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Experience on Fast Reactor MOX fuel dry reprocessing for Closed Fuel Cycle

Experience on Fast Reactor MOX fuel dry reprocessing for Closed Fuel Cycle. Alexander V. Bychkov Director Research Institute of Atomic Reactors Dimitrovgrad, Russia 2010. New Technological Platform. Beloyarsk 3, BN -600.

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Experience on Fast Reactor MOX fuel dry reprocessing for Closed Fuel Cycle

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  1. Experience on Fast Reactor MOX fuel dry reprocessingfor Closed Fuel Cycle Alexander V. Bychkov Director Research Institute of Atomic Reactors Dimitrovgrad, Russia 2010

  2. New Technological Platform Beloyarsk 3, BN-600 Na-related topic: BN-350, BN-600 (all facilities - 140 reactor-years) Pb-related topic: floatingreactors (Pb-Bi) on nuclear submarines Mixed uranium-plutonium fuel SNF reprocessing Basic paths to arrange the architectureof Closed Fuel Cycle (CFC) with fast neutron power units Place of“fast reactor”in energy production/FC Base for new construction Complementary to VVER Light-metal (Na) “Aqueous” Integral economics and ecology of electric energy production and FC Selection of coolant Selection of reprocessing technology Heavy-metal (Pb) “Dry”

  3. New Technological Platform Development of prototypes of CFC infrastructure key elements in Russia Consolidation of competence and responsibilities for NTP Model of new power engineering architecture in economic logics Confirmation of technological readiness for industrial scaling Dense fuel Fast reactor power unit VVER upgrade, power range SNF reprocessing unit BN-800 and MOX fuel production startup 2014* Selection of base fast reactor technology and decision on VVER upgrade Construction of power unit prototypes 2014 2020 Establishment of “dense” fuel production 2017 Scaling of new technological platform 2026 Startup of SNF industrial reprocessing and RW disposal prototype 2018 Start of research reactor MBIR (RIAR) operation 2019

  4. Pyroelectrochemical reprocessing (recycling through molten salt) Vibropacking technology (crystalline particles with getter) Remote controlled automated technologies for fuel pins and fuel assembly manufacturing Key technologies of the Fast Reactor closed fuel cycle with MOX fuel (first stage)

  5. Depleted U (oxides) Metal Pu (weapon) Granulated MOX-fuel BN FAs Pu storage (weapon or civil) PuO2 (civil) Module for vibropacking and assembling Pyro-process module – MOX production BN-800 reactor Implementation Pyroprocess for BN-800 Fuel Cycle Combination of pyroprocess and vibropacking technologyis the basis for BN-type MOX fuel production and recycling in different scenarios. MCC Krasnoyarsk RIAR Dimitrovdrad In future (second stage): For BN and BREST For MOX and (U,Pu)N BN spent FAs BN Reactor BN FAs On site NPP pyro-reprocessing facility

  6. Fundamental research Properties of U, Pu, Th, Np, Am have been studied. Knowledge of physical chemistry and electrochemistry of basic FP is sufficient for processes understanding and modeling. The needed research lines – study of Cm and Tc chemistry. Development of nitride fuel recycle methods is carried out. Development work All technological steps and equipment have been developed for the oxide fuel reprocessing and fabrication processes. The process was tested more than to 7400 kg of fresh fuel for different reactors and up to 40 kg of BN-350 and BOR-60 irradiated fuel. The essentials of technology have been elaborated and feasibility study has been completed for the BN-800 large-scale CFC plant. More than 45 000 fuel pins and more than 1000 FAs Industrial implementation As the readiness of technology is high, work is underway on industrial implementation of U-Pu fuel. The BOR-60 operates on vi-pack fuel. The design of the CFC facility is in progress. 30 FAs have been tested and irradiated in BN-600. These technologies are under implementation as basic for BN-800 industrial MOX fuel production. Current status of pyrochemical development for oxide fuel

  7. Basic research of the molten salt systems allowed for the development of technological processes for production of granulated uranium and plutonium oxides and mixed uranium and plutonium oxides. A distinctive feature of the pyrochemical technology is a possibility to perform all the deposit production operations in one apparatus - a chloriator-electrolyzer Pyrochemical reprocessing consists of the following main stages: Dissolution of initial products or spent nuclear fuel in molten salts Recovery of crystal plutonium dioxide or electrolytic plutonium and uranium dioxides from the melt Processing of the cathode deposit and production of granulated fuel Pyrochemical processes

  8. Na3PO4 Cathode (pyrographite) Ar (Cl2) Cl2+O2+Ar Cl2+O2+Ar Cl2 Cathode Stirrer Stirrer Stirrer pyrographite bath, NaCl - KCl O2 UO22+ UO2 + NpO2 MA,REE UO2 Pu4+ Pu4+ Cl- UO22+ PuO22+ UO22+ UO22+ NpO2+ UO2 PuO2 PuO2 (MA,REE) RW4 Fuel chlorination 700 оС Preliminary electrolysis 680 оС Precipitation crystallization 680 оС Electrolysis-additional 700 оС Melt purification 700 оС Ar (Cl2) UO2 + NpO2 UO22+ NpO2+ Preliminary electrolysis 630 оС + + + + + DDP (Dimitrovgrad Dry Process) MOXPuO2 flow sheet Na3PO4 Cl2+O2+Ar Cathode (pyrographite) Cl2 Cl2+O2+Ar Cathode Stirrer Stirrer pyrographite bath, NaCl -2CsCl MOX MOX MA,REE Pu4+ Cl- UO22+ UO22+ UO22+ PuO2+ PuO2+ UO2 PuO2 (MA,REE) RW4 Main MOX electrolysis 630 оС Fuel chlorination 650 оС Electrolysis-additional 630оС Melt purification 6500 оС DDP MOXMOX flow sheet

  9. Na3PO4 + + + Cathode (pyrographite) Cl2 Ar (Cl2) Cl2+O2+Ar Cl2+O2+Ar Cathode Stirrer Stirrer Stirrer pyrographite bath, NaCl - KCl 1st salt O2 UO22+ UO2 + NpO2 UO2 MA,REE Pu4+ Pu4+ Cl- UO22+ PuO22+ UO22+ UO22+ NpO2+ UO2 PuO2 PuO2 (MA,REE) RW4 Fast Precipitation crystallization 680 оС Fuel chlorination 700 оС Preliminary electrolysis 680 оС Fast Electrolysis- 700 оС Melt purification 700 оС Draft purification from captured salt Na3PO4 Cl2+O2+Ar Cl2 Stirrer Stirrer pyrographite bath, NaCl -2CsCl After accumulation of impurities during some cycles 2nd salt MOX , Cl- Pu4+ UO22+ UO22+ PuO2+ UO2 PuO2 Main MOX electrolysis 630 оС Melt purification 6500 оС Fuel chlorination 650 оС DDP Double Salt flow sheet

  10. RIAR experience in reprocessing of spent fuel of the BOR-60 and BN-350 reactors One BN-600 Spent MOX fuel assembly will be reprocessed on 2011 (10% burnup, 26 kg - core, 20 kg – blanket) Decontamination factors (DF) from main FPs

  11. MOX-MOX reprocessing experiments 2000 1st Main MOX - 3 200 g, Pu content - 10 %wt . Current efficiency – 15 % 2004 Main MOX - 3 400 g, Pu content - 30 %wt . Current efficiency – 35 %

  12. Granulated MOX-Fuel

  13. Pyrochemical Wastes treatment Na3PO4 Salt purification Radioactive Cs Salt residue Pyroreprocessing NaCl CsCl Fission products NdPO4CePO4 Phosphates Evaluations by Toshiba

  14. Vitrification of HLW from pyrochemical process

  15. Fuel rods with granulated fuel are fabricated by vi-pack technique according to the standard procedures (in glove boxes or hot cells) that has been used at RIAR for 30 years. The main advantages of the vi-pack technique and vibropacked fuel rods are the following: Simplicity of the process due to the reduced number of process and control operations, that makes the automation and remote control of the process easier Possibility of usage of the granulate in any form; both in the form of a homogeneous composition and mechanical mixture Reduced thermo mechanical impact of vi-pack fuel on the cladding (as compared with a pelletized core). More flexible requirements for the inner diameter of the fuel rod claddings Vibropacking technique To correct the oxygen potential in the fuel and eliminate the process impurities effect, getter based on U metal powder is introduced into the granulated fuel

  16. Production and testingof vibropacked fuel rods on the basis ofMOX-fuel

  17. Results of the material science studies of vibropacked fuel pins Micro- and macrostructure of the cross section of the BOR-60fuel rod with UPuO2fuel ( the burnup of 32% h.a.) and BN-600 fuel rod (the burnup of 10.5 %)

  18. Recycle of reprocessed fuel in the BOR-60 reactor in vibrocompacted mode • Fuel UO2+PuO2 (mechanical mixture) has burn-up about 17%, • Some fuel pins were under PIE (b.u.4,8 - 9,8 % ) • MOX reprocessed fuel used for new fuel pins production in 2002 and under irradiation in the BOR-60 from 2004 (burnup 15% )

  19. Reprocessing Plant for Two BN-800

  20. Nitride fuel – recycling by pyro-process and simplified pelletizing Metallic fuel (U-Pu-Zr, U-Al, U-Be) reprocessing RBMK Spent Fuel conditioning (metallization by Li/or electrochemical ) Different fuels/targets with Np, Am, Cm Treatment of non-traditional fuel (coated particles (UN covered by W, U-Mo alloy, UC, Pu alloy, PuO2 etc.) Molten salt fuel - (study of reprocessing and MA behavior) Other processes and fuels which are under R&D in RIAR

  21. Cadmium cathode Ar Ar Ar UСl3, PuCl3 Cd U, Pu Т= 450 C LiCl - KCl Anodic basket Spent fuel Concept of the closed fuel cycle Plant for reprocessing and production of (U,Pu)Nfuel and metallic fuel Production of mononitride fuel from the nitride spent fuel at the stage of pyrochemical reprocessing Production of mononitride fuel pellets Fabrication of fuel rods with sublayer on the basis of pelletized fuel Manufacturing of the fuel assemblies Hot cell design and infrastructure are similar as MOX recycling Plant Recent activity (2010-2011): reprocessing test for (U,Pu)N fuel and U-Pu metallic fuel irradiated in the BOR-60 test reactor

  22. New times consideration:DOVITA DOVITA-2 1992 Dry technologies Oxide fuel with MA Vi-pack Integrated disposition same site with the reactor TA Transmutation of Actinides 2006-2009 • Dry technologies • On-site reprocessing • Various type of fuel with MA • Integration of MA recycling into FR Closed Fuel Cycle • TA - Transmutation of Actinides

  23. Flexibility for pyrochemical closed fuel cycle of FR Fast reactor Spent FAs Dismantling & Decladding Spent MOX-fuel 238UO2 powder Pyrochemical reprocessing in chloride melt Precipitation Electrolysis/ Precipitation FP PuO2+ MA + FP 238UO2+ MA + FP MA MA Conditioning in chloride melt Fabrication of Vipac MA targets PuO2 Fabrication of pellets and FAs Fabrication of Vipac FAs FP Waste conditioning Waste disposal

  24. a b Comparison with powder from oxalate Particle image: a) UO2 from oxalate, T=750oC; b) PuO2 from 3LiCl-2KCl, T=450oC;

  25. Fabrication of MOX andPuO2 pellets

  26. Main goals for dry technologies developmentfor 2020 Development of Pyro reprocessing technologies on a semi-industrial level: FR SNF – molten salt technologies MOX Mixed Nitrides Metallic LWR SNF – combination of fluoride volatility and molten salt technologies UOX MOX Others So called hard-to-reprocessing SNF (test and transportation reactors) Innovation types of fuel (IMF, MSR +++) Demonstration of Closing of BN-800 Fuel Cycle - on a semi-industrial level up to 30 % annual loading, i.e. up to 3,5 – 4 t of MOX SNF per Year Testing and Demonstration of Closing FR Fuel Cycle for MA Develop the Initial Data for full scale Design of Industrial Pyro Module for FR SNF Reprocessing 27

  27. 3D View on MultiPhunctional Complex 28

  28. Layout of MPC HLW treatment Isotopic Production Water reprocessing Deccladding Fluoride volatility repr. Molten salt reprocessing Repair Zone Repair Zone 29

  29. Basic studies on pyrochemical processes in molten chlorides are mainly completed Different technological methods developed and tested for oxide and nitride fuel reprocessing and refabrication Pyroelectrochemical technology for production of MOX vibropacked fuel for the BN-800 fast reactor is under implementation in Russia. Both type of plutonium – military and power grade civil - will be used for MOX fuel production. Dry technologies were choose as basic advanced processes for the closed fuel cycle with the fast reactors New facilities are under design and construction for investigation and demonstration of industrial closed fuel cycle with the fast reactors in Russia Conclusions

  30. Thank you for your attention! Alexander Bychkov State Scientific Centre Research Institute of Atomic Reactors

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