The Indian Fast Reactor Programme: Current status and directions

P.R. Vasudeva RaoIndira Gandhi Centre for Atomic ResearchKalpakkamvasu@igcar.gov.in

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)

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FBTR(Carbide +CW 316 SS)

(Oxide + D9)

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Fuels and Structural Materials in FBRs

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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

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FUSTIN Prediction

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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

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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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