Presented by: David Boyes STL Nuclear IAEA - October 2015
2 Contents Fuel Sphere Design Overview Matrix Graphite Powder (MGP) Manufacture Coated Particle Over-coating (OCP) Fuel Sphere Manufacture (FS) Mould Manufacture Complex Processes
3 Fuel Sphere Design Overview
4 Fuel Sphere Design Overview (Cont.) The Kernel contains the heat-generating fuel material and provides chemical hold-up of fission products The Buffer Layer provides void volume for gaseous fission products and accommodates Kernel swelling The Inner Pyrolytic Carbon Layer provides a gastight diffusion barrier for metallic fission products and reduces tensile stresses on the Silicon Carbide Layer The Silicon Carbide Layer is the main diffusion barrier to metallic fission products and the primary pressure-retaining layer The Outer Pyrolytic Carbon Layer provides a barrier to gaseous fission products, a diffusion barrier to metallic fission products and reduces tensile stresses on the Silicone Carbide Layer
5 Fuel Sphere Design Overview (Cont.) The Graphite Matrix: - consists of carbonized organic binder and nuclear-grade graphite material which acts as a fission neutron moderator - provides the contact with the Coated Particles as a heat transfer medium and acts as a buffer to prevent exposure and damage of Coated Particles - should exhibit high density, high thermal conductivity, high mechanical strength, low thermal expansion, low anisotropy, low Young s modulus, good corrosion resistance and good dimensional stability under neutron irradiation
6 MGP Manufacture - Process Flow Graphite Powder Natural (64 %) Graphite Powder Electro (16 %) Phenolic Resin (20 %) Methanol Homogenization Dissolving Kneading Drying (100 0 C) Pre-Crushing Swarf from Fuel Sphere Manufacture (~11%) Hammer Milling Homogenization Fine Milling To Coated Particle Over-coating To Fuel Sphere Manufacture
7 Matrix Graphite Powder Manufacture SOLVENT (METHANOL) & PHENOL BINDER ELECTROLYTIC GRAPHITE NATURAL GRAPHITE DISSOLVER RECYCLED GRAPHITE (SWARF) MATRIX GRAPHITE KNEADER METHANOL RECOVERY TO MANUFACTURE DRYING OVEN Coarse Milling MILLING FINE MILLING OVERCOAT MATRIX
8 Matrix Graphite Powder Manufacture SOLVENT (METHANOL) & PHENOL BINDER ELECTROLYTIC GRAPHITE NATURAL GRAPHITE DISSOLVER RECYCLED GRAPHITE (SWARF) MATRIX GRAPHITE KNEADER METHANOL RECOVERY TO MANUFACTURE DRYING OVEN Coarse Milling MILLING FINE MILLING OVERCOAT MATRIX
9 Matrix Graphite Powder Manufacture SOLVENT (METHANOL) & PHENOL BINDER ELECTROLYTIC GRAPHITE NATURAL GRAPHITE DISSOLVER RECYCLED GRAPHITE (SWARF) MATRIX GRAPHITE KNEADER METHANOL RECOVERY TO MANUFACTURE DRYING OVEN Coarse Milling MILLING FINE MILLING OVERCOAT MATRIX
10 Matrix Graphite Powder Manufacture SOLVENT (METHANOL) & PHENOL BINDER ELECTROLYTIC GRAPHITE NATURAL GRAPHITE DISSOLVER RECYCLED GRAPHITE (SWARF) MATRIX GRAPHITE KNEADER METHANOL RECOVERY TO MANUFACTURE DRYING OVEN Coarse Milling MILLING FINE MILLING OVERCOAT MATRIX
11 Matrix Graphite Powder Manufacture SOLVENT (METHANOL) & PHENOL BINDER ELECTROLYTIC GRAPHITE NATURAL GRAPHITE DISSOLVER RECYCLED GRAPHITE (SWARF) MATRIX GRAPHITE KNEADER METHANOL RECOVERY TO MANUFACTURE DRYING OVEN Coarse Milling MILLING FINE MILLING OVERCOAT MATRIX
12 Matrix Graphite Powder Manufacture SOLVENT (METHANOL) & PHENOL BINDER ELECTROLYTIC GRAPHITE NATURAL GRAPHITE DISSOLVER RECYCLED GRAPHITE (SWARF) MATRIX GRAPHITE KNEADER METHANOL RECOVERY TO MANUFACTURE DRYING OVEN Coarse Milling MILLING FINE MILLING OVERCOAT MATRIX
13 Matrix Graphite Powder Manufacture SOLVENT (METHANOL) & PHENOL BINDER ELECTROLYTIC GRAPHITE NATURAL GRAPHITE DISSOLVER RECYCLED GRAPHITE (SWARF) MATRIX GRAPHITE KNEADER METHANOL RECOVERY TO MANUFACTURE DRYING OVEN Coarse Milling MILLING FINE MILLING OVERCOAT MATRIX
14 OCP Manufacture - Process Flow Fine Milled MGP from Matrix Graphite Powder Manufacture Methanol Over-coating (200µm) Drying (80 0 C) Coated Particles Portioning Removal of Over-coat Layer Sieving Scrap Sorting Scrap To Fuel Sphere Manufacture Combining and Portioning
15 Coated Particle Over-coating OVERCOAT GRAPHITE & SOLVENT (METHANOL) COATED PARTICLES METHANOL REMOVAL SIEVING &SORTING DRYING OVERCOATING REJECT COMBINING & PORTIONING
16 Coated Particle Over-coating OVERCOAT GRAPHITE & SOLVENT (METHANOL) COATED PARTICLES METHANOL REMOVAL SIEVING &SORTING DRYING OVERCOATING REJECT COMBINING & PORTIONING
17 Coated Particle Over-coating OVERCOAT GRAPHITE & SOLVENT (METHANOL) COATED PARTICLES METHANOL REMOVAL SIEVING &SORTING DRYING OVERCOATING REJECT COMBINING & PORTIONING
18 Coated Particle Over-coating OVERCOAT GRAPHITE & SOLVENT (METHANOL) COATED PARTICLES METHANOL REMOVAL SIEVING &SORTING DRYING OVERCOATING REJECT COMBINING & PORTIONING
19 Coated Particle Over-coating OVERCOAT GRAPHITE & SOLVENT (METHANOL) COATED PARTICLES METHANOL REMOVAL SIEVING &SORTING DRYING OVERCOATING REJECT COMBINING & PORTIONING
20 FS Manufacture Process Flow Core and Final Moulds from Mould Manufacture OCPs from Over-Coated Particle Manufacture Core Pressing Final Pressing (3 t/cm 2 ) MGP from Matrix Graphite Powder Manufacture Machining Swarf to MGP Manufacture Argon Carbonizing (800 0 C) Annealing ( C in vacuum) Storage
21 Fuel Sphere Manufacture (Sheet 1) OVERCOATED PARTICLES PRE SPLITTER SCREW FEEDER INMOULD CORE PRESS SPHERE CORE CORE MOULD SHELL FORMING ROBOT FINAL PRESS X-RAY INSPECTION QA SPHERE FINAL MOULD
22 Fuel Sphere Manufacture (Sheet 1) OVERCOATED PARTICLES PRE SPLITTER SCREW FEEDER INMOULD CORE PRESS SPHERE CORE CORE MOULD SHELL FORMING ROBOT FINAL PRESS X-RAY INSPECTION QA SPHERE FINAL MOULD
23 Fuel Sphere Manufacture (Sheet 1) OVERCOATED PARTICLES PRE SPLITTER SCREW FEEDER INMOULD CORE PRESS SPHERE CORE CORE MOULD SHELL FORMING ROBOT FINAL PRESS X-RAY INSPECTION QA SPHERE FINAL MOULD
24 Fuel Sphere Manufacture (Sheet 1) OVERCOATED PARTICLES PRE SPLITTER SCREW FEEDER INMOULD CORE PRESS SPHERE CORE CORE MOULD SHELL FORMING ROBOT FINAL PRESS X-RAY INSPECTION QA SPHERE FINAL MOULD
25 Fuel Sphere Manufacture (Sheet 1) OVERCOATED PARTICLES PRE SPLITTER SCREW FEEDER INMOULD CORE PRESS SPHERE CORE CORE MOULD SHELL FORMING ROBOT FINAL PRESS X-RAY INSPECTION QA SPHERE FINAL MOULD
26 Fuel Sphere Manufacture (Sheet 1) OVERCOATED PARTICLES PRE SPLITTER SCREW FEEDER INMOULD CORE PRESS SPHERE CORE CORE MOULD SHELL FORMING ROBOT FINAL PRESS X-RAY INSPECTION QA SPHERE FINAL MOULD
27 Fuel Sphere Manufacture (Sheet 1) OVERCOATED PARTICLES PRE SPLITTER SCREW FEEDER INMOULD CORE PRESS SPHERE CORE CORE MOULD SHELL FORMING ROBOT FINAL PRESS X-RAY INSPECTION QA SPHERE FINAL MOULD
28 Fuel Sphere Manufacture (Sheet 2) SWARF TO MGP MANUFACTURE VACUUM LIFTING INTO TRAYS BUFFER MACHINING BUFFER REJECTS QA FINAL TO CARBONISING CHARGE CARRIER CARBONISING FURNACE COOLING TOWER ANNEALING FURNACE DIMENSION INSPECTION VISUAL INSPECTION MASS CONTROL X-RAY
29 Fuel Sphere Manufacture (Sheet 2) SWARF TO MGP MANUFACTURE VACUUM LIFTING INTO TRAYS BUFFER MACHINING BUFFER REJECTS QA FINAL TO CARBONISING CHARGE CARRIER CARBONISING FURNACE COOLING TOWER ANNEALING FURNACE DIMENSION INSPECTION VISUAL INSPECTION MASS CONTROL X-RAY
30 Fuel Sphere Manufacture (Sheet 2) SWARF TO MGP MANUFACTURE VACUUM LIFTING INTO TRAYS BUFFER MACHINING BUFFER REJECTS QA FINAL TO CARBONISING CHARGE CARRIER CARBONISING FURNACE COOLING TOWER ANNEALING FURNACE DIMENSION INSPECTION VISUAL INSPECTION MASS CONTROL X-RAY
31 Fuel Sphere Manufacture (Sheet 2) SWARF TO MGP MANUFACTURE VACUUM LIFTING INTO TRAYS BUFFER MACHINING BUFFER REJECTS QA FINAL TO CARBONISING CHARGE CARRIER CARBONISING FURNACE COOLING TOWER ANNEALING FURNACE DIMENSION INSPECTION VISUAL INSPECTION MASS CONTROL X-RAY
32 Fuel Sphere Manufacture (Sheet 2) SWARF TO MGP MANUFACTURE VACUUM LIFTING INTO TRAYS BUFFER MACHINING BUFFER REJECTS QA FINAL TO CARBONISING CHARGE CARRIER CARBONISING FURNACE COOLING TOWER ANNEALING FURNACE DIMENSION INSPECTION VISUAL INSPECTION MASS CONTROL X-RAY
33 Fuel Sphere Manufacture (Sheet 2) SWARF TO MGP MANUFACTURE VACUUM LIFTING INTO TRAYS BUFFER MACHINING BUFFER REJECTS QA FINAL TO CARBONISING CHARGE CARRIER CARBONISING FURNACE COOLING TOWER ANNEALING FURNACE DIMENSION INSPECTION VISUAL INSPECTION MASS CONTROL X-RAY
34 Complex Processes Complex Processes are: To produce a particle size and distribution with hammer milling for reaching optimum density with the Graphite Matrix Mould tooling design Assembly of a fuel sphere Over-coating of coated particles Sorting of coated particles Understanding the splitting and portioning of Over-coated Particles to obtaining the correct fissile material loading per fuel sphere
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