P. Puthiya Vinayagam and P. ChellapandiIndira Gandhi Centre for Atomic Research

Kalpakkam, India

Sustainable Energy Security from

Fast Breeder Reactors

6th Nuclear Energy ConclaveOrganised by India Energy Forum at New Delhi on 14th October 2014

Provides a perfect link covering the natural nuclear resources of India

Effective utilisation of uranium – better resource management

Long term energy supply

Higher growth rate with breeding

Waste management - Incineration of radioactive waste from spent fuel and reduction of long term storage requirements

Enhanced performance parameters – high temp of operation leading to higher thermodynamic efficiency

Closed fuel cycle program is essential in the 2nd and 3rd stage

FBR : A Vital Stage in Indian Nuclear Power Program

FBRs : Inevitable for long term security & sustainability of nuclear power

Nat U

Pu & Depleted U

U233

Th

Stage I

Stage II

Stage III

Pu

U233

Th

Growth and Waste Minimization Strategy

Growth

Higher growth rate possible only if fuel generation is more;

Hence, breeders are essential (with high breeding ratio)

Recycling & Waste Minimization

Effective incineration with higher energy spectrum;

FBRs are high energy systems

Key Parameters: Burnup, Breeding Ratio & Doubling Time (Growth)

FBR Program in India

• FBR program started with construction of test reactor –

Fast Breeder Test Reactor with French know-how

• Prototype scale reactor : PFBR 500 MWe - Indigenous

Design & Construction – Under commissioning

• Comprehensiveness in development of Design based on

systematic R&D

• Synthesis of Operating Experiences

• National & International Collaborations

• Emphasis on sustaining quality human resources

• Future FBR Design : Improved economy & enhanced

safety

Fast Breeder Test Reactor

FBTR, in operation since 1985, is the flag-ship of IGCAR and is the test bed for fast reactor fuels and materials.

22 campaigns were completed so far for various irradiation programs.

Training of PFBR operators in progress

High burnup experience from mixed carbide fuel (165 GWd/t) PFBR MOX fuel tested and design demonstrated (112 GWd/t) Structural materials irradiation program Irradiation testing of advanced fuel types (vibrocompacted MOX fuel) Sodium systems performance is excellent and confidence in operation Material and fuel irradiation for other Indian reactors which are under

development

Major Achievements

40 MWt

13.5 MWe

Loop type

(Pu-U)C fuel

MFBR1000 MWe

Proven Prototype Concepts

Design, Mfg. and Safety re

view Experience

FBR 1 & 2 - 500 MWeMOX, Pool, Twin

units, Indigeneous

PFBR - 500 MWeMOX , Pool type, Indigeneous

Metal fuel Demonstration Fast Reactor – 500 MWeSame reactor concepts,

Indigeneous

Evolution of SFR Power Reactor Concepts

FBR-600 MWe Preliminary Conceptual Design options worked outPower : 600 MWe with expanded coreTargets : Higher breeding ratio compared to PFBRVessel size : same as PFBR Reactor Assembly design concepts : same as FBR1&2Core type: Heterogeneous as an optionAdvantage : Existing MOX technology & economy

Improved economy- Higher reactor power (600 MWe – Specific capital cost reduction) - Core optimisation for higher breeding ratio (not fuel inventory alone)- Specific material inventory reduction (t/MWe) (~ 20% in 316LN & carbon steel, ~ 15% in Ferritic steel, ~ 6% in sodium)- Simplified systems and components (e.g fuel handling)- Integrated manufacture & erection - reduction of gestation period

-Twin units sharing non-safety systems (cost reduction)-Steam generator (longer length ) & Standardized turbine

Enhanced safety - Addition of passive features in shutdown systems & addition of 3rd system based on liquid absorbers / B4C granules

- Enhanced reliability of decay heat removal systems with addition of passive features- Enhanced in-service inspection and repair features

Design Approach for Future FBRs

No major R&D requirement for Design as well as Technology development beyond those planned for 500 MWe reactors

FBR-600 MWe : Plant Parameters

Parameter PFBR FBR-600

Power, MWe 500 600

Fuel MOX MOX

Reactor coolant inlet/outlet temp, oC 397 / 547 397 / 557

Core layout Homogeneous Heterogeneous

No. of enrichment zones 2 1

Fissile enrichment, % 20.7 / 27.7 29.5

Fissile inventory, kg 1980 3310

Breeding ratio 1.05 1.13

Secondary loops 2 2

No. of Primary Sodium Pump 2 3

No. of IHX 4 4

No. of Secondary Sodium Pump 2 2

No. of SG / loop (tube height, m) 4 (23 m) 3 (30 m)

Steam temp/Pressure (oC / MPa) 490 / 17 510 / 17

Main vessel diameter, m 12.9 12.9

Load factor, % 75 85

Strategy for the Development of Metal Fuel Reactors

Pin and subassembly level irradiation in FBTR mainly to demonstrate pin production, reprocessing and re-fabrication technologies

Irradiation of a few subassemblies in PFBR after demonstrating the stable operation at rated power levels

Re-fabrication of pins for both FBTR & PFBR irradiation pins in an integrated facility

Accumulating operating experiences through demonstration plant Metal Demonstration Fast Reactor (MDFR), preferably of medium size plant with reasonable breeding

Deriving technological maturity on pyro metallurgical recycle technology in industrial scale

Demonstration of closed fuel cycle mode through MDFR

Series construction of 500-1000 MWe plants

Metallic Fuel Development

Doubling time: 30years for oxide, 12 years for metal (ternary fuel) and 8 years for improved metallic fuel (binary fuel without Zr)

Reference compositions:

U-19%Pu-6%Zr (sodium bonded)U-15% Pu (mechanically bonded)

Sodium bonded EU-6%Zr and U-Pu-Zr pins fabricated and are under irradiation in FBTR

Physicochemical property measurements and clad compatibility studies under way

Scenario for Metal Fuel Power Reactor Assessment with optimum pin diameter 8 – 8.5 mm for growth

Based on preliminary assessments with a matrix of case studies

ParameterSodium Bond Mech Bond

10 % Zr 6 %Zr 0 % ZrLHR, W/cm 450-530 420-470 375-400

Breeding Ratio (including ext. blanket )

1.2 – 1.25 1.30 – 1.35 1.4 – 1.45

Burnup, GWd/t 100-125 100-125 100-125Sodium Void Reactivity coeff, $ 4.5 – 5.0 5.0 – 5.5 5.5 – 6.0

Fissile enrichment zones (500/1000) 2 / 3 2 / 3 2 / 3

No of SA (500 MWe) 180 195 220

Na outlet temp oC 510-520 510-520 510-520

Spent fuel storage Sodium Sodium Water

Reprocessing Pyro Pyro Purex

Plant Parameters : A Comparison (MOX & Metal)

Closed Fuel Cycle for PFBR

• Closure of fuel cycle of PFBR is essential to make it self-sustaining

• Thermal reactor Plutonium will be used for building of more FBRs.

• Fast Reactor Fuel Cycle Facility (FRFCF) being located at Kalpakkam.

• FRFCF would be a ‘first of its kind’ facility in the country

• Co-location of the facility with reactor would reduce cost due to transport and also avoid security issues

• Basic technologies required for the facility is available

• Designed to augment additional capacity to meet the requirements of two more 500 MWe FBRs to be built at Kalpakkam site.

FRFCF – Bird’s Eye View

MA Burner – design to burn self-production and external MA feed;

MA Burnt ~ 100 kg/GWey MA produced ~ 20 kg/GWey Net Transmutation ~80kg/GWey

Sustainability Consideration

Minor Actinide Management – A scenario

• Study based on Indian power reactor program

• Metal fast reactors are ideal for MA burning

• Introduction of MA Burner together with power production at an appropriate time

• Fast Breeder Reactors – Essential for Energy Security and Sustainability

• Experience from FBTR operation and PFBR design, manufacture, construction & safety review have given confidence for FBR deployment in series in closed fuel cycle mode. No technological constraints are foreseen.

• Towards higher growth rate, R&D on metal fuel with high breeding potential along with associated fuel cycle technologies is in progress.

Summary

Thank You for your attention