indian fast reactor program
DESCRIPTION
Indian fast reactor programTRANSCRIPT
The Indian Fast Reactor Programme: Current status and directions
P.R. Vasudeva RaoIndira Gandhi Centre for Atomic [email protected]
VECC05 Oct 2014
Diamond Jubilee
Thermal• Coal - 153• Gas - 22.6• Oil - 1.2
176.8 (69.6 %)
Nuclear 4.8 (1.9 %)Hydro 40.8 (16.1 %)Renewable 31.7 (12.5 %)Total 254.0
All India Installed Capacity (GWe) As on 22-10-2014
Capacity Addition Planned in XII Plan (GWe) Coal Oil Nuclear Hydro Renewable Total30.0 10.0 6.0 20.0 33.0 99.0
Why are fast reactors important for India?
Thermal reactors use mainly the U-235 content of the uranium; fast reactors are important for the effective utilization of the limited uranium resources in the country
India has a large resource base of thorium; to utilize thorium through its conversion to U-233, fast reactors are ideal systems due to their neutronic characteristics
Among current technologies, fast reactors are the best systems for burning of minor actinides
Fast reactors have several other advantages including the possibility of design for passive safety
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Indian Strategy for Long-term Energy Security
Hydroelectric
Non-conventional
Coal domestic
Hydrocarbon
Nuclear (Domestic 3-stage programme)
Projected requirement*
*Ref: “A Strategy for Growth of Electrical Energy in India”, document 10, August 2004, DAE
No imported reactor/fuel
Deficit to be filled by fossil fuel / LWR imports
LWR (Imported)
FBR using spent fuel from LWR
LWR import: 40 GWe Deficit 412 GWe
Required coal import:1.6 billion tonne* in 2050
* - Assuming 4200 kcal/kg
The deficit is practically wiped out in 2050
YearWith thorium, nuclear installed capacity (600 GWe) canbe sustained for very long period
India’s Nuclear Roadmap
• India has indigenous nuclear power program (4780 MW out of 20 reactors) and expects to have 20,000 MWe nuclear capacity on line by 2020 and 63,000 MWe by 2032.
• Foreign technology and fuel are expected to boost India's nuclear power plans considerably. All plants will have high indigenous engineering content.
• India has a vision of becoming a world leader in nuclear technology due to its expertise in fast reactors and thorium fuel cycle.
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Nuclear Power Capacity Projection (in MWe)
• PHWRs from indigenous Uranium• PHWRs from imported Uranium• Imported LWR to the extent of 40 GW(e)• PHWRs from spent enriched U from LWRs
(under safeguards)• FBRs from reprocessed Pu and U from PHWR• FBRs from reprocessed Pu and U from LWR
(under safeguards)• U-233-Thorium Thermal / Fast Reactors
FBR’s Role in Nuclear Contribution in India
Feature PHWR FBR Remark on FBR
Fissile concentrationLow
(0.7 %)High
(24 %)High burnup for FBR
Core volumeLarge
77,000 l(770 MWt)
Small3,000 l
(1250 MWt)High power density.
Power density 10 kWt/l 400 kWt/lMetal (sodium) coolant required.
Thermal efficiency 28 % 40 %Lower thermal pollution.Lower radwaste.
Fuel burnup 7 GWd/t >100 GWd/t Less fuel cycle to be processed
High level wastes Produced Partly incinerated
Long term storage reduced.
FBRs vs PHWRs
FBRs vs LWRs
Parameter LWR Fast Reactor
Fissile enrichment 0-3% U235 10 – 30% Pu239
Av. neutron energy ~0.025 eV ~100 keV
Burnup (MWd/t) ~ 40,000 ~100,000
Neutron flux, n/cm2s 1014 5-10 x 1015
Neutron fluence (max.) n/cm2
1022 2-10 x 1023
Av. core power density, W/cm3
~ 40 ~ 400
Characteristics of Fast Reactors
• Higher fissile material enrichment• Control rod material – boron also needs to be
enriched• Higher Neutron Flux ⇒ Damage• Higher Burn-up ⇒ Damage• Higher power density ⇒ Heat transfer• Liquid Sodium as coolant - challenges in maintaining
purity, fire safety to be paid special attention• Can be designed for passive safety
Advantages of Fast ReactorsEnsure effective utilisation of uranium and thorium resourcesCan be designed for passive safetyHigh “burn-up”: More than 100000 MWd energy from one tonne of fuel- Less fuel fabrication, reprocessing; less volume of waste per MW energy generatedHigh temperature of operation as compared to thermal reactors: better energy efficiency and less environmental pollutionLess radioactivity discharge to environment
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Flow sheet of a Typical Fast Reactor
Challenges in Fast Reactor development•Limited international experience (400 reactor years) as
compared to thermal reactors (over 15000 reactor years)
•Many countries have discontinued fast reactors.
•Very few countries are currently pursuing fast reactors
•Fuel Cycle is associated with handling of fuel with high Pu content; very few countries have had experience with such fuel cycles, and the details of experience are not shared in public domain
• Limited experience in the country on manufacturing of large size, intricate components required for FBRs
•Need for absorption of changing safety requirements
Fast neutron spectrum
Sodium-potassium coolant
Enriched metallic uranium fuel
Demonstrated the concept of breeding
Decommissioned in 1964
EBR I: world’s first nuclear plant to produce electricity
Idaho, 1951
RAPSODIE(Cadarache, France)
Fore runner of Indian FBTR; 40 MWth; Commissioned in 1967; shut down in 1983
Phénix (France)
Rating: 565MWt/255MWeCoolant: NaStarted in 1973; shut down in 2009
Chinese Experimental Fast Reactor (CEFR)
• 65 MWth; 20 MWe
• U,Pu Mixed oxide / enriched uranium oxide fuel
• Sodium cooled pool type reactor
• Went critical on 21 July 2010
BN-600 (Beloyarsk, Russia)
In operation since 1980
Over 30 years, the reactor has performed with high availability factors; average 74 %; maximum 84 %
Fast Breeder Reactor and Fuel Cycle Programmes
FRFCF
FBTR
PFBR(500 MWe)
FBR I & II (2 x500 MWe)
MFDR MFBR (1000 MWe)
DFRP
CORAL
Fast Reactor Fuel Cycle Facility
Prototype Fast Breeder Reactor
Fast Breeder Test Reactor
Metal Fuel Demonstration Reactor
Metal Fuel Breeder Reactor
Fast Breeder Test ReactorFBTR, in operation since 1985, is the flag-ship of IGCAR and is the test bed for fast reactor fuels and materials and training ground for operators
The performance of the reactor has been excellent. The sodium pumps have operated continuously for over 750,000 hours
• Fuel for FBTR: (U0.3Pu0.7)C and (U0.45Pu0.55)C• Such high Pu content fuel has not been used as driver fuel anywhere
in the world• FBTR fuel has set world record for performance (165000 MWd/t) • Such fuel has not been reprocessed anywhere in the world; IGCAR
has developed this technology • The recovered plutonium has been used to refabricate fuel, closing
the fuel cycle
Prototype Fast Breeder Reactor
• 1250 MWt, 500 MWe, pool type reactor• Fuel: uranium, plutonium mixed oxide with 21/27
% Pu • Coolant: liquid sodium• Control rod material: boron carbide with 65 %
enrichment in B-10• Fuel pins fabricated at AFFF, Tarapur and
assembled at IGCAR• Breeding ratio: 1.06• Fuel cycle to be closed in FRFCF
Current Status of PFBR Project
Main vessel Grid plateThermal baffles
Safety vessel
Inner vessel Roof slab
To be made critical by March 2015
Manufacturing Technology Development for PFBR
Components manufactured under technology development exercises
Industries involved in PFBR RA Construction
MTAR (Hardfacing by OMPLAS)Grid Plate9L&T PowaiPrimary Pipe10
GodrejLRP & SRP12MTAR, HyderabadControl plug13
MTAR, HydrabadCSRDM & DSRDM2
WIL, WalchandnagarCore Catcher7
L&T (SAS with KRR petals)Safety Vessel3
NFC, Hydrabad & L&T HaziraCore Subassemblies1
L&T (SAS with KRR petals)Main vessel4BHEL, TrichyThermal Baffles inc. cooling pipe5BHEL, TrichyInner Vessel6
L&T HaziraRoof slab11
WIL,WalchandnagarCore Support Structure8
IndustriesComponentsSl.no
MTAR (Hardfacing by OMPLAS)Grid Plate9L&T PowaiPrimary Pipe10
GodrejLRP & SRP12MTAR, HyderabadControl plug13
MTAR, HydrabadCSRDM & DSRDM2
WIL, WalchandnagarCore Catcher7
L&T (SAS with KRR petals)Safety Vessel3
NFC, Hydrabad & L&T HaziraCore Subassemblies1
L&T (SAS with KRR petals)Main vessel4BHEL, TrichyThermal Baffles inc. cooling pipe5BHEL, TrichyInner Vessel6
L&T HaziraRoof slab11
WIL,WalchandnagarCore Support Structure8
IndustriesComponentsSl.no
In-sodium Testing of Fuel Handling Machines
Testing for 10 % of total number of cycles in reactor life. Operating condition in reactor is simulated
in sodium at 200°C & 550°C
IFTM
Transfer ArmPTM
Grid plate
REP
PR Liner
PR / PTM Testing Transfer Arm Testing
Both equipments qualified and delivered to BHAVINI
Manufacturing Challenges of Steam generators
Critical component since sodium and water (which can undergo violent chemical reaction generating high temperature, pressure and hydrogen) coexists
~550 nos. of 23 long tubes to be welded with thick tube sheets on either sides with in-bore welding technique.
Reliability requirement is very high since, this component decides the plant load factor
Material: G91 ferritic steel (mod. 9 Cr-1Mo)
Testing of PFBR model Steam Generator in Steam Generator Test Facility
Comparison of PFBR SG and SGTF SG
Features PFBR SG SGTF SGNo. of tubes 547 19
Power 157 MWt 5.5 MWt
Steam temperature 493°C 493°C
Steam pressure 172 bar 172 bar
Material Mod 9Cr-1Mo Mod 9Cr-1Mo
Tube diameter 7.2 mm 17.2 mm
Tube thickness 2.3 mm 2.3 mm
Tube length 23 m 23 m
PFBR SG SGTF SG
Furnace oil fired heater is used in SGTF to heat liquid sodium which in turnheats water in steam generator to produce high pressure superheated steam.
Experiments completed on SGTF Steam Generator Evaluation of the heat transfer performance of steam generator Assessment of sodium flow induced vibration of SG tubes Experimental evaluation of hydrogen flux diffusion from feed
water to sodium in steam generator Studies on SG thermodynamic flow instability due to two phase Performance assessment of thermal baffles during transients Demonstrating operation of steam generator with a plugged tube Steam generator endurance test Feasibility of using acoustic sensors for SG tube leak detection
STEAM GENERATOR TEST FACILITY
Fuel materialThermochemical & thermophysicalpropertiesInteractions with cladding
Clad materialPerformance at high Burn-up Swelling resitanceCompatibility with coolant and fuel
Sodium coolantFuel-sodium reactionsTransport of activation andcorrosion productsImpurity control and monitoring
SafetyHigh temperature phenomena
Structural MaterialNon-replaceable, high performance , extended life
Control Rod MaterialEnriched Boron Carbide
Materials Issues for FBRs
HIGH
BREEDING
HIGH BURN UP ~ 200 GWd/t
HIGH BREEDING RATIO ~ 1.5
LONG PLANT LIFE ~ 100 YEARS
COST COMPARABLE TO FOSSIL POWER
BURN-UP (dpa)
BR
EED
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RAT
IO TARGET
FBTR(Carbide +CW 316 SS)
(Oxide + D9)
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(Metallic Fuels)
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1.5
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ODSFerritics
Ferritics
D9
316SSBur
n-up
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PFBRFBTR FUTURE
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PFBR
Fuels and Structural Materials in FBRs
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PH Ferritic/Martensitic
Austenitic
ODSHigh Temperature
Strength
RadiationResistance
Max
imum
Tem
pera
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(K)
Radiation damage studies
1.7 MV Tandetron accelerator
Simultaneous irradiation of MeV heavy ions like Ni along with KeV He ions simulates the damage in materials “similar” to neutrons in a reactor. As the dpa/s is much larger in Accelerator damage, what happens in reactor over a few years can be simulated in a day in an accelerator.
Accelerator based structural materials screening is important for identification/ development of void-resistant materials
Variable low energy positron beam for depth profiling of defects
400 KV Accelerator
Materials screening - Void swelling and Positron annihilation Studies on 20% CW D9 Alloy with 0.15 Ti (Ti/C =4) and 0.25 Ti (Ti/C =6)
Positron Annihilation studiesModel alloy without Ti
Ti : 0.25 Ti/C = 6
Ti : 0.15 Ti/C = 4
(823K) (923K)
TiC precipitates
D9 alloy with Ti/C =6 has lower void-swelling, hence preferred. J. Nucl. Mater (2008)
Step-height measurements provided macroscopic information on swelling
Positron annihilation provides insights at atomistic level with regard to the role of Ti in solution as well as TiC precipitates.
Step-height Swelling studies at 100 dpa
Add % CW vs selling – i have i ll give this figure
Materials Technologies• Excepting a few forgings, all clad and structural
materials for PFBR have been indigenously produced
• New stainless steel alloys indigenously developed upto commercial scale production and fully characterised with respect to mechanical properties, irradiation behaviour, weldability, etc.,
• Examples: Ti stabilised austentic stainless steel, oxide dispersion strengthened ferritic martensitic steel;
• Advanced welding and inspection techniques developed
• All facilities and techniques developed for Post-irradiation studies on materials: unique test equipment for remote operation
AdvantagesHigh thermal conductivityLow M.P (371 K) & High B.P (1156 K) Low vapor pressures at operating temperatures
Low density (0.9 g/cc) Low viscosityEasy availability
Liquid Sodium : Coolant for FBRs
Challenges:
High reactivityAffinity for oxygenViolent reaction with water
Na
PFBR uses around 1700 tonnes of sodium
Chemical Sensors for impurities in liquid sodium
Corrosion of structural steels: depends on oxygen concentration in sodium
Hydrogen concentration in sodium: a sensitive indicator of sodium-water reaction
Carburisation is detrimental to structural integrity of steels
Detection of Steam Leak using Hydrogen Sensors
Self- propagating in nature Damages nearby healthy
tubes also Detection of leak at its
inception essential
2Na + H2O → 2 NaOH + H2↑
Exothermic rx & highly corrosive product
Steam leak into sodium releases hydrogen
NaOH + 2 Na →Na2O + NaH H2 + 2 Na → 2NaHNaH + {Na} →[NaH]Na
pH2 in equilibrium with sodium:
(pH2)1/2 = CH / k
⇒ Continuous monitoring of hydrogen in sodium needed
Instantaneous increase of H level in sodium
Electrochemical Hydrogen Meters: unique sensors
Response to hydrogen injection into sodium in phase with conventional diffusion based meter
∗10 Nos. of ECHMs being tested for use in PFBR
Indigenously developed, not used elsewhere in the world
Simple, robust and reliable design; can measure 10 ppb increase with a background of 50 ppb
Demonstrated in several facilities in IGCAR including FBTR
Installed in Phenix Reactor , France, in Oct.2007 and performance tested;
Mutual Inductance type Leak Detector for detecting sodium leaks in Main vessel, safety
vessel and double wall pipes of PFBR
In-sodium Sensors
Eddy Current Flow Meter to measure primary discharge flow in PFBR
Extended Spark Plug type Leak Detector for detecting
sodium leak in main and safety vessels of PFBR
Mutual Inductance type discrete and continuous level probes for sodium level measurement in various sodium capacities of PFBR
Sodium Aerosol Detector for area monitoring of
sodium leak in PFBR
Permanent Magnet Flow Meter for measuring sodium
flow rate at various locations in PFBR
a) Sodium spray fires b) Sodium pool firesc) Sodium cable interactiond) Sodium concrete interactione) Sodium water interactionf) Sodium steam interactiong) Small sodium leaksh) Sodium fire extinguishment a) Small spray fire Drop combustion Drop let size distribution Medium spray fire
e) Sodium water interaction
Corrosion due to Na leak
Innovative powder
h) Nitrogen flooding to extinguish sodium fire
d) Na concrete interaction
b) Pool fire c) Na cable fire
f) Sodium steam interaction setup
MINA: Bench mark sodium fire facility
g) Small sodium leak setup
Fundamental studies towards sodium fire safety
Important Consequences of a CDA in SFR
a b cDeformations of
vesselsSodium ejection to
RCBPost Accident Heat
Removal
Numerical
Experimental
CDA: Validation of Numerical Predictions
High speed photography
0 ms 1 ms 2 ms
FUSTIN Prediction
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mm
Displacements by FUSTIN for TRIG-II Vessel
“Enriched” B4C used in fast reactors as control rod material
FBTR uses boron carbide with 95 % enrichment in B-10
PFBR uses boron carbide with 65 % enrichment
Boron carbide fabricated indigenously (IGCAR, BARC, HWB, NFC)
Boron Carbide
Boron Deposit
Boron Enrichment
Boron Electrowinning
FBR FUEL CYCLE
Closing the fuel cycle is essential for a sustainable fast reactor programme
Fast Reactor Fuel Cycle• Closure of Fuel cycle is essential for sustainability of nuclear
power programme: to recover and reuse Pu; to recover bred Pu for use in future systems; to recover and incinerate minor actinides
• Very limited global experience in reprocessing fast reactor fuels• Usually discouraged because of implications of separation of Pu• Very limited scope for collaboration or information exchange• Reprocessing involves remote handling of highly radioactive fuel
(high burn-up; short cooling) and therefore the technology is complex and challenging
• India has large experience in reprocessing of thermal reactor fuel and limited experience with fast reactor fuel
• Reprocessing of FBTR fuel has yielded valuable experience and also demonstrated our technological strengths
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Adopting closed fuel cycle with fast reactors will also help to reduce nuclear waste burden.
Radiotoxicity of spent fuel is determined by FPs for first 100 years. It is then determined mainly by Pu(>90%). If Pu is removed, MAs specially Am (~9%) determine the rest of the long term radiotoxicity.
Natural decay of spent fuel radiotoxicity
With early introduction of fast reactors using (U+Pu+Am) based fuel, long termraditoxicity of nuclear waste will be reduced.
Fuel Reprocessing
16 Stage Centrifugal Extractor Bank
CORAL facility operation area
Mixed carbide fuels with high Plutonium and with a burn-up of 155,000 MWd/t reprocessed for the first time in the world
Pu recovered used to fabricate fuel; fuel introduced in FBTR to close fuel cycle
Over several campaigns, excellent recovery and decontamination have been achieved, and waste volumes reduced
Inside view of the process cell
REACTOR
REPROCESSING
PLANT
FUEL & BLANKET PIN PLANT
FUEL ASSEMBLY PLANT
WMP
CLOSED FUEL CYCLE
Fast Reactor Fuel Cycle Facility (FRFCF) is being planned to close the fuel cycle of PFBR
Financial sanction from cabinet received in July 2013. Construction started; project to be completed by end 2018
A unique project of its kind, and first in India
Fast Reactor Fuel Cycle Facility
Metal Fuelled FBRs• Metallic fuels offer best performance in terms of
breeding of fissile material: doubling time of the order of 8-10 years can be envisaged as compared to oxide fuel (around 40 years)
• Limited international experience on metal fuelled FBRs, and especially the fuel cycle
• Metal fuels are proposed to be reprocessed by pyrochemical schemes
• India proposes to accelerate the expansion of FBR programme by establishing metal fuelled FBRs
• The first metal fuelled FBR is expected to be set up around 2030
Metallic Fuel Development
Substantial Core Metallic Fuel in FBTR
Pin Irradiation in FBTR
Subassembly Irradiation in FBTR
ExperimentalFast 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 FBTRU-Pu-Zr sodium bonded pins fabricated for irradiation in FBTR
Physicochemical property measurements and clad compatibility studies under way
Pyrochemical reprocessing scheme under development
Pyrochemical processing
Chemical processing at high temperatures – eg.Molten salt electrorefining
Advantages:
Suitable for high burn-up, short-cooled fuels,
especially metallic fuels
Compact plants, less problems of criticality
Minimum or no liquid waste
Complex technology; Limited international experience
Pyroprocessactivities at
IGCAR
Ceramic and Metal Waste Form Development
Studies on Direct Oxide Reduction of Actinide Oxides
Development of Materials, Coatings
Modelling and Basic Electrochemical Studies
Engineering Scale Development of Process and Equipment
Lab. scale Studies on Electrorefining and Consolidation of Cathode Deposit
Fast Reactor Programme: India’s unique approach and achievements
Indian has learnt from the problems faced by other countries in establishing a fast reactor and incorporated appropriate measures
Emphasis on indigenous development has enhanced confidence in Indian industry, and enabled the establishment of infrastructure and capabilities for manufacturing of intricate, large components
India is the only country to place a sustained emphasis on closure of fuel cycle, and develop comprehensive capabilities in all domains
The story of FBTR fuel has shown the resilience of Indian science and engineering community in responding to international pressures
Full scale engineering tests on crucial components has been an important confidence-building measure
Emphasis on breeding: unique approach suited for Indian requirement
1.7 MV tandem accelerator
Ion beam simulation of radiation damage
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Temperature(o C)
Swel
ling
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D9 alloy Ti/C 6.75 Ti 0.25100 dpa
Positron Annihilation
Superconductors
Magnetic Materials
Nano-Materials
Multi-functional Materials
Detection of weak ( pico Tesla)
biomagnetic fields
Magnetoencephalography and Cardiography ( MEG & MCG)
Studies on novel Materials
Basic Research
Computer Simulation
• DAE has conceived a systematic road map towards introduction of FBRs to enhance nuclear energy contribution.
• The operating experiences of FBTR, design and construction experience of PFBR, R&D outputs and well planned R&D activities being carried out for the future SFRs to achieve targeted economy and safety, provide high confidence on fulfilling the mission of SFR development.
• Even though FBRs constitute a challenging and complex technology, they have the potential to provide a sustainable and clean energy source of large size.
• Fast Breeder Reactor Programme is an important step for utilization of the limited resources of uranium and the large resources of thorium
Summary
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