Fuel. Presented by David Boyes STL Nuclear South Africa IAEA Indonesia Oct 2015
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1 Fuel Presented by David Boyes STL Nuclear South Africa IAEA Indonesia Oct 2015
2 Overview Fuel Kernel Fuel Sphere Design Fuel Plant Characteristics Plant Systems Main Processes Kernel Coater Fuel Sphere
3 Four barriers in the Pebble Pyrolytic carbon Fuel Kernel Silicon carbide barrier coating Inner pyrolytic carbon Porous carbon buffer layer Thorium/Uranium dioxide fuel kernel 99.99% of all fission products are retained within the fuel kernel. Actual Fuel Kernel
4 Fuel Sphere Design
5 Kernel fabrication Kernel material Gel precipitation Broth composition Droplet formation Gelation medium Washing Thorium/ uranium dioxide External Drying Ar at 80 C Calcination Ar at 300 C Aqueous solution of uranyl nitrate, polyvinyl alcohol, and other non-specified additives Vibrating nozzle 100 Hertz Ammonia gas and ammonia solution Ammonia solution and isopropanol Sintering H 2 at 1600 C 1700 C
6 Main Processes Kernel 1 WATER NITRIC ACID PRE - NEUTRAL ISATION PRE - NEUTRAL ISATION ThN SOLUTION U 3 O 8 DISSOLVING U 3 O 8 F F PVA WATER WATER & SURFACTANT F PVA STORAGE CASTING FLUID PREPARATION STORAGE TEMPER- ATURE CONTROL F TEMPERATURE CONTROL
7 Main Processes Kernel 2 AMMONIA REMOVAL WATER then ISO PROPANOL STEAM VACUUM TEMP CONTROL VIBRATOR 80 C 80 C AMMONIA GAS TEMPERATURE CONTROL AMMONIUM HYDROXIDE AGEING VESSEL WASHING VESSEL DRYING VESSEL CASTING VESSEL (REMOVAL OF AMMON. NITRATE & SPECIALIST ALCOHOL)
8 Main Processes Kernel 3 SCRAP 400 C 800 C 1600 C HYDROGEN SIEVE QC SORT 450 C AIR SINTERING FURNACE (CONVERT TO UO 2 ) CALCINING FURNACE (CONVERT TO UO 3 ) PORTIONING
9 Coating Buffer layer accommodates kernel s mechanical deformation Pyrolitic carbon layers and silicon carbide layer contain fuel and fission products Coating layer Gas Composition Coating Temperature Coating Rate Buffer layer Ar-C 2 H C 6-10 μm/min Inner pyrolitic carbon layer Ar-C 2 H 2 -C 3 H C 4-6 μm/min Silicon carbide layer H 2 -CH 3 SiCl C 0.2 μm/min Outer pyrolitic carbon layer Ar-C 2 H 2 -C 3 H C 4-6 μm/min
10 Coater (German design) D.A. Petti, J. Buongiorno, J.T. Maki, R.R. Hobbins, G.K. Miller, Key differences in the fabrication, irradiation and high temperature accident testing of US and German TRISO-coated particle fuel, and their implications on fuel performance, Idaho National Laboratory, June 2002.
11 Main Processes - Coating (Th,U)O 2 KERNELS SIEVE QC SORT QC INSPECTION STORAGE MTS 5 kg EITHER OR HEATING COATED PARTICLE COLLECTION COOLING MTS EVAPORATOR ELECTRIC HEATING ELEMENT OFF GAS COOLERS COATER SOOT HYDROGEN / ARGON CAUSTIC NEUTRALISATION OFF GAS TREATMENT BAG FILTER ACETYLENE / PROPELYNE EFFLUENT TO RECOVERY
12 Fuel Fabrication at Necsa
13 Fuel Development laboratory
14 PBMR Fuel : Success!
15 SA Fuel Quality : First Attempt
16 History of the PBMR Fuel Plant Feasibility Study Conceptual design Basic Design Detail Design Project Closure 2010
17 Main Processes Balance of Plant Systems Storage of HM Effluent Treatment Discharge Matrix Graphite Powder Manufacturing Heavy Metal Kernel Manufacturing Coated Particle Manufacturing Fuel Sphere Manufacturing Storage of Fresh Fuel Recovered HM Rejected Kernels Rejected CPs Heavy Metal Recovery Scrap Coated Particles Rejected FS Transport to Reactor
18 Plant Systems Process Systems Kernel Manufacturing Coated Particle Manufacturing Matrix Graphite Powder Manufacturing Fuel Sphere Manufacturing Heavy Metal Recovery Effluent Treatment Balance of Plant Systems Utilities HVAC Fire & Gas Protection Civil & Structural Material Handling Waste Handling Security QC Laboratories Various other systems
19 Technology Based on HOBEG (Nukem) technology Processes: Four main Areas: Kernel manufacturing Coated particle manufacturing Matrix graphite powder manufacturing Fuel sphere manufacturing Two supporting Areas: Technology Pelindaba (NECSA) Effluent treatment Uranium recovery
20 Fuel Plant Characteristics Plant throughput = FS/a Can accommodate (Th,U)O 2 or UO 2 fuel cycles Batch and semi-continuous processes 45+ weeks/annum, 5-7 days/week, 1-3 shifts/day Building Floor Space = >17 200m 2 (excl. tank farm) Building Height = ~14m Basement Level, Ground floor with a double volume
21 Up to FS/a Building = ~20 000m 2 Height = 14m Tank Farm = 5 500m 2 Site = m 2
22 Support Systems
23 Fuel Qualification Licensing Safety Case EIA Fuel Design Long Lead Items Runaway Cost Schedule Creep Risks
24 Fuel Plant Costs Influenced by options Typical scaled down and simplified version of PFP: Process Areas Capex ~ 40 m Balance of Plant Capex ~ 20 m Total Capex ~ 60 m
25 Fraction of Total FS Cost Fuel Costs: HM Loading FS Cost Components 80.0% 70.0% CP, MGP, FS Kernel 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% 1 g 2 g 3 g 4 g 5 g 6 g 7 g 8 g 9 g 10 g 11 g 12 g HM/FS
26 What is available in South Africa Know-how on Fuel Plant Design and specific HTR technology Engineering experience Licensing and safety experience Project management experience Engineering management experience Access to senior engineering resources with HTR know-how Access to equipment suppliers and raw material suppliers
27 Thank you Questions?
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