HTGR Plant Design. Training Course on High Temperature Gas-cooled Reactor Technology October 19-23, Serpong, Indonesia

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1 HTGR Plant Design Training Course on High Temperature Gas-cooled Reactor Technology October 19-23, Serpong, Indonesia Hiroyuki Sato Japan Atomic Energy Agency

GTHTR300: JAEA s Commercial HTGR General features A Generation IV system Cooperative design of JAEA and domestic industries (MHI, Fuji

) Multiple applications, passive safety, compelling economics, flexible plant siting Near-term deployable H 2 plant Reactor power plant

pressure vessel, non-intercooled direct cycle, horizontal gas turbine Water or air coolable Turbine Compressor 140 o C 0.

2 GTHTR300: JAEA s Commercial HTGR General features A Generation IV system Cooperative design of JAEA and domestic industries (MHI, Fuji electric, KHI, etc.) Multiple applications, passive safety, compelling economics, flexible plant siting Near-term deployable H 2 plant Reactor power plant Plant Design Plant is designed to minimize R&D and to obtain compelling economics Original design features of conventional steel pressure vessel, non-intercooled direct cycle, horizontal gas turbine Water or air coolable Turbine Compressor 140 o C 0.5% of main flow Non-intercooled, horizontal gas turbine Recuperator Gas turbine Thermal rating: 600 MW Net electricity: up to 300MWe Hydrogen rate: up to 5.2 t/hr Helium gas turbine Reactor Inherent RPV cooling scheme Air cooler Precooler Reactor Dry cooling configuration p.2

output) 600 MWt Reactor temperature 850-950 o C Reactor coolant pressure 7 MPa

3 GTHTR300 Outline GTHTR300 (Gas Turbine High Temperature Reactor 300) Recuperator Helium Gas Turbine Reactor power (max. output) 600 MWt Reactor temperature o C Reactor coolant pressure 7 MPa Refueling interval/period yrs/30 days Plant load factor 90% Precooler Reactor Sole Power Generation Plant Cogeneration Plant p.3

4 Design Philosophy Simplicity, Economical Competitiveness and Originality (SECO) 1. Sharing of common technologies by all design variants a unified reactor primary circuit an aerodynamically and mechanically similar line of gas turbines the selected hydrogen production process, the IS process 2. Focused development that limits cost and risk HTTR-type high burnup fuel, a baseline gas turbine, and IS process ation 3. Original design attributes Conventional material RPV, high burnup fuel cycle Horizontal gas turbine, non-intercooled power conversion cycle New IS process technologies p.4

5 Design Features K. Kunitomi, JAEA-Conference (2007). p.5

System Configuration, Reactor Standpipe Control rod guide tube Upper shroud Recuperator 588 o C 850 o C Turbine Compressor RPV Core barrel Reactor 136 o

6 System Configuration, Reactor Standpipe Control rod guide tube Upper shroud Recuperator 588 o C 850 o C Turbine Compressor RPV Core barrel Reactor 136 o C, 7.0 MPa Generator 28 o C, 3.5 MPa Hot plenum block 22 o C Precooler Core support plate Plant Layout (GTHTR300) Reactor bird s eye view (GTHTR300) p.6

Core, Fuel Element Control rod insertion hole Reserve shut down channel Helium coolant Upper plate Control rod guide block ダウエル A Dowel pin Spacer Fuel compact Fuel block Fuel block Outer replaceable

7 Core, Fuel Element Control rod insertion hole Reserve shut down channel Helium coolant Upper plate Control rod guide block ダウエル A Dowel pin Spacer Fuel compact Fuel block Fuel block Outer replaceable reflector Permanent side reflector Inner replaceable reflector Fuel brock horizontal cross section Fuel channel Fuel brock handling hole Coolant channel Center rod Bottom plate Fuel rod vertical cross section Core horizontal cross section (GTHTR300) Fuel block & fuel rod cross sections (GTHTR300) p.7

8 Why Helium Gas Turbine? 1 Most efficient and economical power generation possible by HTGR Direct Brayton cycle helium turbine enables 50% efficiency at least count of components 2 Wide range of heat application without drawbacks in efficiency Cogeneration of desalination, which utilizes sensible waste heat rejected of Brayton power generation cycle can attain overall energy efficiency of 88% 3 Exclusion of water related safety events High temperature waste heat rejection enables efficient dry cooling which can eliminate core water ingress accident and allow inland installation p.8

class Aerodynamic Scaling from baseline design for all

9 Why Helium Gas Turbine? Baseline Design for GTHTR300: 6 turbine stages, 20 compressor stages, non-intercooled, horizontal shaft, 3600 rpm synchronous, magnetic bearing, and 300 MWe class Aerodynamic Scaling from baseline design for all other units: GTHTR300+, GTHTR300C and GTHTR300H: X. Yan, JAEA-Conference (2007). p.9

Helium Gas Turbine Outline Only R&D on the baseline design is necessary

Brayton cycle helium gas loop: 2. Helium turbine aerodynamics R&D: 3.

Magnetic bearing design and control: Designed and partially constructed

10 Helium Gas Turbine Outline Only R&D on the baseline design is necessary (see design philosophy) ophy) JAEA s R&D activities: 1 1. Brayton cycle helium gas loop: 2. Helium turbine aerodynamics R&D: 3. Helium compressor aerodynamics R&D: 4. Magnetic bearing design and control: Designed and partially constructed Designed and partially built Program nearly completed Test rig under commissioning X. Yan, JAEA-Conference (2007). p.10

11 Compressor Aerodynamics R&D The Background Neither successful helium compressor nor proven design existed, prior to the present program! The R&D Goal Development of high performance helium compressor for VHTR The Results 1. Proposal of original design techniques 2. 1/3 of full scale compressor tests 3. Establishment of performance evaluation methods X. Yan, JAEA-Conference (2007). p.11

12 R&D Results (1/3) The Results (1/3) 1. Proposal of original design techniques 1 High performance compressor flowpath: nonintercooled, synchronous, and minimum number of compressor stages 2 Tight blade tip clearance: 1.2 mm equivalent in full scale, through a patented shaft-bearing system 3 3D blade airfoil: shown to eliminate boundary layer flow separation on blade Airfoil Case-A CASE MPa Airfoil A streaklines Steaklines 1S 1C 1 32 streaklines Steaklines Airfoil Case-B CASE MPa 1S Airfoil B 1C Rotor blade stator blade Rotor blade stator blade 3 TE Contour of Mach Number TE Contour of Mach Number X. Yan, JAEA-Conference (2007). p.12

measurements 4) Compressor efficiency and surge margin

13 R&D Results (2/3) 2. 1/3 of full scale compressor tests 1) Internal flowpath boundary layer measurements 2) Airfoil performance measurements 3) Inlet/outlet casing geometry performance measurements 4) Compressor efficiency and surge margin Detailed internal flowpath measurement of aerodynamic variables Helium compressor test rig X. Yan, JAEA-Conference (2007). p.13

14 R&D Results (3/3) Polytrophic Polytropic efficiency Efficiency (ηp, %) η p, % The Results (3/3 B) 3. Establishment of performance evaluation methods B. Reynolds Correlation method Extensive test measurements Viscous CFD analytical insights to identify flow regimes Correlation of efficiency with Compressor performance Reynolds impact number, on Re plant -n, subject efficiency to critical Reynolds number new method existing method Compressor Compressor Compressor performance performance Overall plant efficiency efficiency impact on plant efficiency impact on plant efficiency 92% 46.0% Compressor Overall plant Compressor efficiency Overall efficiency plant efficiency efficiency 92% 46.0% 92% 46.0% 87% 43.5% Efficiency vs. Reynolds Number Correlation for Blade Section (from Case-1 all runs & Case-2 run1 measurement) η p ~ R e Correlation of efficiency based on test data Efficiency New method 1 ~Re R e,critcal =4x10 5 for 1/3 scale p n Critical Re in 1/3 scale test pinch point R e extrapolation (full scale, 4 stages) R e,critcal =1.2x10 6 for full scale Throughflow prediction (full scale, 20 stages) Efficiency pinch point for commercial GT Existing methods Airfoil Case 1: Inlet A Airfoil Case 1: Inlet B Airfoil Case 2: Inlet B Airfoil Case 2: Inlet C Reynolds number Reynolds number X. Yan, JAEA-Conference (2007). Chord Re in commercial GT Efficiency pinch point for 1/3 scale test Critical Re in commercial GT 92% 92% 87% 88% p.14

15 Building Size Comparison GTHTR300 (275MWe 4) BWR-5 (1100MWe) m 68.5 m Reactor Building Turbine Building A 45 m 84.0 m 建屋容積 :485,000 m m 47 m 24 m 53 m 80 m 76 m A 22 m Turbine Building A-A 断面 Building capacity:533,000 m m 11 m Building Capacity:674,000 m 3 Reactor + Affiliation:354,000 m 3 Turbine:320,000 m 3 79 % of BWR-5 K. Kunitomi, JAEA-Conference (2007). p.15

16 Safety Analysis (1/2) Axial distance (m) Max. fuel temp. < Limit temp. (1600 o C) Upper reflector Fuel region 0hr 30hr 70hr 120hr 200hr 1000hr 5000hr 10000hr 系列 2 Lower reflector Temperature ( ) Temperature distribution in GTHTR300 during DLOFC Cooling panels Reactor pressure vessel Stack Air outlet Air inlet Upward air flow (natural circulation) Insulator Downward air flow (natural circulation) Heat removal by radiation and natural circulation Concrete biological shield Decay heat is removed passively from the outside of RPV K Katanishi et al., Nucl. Eng. Des.,237, (2007). p.16

17 Safety Analysis (2/2) Flow rate (kg/h) Time (Days) Natural circulation flow in GTHTR300 SiC (s) + O 2 (g) SiO (g) + CO (g) SiC (s) + 3/2O 2 (g) SiO 2 (g) + CO (g) Fuel failure due to oxidation in GTHTR300 The fuel remains intact during DLOFC accident K Katanishi et al., Nucl. Eng. Des.,237, (2007). p.17

18 Economics (1/2) Analysis condition (plant specifications) GTHTR300 1) : Commercial HTGR designed by JAEA in cooperation with reactor vendors - plant unit: 4 units/plant - plant power: thermal power 600MWt/unit electric power ~275MWe/unit (gross) ~269MWe/unit (net) - average burn-up: 120GWd/ton Key assumption Construct at current LWR site Take into account standardization of design, related codes & standards, operation & maintenance practices, components, regulatory, and project management equipment directly carried from an on-site exclusive port a reactor building and structures based on those of the HTTR seismic condition same as that of the HTTR including design and fabrication of facilities, plant construction cost and test operations p.18

19 Economics (2/2) a) Plant construction cost (NOAK) c) Power generation cost (NOAK) GTHTR300 Reactor components Power conversion system Auxiliary system GTHTR300 capital cost operating cost fuel cost LWR(PWR) Electric and control system buildings LWR(PWR) Construction cost (10000 Yen/kWe) Power generation cost (Yen/kWh) b) Fuel cost (NOAK) GTHTR300 LWR(PWR) Fuel cost (Yen/kWh) U purchase, conversion enritchment fabrication MOX storage reprocessing waste disposal Ref) K. Kunitomi, et al., Proc. ICAPP2007, Nice, France, May 13-18, 2007, Paper Power production by HTGR has economical advantage against LWR fleet because of significant cost savings through simplified plant design, high efficiency power conversion, etc. Can expect further improvement by increasing turbine inlet temperature, and taking into account profit from waste heat usage such as desalination 19 p.19

Multi-purpose Small-sized HTGR Project Scope: Electricity and heat supply to Kurchatov in Republic of Kazakhstan at an early date Establishment of exporting business & creation of new industries in

technologies required in commercial plant such as helium gas turbine, etc.

20 Multi-purpose Small-sized HTGR Project Scope: Electricity and heat supply to Kurchatov in Republic of Kazakhstan at an early date Establishment of exporting business & creation of new industries in the future Design philosophy: Utilize technologies based on the HTTR construction as much as possible Simplification of engineered safety features actuation systems from the HTTR Demonstrate technologies required in commercial plant such as helium gas turbine, etc. Status: 2010: System design 1), Safety design 2) 2011: Core design3), 4) 2012: Plant design 5), Safety Evaluation 2) Conceptual design completed Reactor IHX Steam generator Steam turbine Isolation valve H 2 plant District heating 1) H. Ohashi, et al., JAEA-Technology (2011). 2) H. Ohashi, et al., JAEA-Technology (2013). 3) M. Goto, et al., JAEA-Technology (2012). 4) Y. Inaba, et al., JAEA-Technology (2012). 5) H. Ohashi, et al., JAEA-Technology (2013). p.20

Core Design Approach for Small-sized HTGR 3480 mm Core depth [m] Core height (cm) 3.

5 MW/m 3 Enrichment count : Less than 6 Effective Full Power Days: 730 days Approach Optimization of

direction - Flatten power distribution in radial direction Preservation of optimized power distribution

region Results Result Criteria Average power density [MW/m 3 ] 3.5 > 3.

Goto, et al., Proc. ICAPP2012, Chicago, IL, USA, Oct. 9-13, 2012, Paper 12415. 0 348 290 232 1.

21 Core Design Approach for Small-sized HTGR 3480 mm Core depth [m] Core height (cm) 3.48 m Core height (cm) Target Average power density: 3.5 MW/m 3 Enrichment count : Less than 6 Effective Full Power Days: 730 days Approach Optimization of power distribution by enrichment arrangement - Follow optimized power distribution curve for axial direction - Flatten power distribution in radial direction Preservation of optimized power distribution during the whole operational time by BP arrangement - Maintain CR position in the first layer of fuel region Results Result Criteria Average power density [MW/m 3 ] 3.5 > 3.5 Enrichment count 3 < 6 Effective Full Power Days Maximum fuel temp. [ o C] 1467 < 1495 Ref) M. Goto, et al., Proc. ICAPP2012, Chicago, IL, USA, Oct. 9-13, 2012, Paper Optimized curve Fuel region 1 Fuel region 2 Fuel region 3 Fuel region Coolant flow CR position Power density density (W/cc) Burn-up (EFPD) [MW/m 3 ] p.21

22 Business Model for Small-sized HTGR (1/2) Manufacturing cost [$/bbl] Gas to liquids (GTL) is a refinery process to convert natural gas into liquid synthetic fuels such as gasoline or diesel fuel. Manufacturing cost highly depends on raw material cost, i.e. natural gas price. HTGR can contribute to reduce natural gas consumption by 30% by replacing its use for fuel with high temperature heat & steam from HTGR Plant size: 15,000 bbl/day Construction cost: 488 M$ Lifetime: 15 years 44% 61% 70% 76% Natural gas price [$/MMBTu] HTGR Raw material cost Capex Operation cost *Pertamania & JOGMEC, Feasibility study of Gas to Liquid technology (2003). High temperature heat Steam Fuel use / Loss Material Air Air Separation 30% 70% Natural gas Gas Synthesis Gas processing FT(Fischer-Tropsch) process Upgrading Process Natural Gas Diesel Naphtha Parafin GTL process Synthetic fuel 850 o C 200 o C o C Replace by heat supplied from HTGR p.22

23 Manufacturing cost [$/bbl] Manufacturing cost [$/bbl] Business Model for Small-sized HTGR (2/2) Analysis condition - Reactor thermal power: 200MW - Construction cost: $2B (Conservative assumption) - Fuel & O&M cost: Based on literature* - Heat utilization: 90% Analysis results Manufacturing cost of HTGR-GTL combined process becomes low considering export loss of natural gas even the construction cost of HTGR becomes high. The break-even point of natural gas price is 8.8 USD/MMBtu considering export loss HTGR+GTL GTL Diesel HTGR+GTL general GTL Diesel Natural gas price: 10 USD/MMBtu 50 0 $8.8/MMBTu Natural gas export loss Diesel HTGR (Fuel) HTGR (O&M) HTGR (Capital) GTL (Non gas O&M) GTL (Capital) GTL (Gas usage) GTL w export loss HTGR+GTL Natural gas price [$/MMBTu] HTGR-GTL combined process would be economically competitive against conventional oil refinery & general GTL process *INL, TEV-1196 (2012) p.23

Nuclear Renewable Hybrid System Electric power + Constant power Hydrogen Short time-scale (seconds/minitues) Adjust power generation rate by coolant flow rate control corresponding to renewable

24 Nuclear Renewable Hybrid System Electric power + Constant power Hydrogen Short time-scale (seconds/minitues) Adjust power generation rate by coolant flow rate control corresponding to renewable output variation. Constant power Nuclear Solar, Wind Time Heat supply rate control Nuclear renewable hybrid system with HTGR cogeneration system for electricity and hydrogen Coolant inventory Recuperator Reactor Core H 2 plant Power generation rate control Bypass flow rate Gas turbine Renewable energy power plant Power output Power synthesis Power output Constant power Electric grid Precooler IHX Allowable core thermal capacitance: 850 MJ/ o C Generator Control flow Coolant flow p.24

HTGR Brayton Cycle Technology and Operations

MIT Workshop on New Cross-cutting Technologies for Nuclear Power Plants, Cambridge, USA, January 30-3, 207 HTGR Brayton Cycle Technology and Operations Xing L. Yan HTGR Hydrogen and Heat Application Research