A PERSPECTIVE ON THE INDIAN PROGRAMME ON FAST REACTORS AND ASSOCIATED FUEL CYCLES

Transcription

1 A PERSPECTIVE ON THE INDIAN PROGRAMME ON FAST REACTORS AND ASSOCIATED FUEL CYCLES P.R.Vasudeva Rao, P.Chellapandi, G.Srinivasan, K.K.Rajan, R.Natarajan, P.V.Kumar and T.Jayakumar Indira Gandhi Centre for Atomic Research, Kalpakkam , India

2 Fast Breeder and Fuel Cycle Facilities Fast Reactor Fuel Cycle Facility FRFCF CFBR (2 x500 MWe) DFRP PFBR(500 MWe) Prototype Fast Breeder Reactor FBTR Fast Breeder Test Reactor CORAL MFTR (120 MWe) Metal Fuel Test Reactor MFBR (1000 MWe) Metal Fuel Breeder Reactor

3 FBTR: operation summary PFBR test fuel irradiated in FBTR to a burn-up of 112 GWd/t and discharged for Post-irradiation Examination FBTR, in operation since 1985, is the flag-ship of IGCAR and is the test bed for fast reactor fuels and materials. It has completed 20 irradiation campaigns. During the campaigns, the reactor has been operated to a power level of 20.3 MW, and sodium outlet temperature of 540 deg C. Its unique carbide fuel has set an international record in burn-up (165 GWd/t). One fuel pin failure event was observed and the failed fuel subassembly was quickly detected and removed for PIE The performance of sodium systems for the past 27 years has been excellent. Sodium pumps have crossed 7, 39,000 hours of cumulative, continuous operation. Steam generators have performed without a single leak incident

4 Campaign Missions of FBTR Irradiation of six sodium bonded metallic fuel test pins (Natural Uranium + 6% Zr) (continuing) Irradiation of D9 structural materials. Irradiation of Impact specimens of SS304LN and SS316LN for low dose irradiation studies Irradiation of Yttria capsule in a special subassembly for trial production of Sr 89 Irradiation of ferro-boron shielding material Testing of high temperature fission chamber (HTFC) for PFBR, up to a maximum power of 10 MWt Testing of industrial version of Kalman filter based instrument, meant for drop time measurement of DSRDM for PFBR.

5 Life Extension and Safety Evaluation Several refurbishments and modifications have been carried out towards life extension of FBTR, eg. Replacement of steam generator rupture discs, Main boiler feed pumps, etc. Creep-fatigue damage assessment has been calculated and long residual life is available. Life of the reactor is governed by dose on the Grid Plate. Irradiation of specimens indicated that the allowable residual ductility of 10% for core structures is reached at 4.37 dpa. The effective residual life is estimated as ~ 7 Effective Full Power Years. Post Fukushima, safety studies were taken up and the plant was seen to be safe against even extended blackout. Retrofits planned for protection against flooding

6 Carbide Fuel Cycle of FBTR Fuel Fabricated at BARC Over 1200 Mark-I fuel pins have reached 155 GWd/t burn-up in FBTR; maximum burn-up reached 165 GWd/t Fuel discharged at burn-up upto 150 GWd/t reprocessed in CORAL facility 100 GWd/t The plutonium recovered from reprocessing has been used to fabricate fresh fuel for FBTR, thus closing the fuel cycle

7 FBTR Fuel Reprocessing 16 Stage Centrifugal Extractor Bank DFRP: View of Cell Piping CORAL facility: Over the years, the decontamination factors have been improved, and the waste volumes have been reduced

8 Sodium Filling by End of 2013 Current Status of PFBR (500 MWe) Hot commissioning during first quarter of 2014 Reactor criticality by Sep.2014 Dummy core in core LRP/SRP on Roof Slab All SGs erected Erection of sodium piping Turbo Generator

9 Vault Top View

10 Component Testing for PFBR Performance testing of Critical PFBR Components Shut down Mechanisms CSRDM, DSRDM Tested, qualified and delivered to BHAVINI Fuel Handling machines IFTM: PR &PTM tested, qualified & erected in PFBR Transfer Arm : Sodium testing is in progress Electromagnetic pumps; Tested in sodium Primary Ramp & Primary Tilting Mechanism of PFBR in LCTR Annular linear induction pump (ALIP) Transfer Arm testing in air and sodium in LCTR DSRDM CSRDM

11 In-sodium Sensors Mutual Inductance level Probes Ultrasonic transducers for Under Ultrasonic sodium scanner Eddy Current Flow meters for primary pump and core flow measurement Sodium aerosol detector Under sodium ultrasonic transducer sodium aerosol detector Mutual Inductance Level probes for PFBR and its calibration in LCTR Under sodium ultra sonic scanner of PFBR Eddy Current Flow meter for primary pump and core flow monitoring

12 PFBR TRAINING SIMULATOR AT BHAVINI Simulated Sub Systems include Neutronics, Primary and Secondary Sodium, Safety Grade Decay Heat Removal, Core Temperature Monitoring, Steam Water, Electrical and Fuel Handling System.

13 PIE of PFBR MOX Test FSA in FBTR up to 112 GWd/t MOX fuel composition (U 0.29 Pu 0.71 ) O % U 233 O/M 1.98 to 2.00 No. of fuel pins & Fuel stack length Linear mass 37 pin, 240 mm 2.18 g/cm Fuel Density 91 1 % TD Pellet diameter OD & ID Fuel pin OD & ID 5.55 & 1.75 (mm) 6.6 & 5.7 (mm) Clad & Wrapper material 20 % CW D9 Dimensional changes in wrapper & clad Peak linear power Neutron dose 450 W/cm 62 dpa Stress-Strain curve of clad & wrapper Diametral strain on D9 cladding has both void swelling & irradiation creep Retention of adequate strength and ductility in D9 clad & wrapper Fission gas release and fission product distribution by gamma scanning X-ray & Neutron- radiographs of MOX fuel pin Inter pellet gap & radial cracks 12kW 22min In (Epithermal neutrons) Central hole in the pellets Fuel stack length increase measured by different NDE techniques is in the range of % Post Irradiation Examination established that the MOX fuel and D9 clad/wrapper of PFBR test SA have performed well in FBTR up to a burnup of 112 GWd/t.

14 PFBR Fuel Subassembly Fabrication Pins being assembled Welding in progress

15 Fast Reactor Fuel Cycle Facility FUEL ASSEMBLY PLANT REACTOR CLOSED FUEL CYCLE WMP REPROCESSING PLANT Fast Reactor Fuel Cycle Facility (FRFCF) is being planned to close the fuel cycle of PFBR Design of the facility has been completed and MoEF clearance has been obtained. Consent for construction expected. FUEL & BLANKET PIN PLANT

16 Challenges in Future FBR Development Cost Capital Cost Design Improvement Construction time Fuel Cycle Cost Burn-up Improved materials Shutdown System with Passive Features Safety Passive Decay Heat Removal Sodium Fire Protection High Breeding Ratio Faster Growth Metallic Fuels

17 Reactor Assembly of PFBR & FBR-1 Box Thick to Thick plate plate Rotatable rotatable plugs Box to Dome shaped Dome shaped roof slab Roof slab Support under Tension compression to compression Separate Embedded Safety safety vessel vessel to Embedded vessel Conical Inner vessel to Toroidal with Doubled Inner curved vessel torus Bolted to Welded Eight primary pipes Grid plate PFBR Four Primary Welded grid plate pipes to Eight Motivation to introduce innovations FBR 1 PFBR construction experience, significant saving in capital cost & reduced construction time, enhanced safety the features adoptable for future SFR series

18 Technology Demonstration of Key Innovative Components FBR 1 & 2 Large Diameter Bearing Tri-Junction Forging Thick Plate Welding Welded Grid Plate Inner Vessel

19 Metallic Fuel Development Pin Irradiation in FBTR Doubling time: 30years for oxide, 12 years for metal and 8 years for improved metallic fuel without Zr) Subassembly Irradiation in FBTR Substantial Core Metallic Fuel in FBTR 120 MWe Experimental Fast Reactor Metallic Fuel Design 1000 MWe Units Reference compositions: U-19%Pu-6%Zr (sodium bonded) U-19% Pu (mechanically bonded / sodium bonded) EU-6%Zr sodium bonded fuel pins under irradiation in FBTR U-Pu-Zr sodium bonded pins fabricated for irradiation in FBTR Physicochemical property measurements and clad compatibility studies under way

20 Unique Spot technique for measurement of solidus liquidus temperatures of fuel materials SOLID LIQUIDUS SOLIDUS + LIQUID Precise (+ 5 K) measurement of transition temperatures; Provides a view of the transition and also data

21 The Experimental set-up for Nuclear Fuel Materials Sample cell & RF coil Lids K Cell Ta susceptor K-Cell Assembly W-legs Mo Table SS support Sample mount Long distance Microscope High vacuum system Vacuum Chamber IR tow color pyrometer

22 T / K Solidus-Liquidus data on U-Zr system T S - Present study T L - Present study T S Summers-Smith [1] T L Summers-Smith [1] X Zr T S Kanno [2] T L Kanno [2] T L Ohimichi [3] T L Maeda [4] T S Leibowitz [5] T L Leibowitz [5] ASM diagram [7]

23 First measurements on solidus temperature of Mark I Fuel of FBTR (MC + M 2 C 3 ) (Pu/(U+Pu) =0.7 Ref 1 1 mm K-Cell orifice Solidus Tempereature of Mark I fuel This work Solidus Temp. / K Technique Spot technique Fuel after melting & solidification Ref Incipient melting (metallogra phy) 1. Sengupta et al. J. Nucl. Mater (385) Spots indicating fuel melting at solidus 2. Sengupta et al. in Fast Reactor Fuel Cycle Symposium Ed. C.K. Mathews 10-12, Feb 1986, Kalpakkam, India.

24 Sodium Bonded Metallic Test Fuel Pin Fabrication Sodium handling glove box with argon recirculation system Sodium extruder Pin welding Sodium bonded U-19Pu-6Zr test fuel pin Glove box train facility for sodium bonded metallic fuel pin fabrication

25 Metal Fuel Test Reactor: Objectives Full-scale testing of metal fuel subassemblies To validate reactor physics parameters of metal fuel Demonstrating safe operation in closed cycle mode Mastering the industrial scale manufacture and reprocessing of metal fuel subassemblies Material irradiation for developing advanced fuels and structural materials Facility for isotope production for medical applications A forerunner of a large size metallic fuelled reactors planned in future

26 Metal Fuel Test Reactor: Main Features Fuel type : U-Pu-6%Zr Bonding : Na/Mech. Fuel smear density : 75% of TD Clad material : Ferritic steel Core inlet/outlet temp. : 360/510 C Average fuel temp. : 750 C

27 Lab. scale Studies on Electrorefining and Consolidation of Cathode Deposit Engineering Scale Development of Process and Equipment Ceramic and Metal Waste Form Development Pyroprocess activities at IGCAR Development of Materials, Coatings Modelling and Basic Electrochemical Studies Studies on Direct Oxide Reduction of Actinide Oxides

28 Lab. scale studies on electrorefining and consolidation of cathode deposit Electrorefining of U & U bearing alloys as anode and solid cathode studied Electrorefining of Pu in LiCl-KCl-PuCl 3 using Pu as anode (20 g) and solid cathode in LiCl-KCl-PuCl 3 electrolyte; T= 773 K Electrorefining of Pu-Ce-La at 20 g scale with solid cathode & Consolidation of Pu metal deposit by melting the deposit at 1073 K Lab. scale facility Studies on Pu alloys with other lanthanides being continued Pu metal PuCl 3 -LiCl-KCl salt Pu deposit on cathode

29 Engineering Scale Facility for Electrorefining Studies Engineering Scale Facility for studies using 1-3 kg of U alloys set up & commissioned Equipments housed in the containment box - Fuel pin Chopper - Electrorefining vessel, salt receiving vessel - Distillation cum melting furnace - Power manipulator for remotisation Experiments on electrorefining conducted with U-Zr alloys on 1 kg scale Argon atmosphere Containment Box U metal ingot Inner view of box U deposit on solid cathode

30 Scaling up: Ambient Temperature ElectroRefiner (ATER) Ambient Temperature ElectroRefiner set up and commissioned Copper electrorefining to be carried out Automation and remote handling aspects to be validated and used for HTER design Top view of ATER ATER and sub-systems Electrode assembly stations 30

31 frequency of the dispersoids 6.6 mm OD/0.45mm WT/4.2 m long cladding tube Cr C W Ti %Cr ODS Steel Fuel Cladding Tubes Pre-alloyed powder Yttria powder Milled particle Y 2 O Mn < 0.04 N < 0.01 O Size (nm) Pressure Resistance Weld

32 ROBOTICS AND IN-SERVICE INSPECTION DEVICES FOR PFBR COMPONENTS AND REPROCESSING FACILITIES Sample handling robot for fuel reprocessing plant Power manipulator developed for pyro processing facility Devices developed for ISI of Main Vessel / Safety Vessel Robot system developed for ISI of DFRP waste vault

33 R&D on Safety related to Sodium Fundamental Tests in MINA: Sodium spray fire scenarios, sodium fire followed by cable fire, sodium concrete interactions, sodium water/steam reactions, qualification innovative sodium sensors and sodium fire extinguishes, etc Medium & Large Scale Experiments (SOCA, SFEF): Qualification of sodium leak collection trays, sodium fire scenarios to investiagte the integrity of safety related components on the top sheild platform LabView Sodium School: 20 ms 24 ms 32 ms 7200 ms 7600 ms 8600 ms Sodium fire followed by cable fire Performance Evaluation of Sodium Leak Collection Tray IGCAR-CEA Cooperation SOCAFacility to simulate Na fire scenario on top shield

34 Simulation of Severe Accident Scenario Mechanical consequence: Vessel deformations, integrity of SGDHR, sodium release to Reactor Containment Building Molten Fuel Coolant Interaction Studies Post Accident Heat Removal Scenario: Molten fuel coolant interactions Core catcher performance Woods metal in water Potential of main vessel: 1200 MJ SOFI Facility Uranium in sodium Grid plate melt-through scenario Estimation of work potential Characterisation of debris: (constitution, size & heat trasfer) Dispersion on core catcher Post accident heat transfer modes

35 Conclusion Indian fast reactor programme being developed with comprehensive attention to all aspects High emphasis on safety and economics Fuel cycle development undertaken simultaneous with reactor development Emphasis on breeding: metal fuel development for long term High confidence level in manufacturing industry R & D in various domains, as well as human resource development given emphasis

36 Thank You

37 Welcome To India