nuclear fuel for vver reactors. actual state and...

NUCLEAR FUEL FORNUCLEAR FUEL FORVVER REACTORS.VVER REACTORS.ACTUAL STATE AND ACTUAL STATE AND TRENDSTRENDS

Presented byPresented by VV. . MolchanovMolchanovdeputy executive directordeputy executive director

8th International Conference on VVER Fuel Performance, Modeling and Experimental Support 27.09–02.10.2009, Helena Resort, Bulgaria

P. LavrenyukV. MolchanovV. Ionov

8th International Conference on VVER Fuel Performance, Modeling and Experimental Support 27.09–02.10.2009, Helena Resort, Bulgaria 2

Development, fabrication and implementation of new Development, fabrication and implementation of new generation of fuel assemblies for VVERgeneration of fuel assemblies for VVER--type reactorstype reactors

Satisfaction of Customer needs Satisfaction of Customer needs regarding nuclear fuel performance regarding nuclear fuel performance

and value improvementand value improvement

Competitive advantages and marketing developmentCompetitive advantages and marketing development

Providing enhanced safety of fabrication and use of nuclear fuelProviding enhanced safety of fabrication and use of nuclear fuel

TVEL Corporation Prime ObjectivesTVEL Corporation Prime Objectives


Tasks to be solved and Methods of SolutionTasks to be solved and Methods of Solution

Increasing of FA service Increasing of FA service lifetimelifetime

Improving reliabilityImproving reliability((demountable FA, debris demountable FA, debris

filtersfilters, , chatterchatter--resistant FAresistant FA))

Increasing of fuel Increasing of fuel burnburn--upup

UprateUprate

Implementation of Implementation of 55--66––years fuel cyclesyears fuel cycles

Decreasing of irradiation impact Decreasing of irradiation impact on the rector vesselon the rector vessel

Implementation of safe and costImplementation of safe and cost--effective fuel effective fuel cyclescycles


Эксплуатируемыеэнергоблоки 24

Novovoronezh NPPNovovoronezh NPP

Armenian NPPArmenian NPP

BoguniceBogunice NPPNPP MohovceMohovce NPPNPP Rivne NPPRivne NPP

DukovanyDukovany NPPNPP LoviisaLoviisa NPPNPP Kola NPPKola NPP

Number of Number of operating unitsoperating units 2323

VVERVVER‐‐440 Nuclear Fuel440 Nuclear Fuel: : sales geographysales geography

PaksPaks NPPNPP


RKRK--22 typetype

20% decrease of number of 20% decrease of number of FA in reload batchFA in reload batch

Cost cutting for Cost cutting for spent fuel handlingspent fuel handling

Enhanced Enhanced parameters of parameters of

nuclear safety for nuclear safety for fresh Ufresh U--Gd fuel Gd fuel

handling handling

possibility of possibility of withdrawing of failed withdrawing of failed pin (with necessary pin (with necessary

equipment)equipment)

10% decrease of 10% decrease of natural uranium rate natural uranium rate

consumptionconsumption

Advantages of 2Advantages of 2ndnd generation of VVERgeneration of VVER‐‐440 FA440 FA


Substantiation and ImplementationSubstantiation and Implementation of VVERof VVER‐‐440440 FAFA

UnitUnit 1: 1: Implementation of Implementation of FAFA with with chatterchatter--resistant design resistant design ((since since 20020099))

UnitUnit 2: 2: Commercial operation of FA with Commercial operation of FA with chatterchatter--resistant design (since 2008)resistant design (since 2008)

UnitUnit 3: 3: Commercial operation of FA and Commercial operation of FA and followers of 2followers of 2ndnd generation generation ((since since 2008)2008)

Kola NPPKola NPP

UnitUnit 44: : Commercial operation of FA and Commercial operation of FA and followers of 2followers of 2ndnd generation generation ((since since 2008)2008)


Power upratePower uprate

Implementation oImplementation of f VVERVVER‐‐440 Nuclear Fuel440 Nuclear Fuel

DukovanyDukovany105%105% Implementation of Implementation of 2nd 2nd generation ofgeneration of FAFA

BoguniceBogunice107%107%

MohovceMohovce107%107%

PaksPaks108%108% Substantiation of nuclear fuel operation Substantiation of nuclear fuel operation

in in ““load followload follow”” modesmodesRivneRivne

108% (108% (plannedplanned))

LoviisaLoviisa110%110%

Development of demountable follower Development of demountable follower designdesign


Next step forward: 3Next step forward: 3rdrd generation of VVERgeneration of VVER‐‐440 FA440 FADevelopment of the 3Development of the 3rdrd generation of FA is based on operation generation of FA is based on operation experience of 2experience of 2ndnd generation of FA and results derived from generation of FA and results derived from development of FA for VVERdevelopment of FA for VVER--440, TVSA type and TVS440, TVSA type and TVS--2 type for 2 type for VVERVVER--10001000. . The waterThe water--uranium ratio was significantly improved due to use of uranium ratio was significantly improved due to use of angle bars in combination with water tubes and increasing of fueangle bars in combination with water tubes and increasing of fuel l rod lattice pitch up to 1rod lattice pitch up to 122..6 6 mmmm. . Fuel cycle:Fuel cycle: 66--yearsyears..Expected result of 3Expected result of 3rdrd generation implementation generation implementation –– more effective more effective fuel utilization (up to 10%)fuel utilization (up to 10%)..Project designProject design was issued in was issued in 2007.2007.Supply of pilot batch of 3Supply of pilot batch of 3rdrd generation FA for test operation generation FA for test operation –– 2010.2010.


up to 4.87up to 4.874.254.25 // 4.384.383.823.823.603.60Average reload Average reload batch enrichment, batch enrichment,

w/o Uw/o U235235

FA of the 2nd / FA of the 2nd / 3rd generation, 3rd generation, with wrapperwith wrapper

FA of the 2nd FA of the 2nd generation, generation, with wrapperwith wrapper

Conventional Conventional FA with FA with wrapperwrapper

Conventional Conventional FA with FA with wrapperwrapper

FA TypeFA Type

Shaped, UShaped, U‐‐GdGdShaped, UShaped, U‐‐GdGdShapedShapedNonNon‐‐shapedshapedType of fuel rod Type of fuel rod bundlebundle

before 1997before 1997 19981998––20022002 20032003––20102010 20102010……

Number of FA in Number of FA in reload batchreload batch 105105 8484 6666 6060

BurnBurn‐‐upup, , GWGW××dd/tHM/tHM 3636 4545 5757 6565

Fuel cycleFuel cycle 33‐‐yearyear 44‐‐yearyear 55‐‐yearyear 66‐‐yearyear

Natural Uranium Natural Uranium consumption,consumption,tHM/GWtHM/GW××dd

0.2560.256 0.2090.209 0.1840.184 0.1800.180

Development of VVERDevelopment of VVER‐‐440 Nuclear Fuel440 Nuclear Fuel


d

Zaporozhzhya NPP

Khmelnytska NPP

Rivne NPP

South‐Ukraine NPP

Kudankulam NPP

Busher NPP

Tyanvan NPP

Kozloduy NPP

Rostov NPP, unit 2

Balakovo NPP

Kalinin NPP

Novovoronezh NPP

Rostov NPP, unit 1

Temelin NPP

VVERVVER‐‐1000 Nuclear Fuel1000 Nuclear Fuel: : sales geographysales geography

Number of units Number of units ((operatingoperating / / under under construction)construction)

2288 / / 44


1.1. Casing constructionCasing construction2.2. UU--Gd fuel, average assembly enrichment Gd fuel, average assembly enrichment –– 4,34,3 w/ow/o 235235UU3.3. Fuel cycleFuel cycle 44××300 300 EFPDEFPD

VVERVVER‐‐10010000 Nuclear Fuel for NovovoronezhNuclear Fuel for Novovoronezh‐‐55

Fabrication of FA using Fabrication of FA using unified parts since unified parts since 20102010


3. 3. Provided featuresProvided featuresenhanced burnenhanced burn‐‐upupenhanced FA lifeenhanced FA life‐‐time up to time up to 6 6 yearsyearsimproved reliabilityimproved reliabilitynew generation of fuel rodnew generation of fuel rodload follow modeload follow modesafe performance under power uprate conditions safe performance under power uprate conditions

(Nnom=107%)(Nnom=107%)

1.1. Stable geometric Stable geometric behaviourbehaviour2.2. FailFail--safe operation of RCCAsafe operation of RCCA

TVSATVSA TVSTVS‐‐22

VVERVVER‐‐1001000 Nuclear Fuel for0 Nuclear Fuel for ВВ‐‐320, В320, В‐‐338338,, ВВ‐‐302302New generation of FANew generation of FA


TVSTVS‐‐22

Kalinin NPPKalinin NPP::TVSATVSA sincesince 19981998 Balakovo NPPBalakovo NPP::

TVSTVS‐‐2 2 sincesince 20032003Ukrainian NPPUkrainian NPP::TVSATVSA sincesince 20032003

Kozloduy NPPKozloduy NPP::TVSA since TVSA since 20042004

TVSATVSA

Fuel cycle 4Fuel cycle 4××12, average assembly burn12, average assembly burn‐‐up up 55 55 GWGW××dd//tHMtHMStable geometry during operation Stable geometry during operation ((bowing less than bowing less than 77mmmm))No frettingNo fretting‐‐wear during operationwear during operationOnOn‐‐site repairable dsite repairable demountableemountable ddesignesign

Rostov NPPRostov NPP::TVSTVS‐‐2 2 sincesince 20082008

VVERVVER‐‐1001000 Nuclear Fuel Today0 Nuclear Fuel Today


Main featuresMain featuresfuel stack is increased onfuel stack is increased on 150150 mmmmUOUO22 mass mass –– 552424..11 kgkg1212 spacer gridsspacer gridsantivibration gridantivibration grid3 3 mixing gridsmixing grids –– sincesince 20102010antianti--debris filter debris filter ((restrain particles more than 2 mm restrain particles more than 2 mm

sizesize) ) –– since since 2010 2010

TendenciesTendenciesincreasedincreased uraniumuranium capacitycapacityimproved heat reliabilityimproved heat reliabilityenhanced operational safetyenhanced operational safety

In operation at BalakovoIn operation at Balakovo--11 sincesince 20062006

VVERVVER‐‐1001000 Nuclear Fuel Development:0 Nuclear Fuel Development: TVSTVS‐‐22ММ


Operation at KalininOperation at Kalinin--2, Kalinin2, Kalinin--3 is planned since3 is planned since 20102010


Main featuresMain featuresfuel stack is increased onfuel stack is increased on 150150 mmmmUOUO22 mass mass –– 552424..11 kgkg115 spacer grids5 spacer gridsantivibration gridantivibration gridantianti--debris filter debris filter ((restrain particles more than 2 mm restrain particles more than 2 mm

sizesize))

VVERVVER‐‐1001000 Nuclear Fuel Development:0 Nuclear Fuel Development: TVSATVSA‐‐PLUSPLUS


Antivibration gridAntivibration grid

AntiAnti--debris debris filterfilter

In operation at KalininIn operation at Kalinin--1 since 20061 since 2006


Main featuresMain featuressolid pellet 7.8/solid pellet 7.8/00mmmmUOUO22 mass mass –– 55446 kg6 kg8 spacer grids8 spacer gridsantivibration gridantivibration grid3 3 mixing gridsmixing grids –– sincesince 20102010antianti--debris filter debris filter ((restrain particles more restrain particles more

than 2 mm sizethan 2 mm size) ) –– since since 2010 2010

VVERVVER‐‐1001000 Nuclear Fuel Development:0 Nuclear Fuel Development: TVSATVSA‐‐ALFAALFA


Current Current valuevalue

Advanced Advanced valuevalue

Cladding thicknessCladding thickness, , mmmm 00..6565 00..5757

Pellet diameterPellet diameter, , mmmm 77..57/757/7..6060 77..8080

Central holeCentral hole, , mmmm 11..4 / 14 / 1..22 00

Average grain sizeAverage grain size, , μμmm 1010 2525

Design features providing VVER fuel rod service life timeDesign features providing VVER fuel rod service life time: : ZrZr spongesponge sincesince 20092009Advanced fuel pellets Advanced fuel pellets Optimized E110Optimized E110

L=L=3530 +150 3530 +150 mmmm

L=L=3530 +200 3530 +200 mmmm

VVERVVER‐‐1001000 Nuclear Fuel0 Nuclear Fuel: : Advanced Fuel RodsAdvanced Fuel Rods


sincesince 20032003 AdvancedAdvancedCycle length, Cycle length, EFPDEFPD 44××331010 33××515100 55××310310Reload batchReload batch, , pcspcs 4242 6666 3636Assembly burnAssembly burn--up, GWup, GW··dd//tHMtHM 5555 6060 up to 6up to 688

KalininKalinin‐‐11

Balakovo NPPBalakovo NPPRostov NPPRostov NPP

TVSTVS--22ММsince since 20082008

TVSATVSA--ALFAALFAsincesince 20020088

Fuel cycle Fuel cycle 33××1818

Fuel cycle Fuel cycle 55××12 12

KalininKalinin‐‐2, Kalinin2, Kalinin‐‐33

TVSATVSA--PLUSPLUSsince since 20201010 Fuel cycleFuel cycle 33××1818

Fuel Cycles: UprateFuel Cycles: Upratedd PowerPower ((104% 104% NNnomnom))


ParameterParameter ValueValueOuter/ inner pellet diameterOuter/ inner pellet diameter, , mmmm 77..66 // 11..22Outer / inner cladding diameterOuter / inner cladding diameter, , mmmm 99..11 // 77..7373Increased fuel stack heightIncreased fuel stack height, , mmmm 36803680Spacer gridsSpacer grids, , pcspcs 88Mixing gridsMixing grids, , pcspcs 66Reference fuel cycleReference fuel cycle, , EFPDEFPD 55××320320Lead rod burnLead rod burn--upup, , GWGW··dd//tHMtHM up toup to 7272AntiAnti--debris filterdebris filter yesyes

Design of TVSADesign of TVSA--T is based on TVSAT is based on TVSA--ALFA designALFA designFirst full core loading at Temelin NPP First full core loading at Temelin NPP –– in in 20102010

VVERVVER‐‐1001000 Nuclear Fuel0 Nuclear Fuel: : TVSATVSA‐‐TT for Temelin NPPfor Temelin NPP


before before 19971997

19981998––20102010

sincesince19981998

sincesince20032003

sincesince20062006

sincesince20062006

sincesince20102010

FA typeFA type TVSTVS,,TVSTVS--MM

UTVSUTVS TVSATVSA TVSTVS--22 TVSATVSA--ALFAALFA

TVSTVS--2M2M TVSATVSA--PLUSPLUS

Type of BAType of BA –– UU--GdGd UU--GdGd UU--GdGd UU--GdGd UU--GdGd UU--GdGd

Average Average enrichment of enrichment of reload batchreload batch, , w/ow/o

44..3131 33..7777 up toup to 44..44 44..2626 44..8383 44..8888 4.884.88

Reload batchReload batch, , pcspcs 5454 4848 4242 5454 3636 60 60 –– 6666 60 60 –– 6666

Outer fuel rod Outer fuel rod diameterdiameter, , mmmm 77..57 / 2,357 / 2,3 77..57 / 157 / 1..55 77..57 / 1,457 / 1,4 77..57 / 157 / 1..44 77..8 / 08 / 0..00 77..6 / 16 / 1..22 77..6 / 16 / 1..22

Assembly burnAssembly burn--upup, , GWGW××dd//tHMtHM 4949 4949 5555 5555 додо 6868 додо 6868 додо 6868

Fuel cycleFuel cycle 33××11 33××11 44××(310(310––320)320)

3 3 ××(350(350––370)370)

5 5 ××(310(310––320)320)

3 3 ××(480(480––510)510)

3 3 ××(480(480––510)510)

Uranium Uranium consumptionconsumption, , tHM/GWtHM/GW××dd

00..240240 00..205205 00..199199 00..210210 00..187187 00..230230 00..230230

Development of VVERDevelopment of VVER‐‐1001000 Nuclear Fuel0 Nuclear Fuel


VVERVVER--1000 1000 nuclear fuel provides load follow modesnuclear fuel provides load follow modes

Primary load follow Primary load follow within the range of within the range of ±± 2 % 2 % NNnomnom

Power maneuvering Power maneuvering 100100––7575––100 % 100 % NNelel

raterate up to up to 1% 1% NNnomnom//minmin200 200 cycles through operating periodcycles through operating period

60

70

80

90

100

110

4 0 6 12 18 24

VVERVVER‐‐1001000 Nuclear Fuel0 Nuclear Fuel: : Load FollowLoad Follow


R&D, FA based on TVS-2M design:

Enhanced uranium capacity due to increased fuel stack height and advanced fuel rod design (cladding 9.1 / 7.93 mm, pellet 7.8 / 0.0 mm)

Improved heat reliability at uprated power

Modified Zr alloys

AES-2006 Technical Assignment Requirements

Thermal power – 3200 MW(Тinlet=298.8 °С, mass steam quality up to 13 %)

Fuel cycles 5×12 and 3×18, maximum assembly burn-up up to 70 GW·d/tHM

Load Follow Operation – during 90% of operation time within the range 100-20-100 % Nnom and rate of change 5% Nnom/min

AESAES‐‐2006 Nuclear Fuel2006 Nuclear FuelDevelopment StepDevelopment Step‐‐byby‐‐Step Step (1)(1)


Phase #1 (2007 – 2009)

Base FA design development:

- Thermal PowerThermal Power: : 3200 3200 MWMW-- Increased fuel stack heightIncreased fuel stack height ((pelletpellet 7.67.6 /1.2 /1.2 mmmm, , grain grain

sizesize 25 25 µµmm))-- Average assembly burnAverage assembly burn--up up :: 64 64 GWGW··dd//tHMtHM-- Load Follow Load Follow 100100--7575--100 % 100 % NNnomnom

-- Mixing gridsMixing grids

AESAES‐‐2006 Nuclear Fuel2006 Nuclear FuelDevelopment StepDevelopment Step‐‐byby‐‐Step Step ((22))


Phase #1 Results2. Fuel Cycles

Fuel Cycle, EFPD 5×310 3×510Reload batch, pcs 36 72

Average enrichment of reload batch, w/o 235 U 4.83 4.69

Discharge burn-up, GW·d/tHMAverage assembly burn-upLead rod burn-up

58.464.2

48.357.0

AESAES‐‐2006 Nuclear Fuel2006 Nuclear FuelDevelopment StepDevelopment Step‐‐byby‐‐Step Step ((33))


CONCLUSIONSCONCLUSIONS

VVERVVER--440 Nuclear Fuel440 Nuclear Fuel

Implementation of 2Implementation of 2ndnd generation of FA with the generation of FA with the following performance characteristicsfollowing performance characteristics::-- Average FP failure factor during operation is less than Average FP failure factor during operation is less than 11··1010--66; ;

-- Fuel burnFuel burn--upup: : up to up to 60 60 GW×dGW×d//tHMtHM;;

-- 55--year fuel cycleyear fuel cycle;;

-- Unit thermal power uprate up to Unit thermal power uprate up to 110% 110% NNnomnom;;

-- Load Follow ModeLoad Follow Mode (97,5(97,5±±2,5%2,5% andand 100100--7575--100% 100% NNnomnom))

33rdrd generation of FA is developed (RKgeneration of FA is developed (RK--3 Type)3 Type)


VVERVVER--10001000 Nuclear FuelNuclear Fuel

1)1) New generation of FA (TVSA and TVSNew generation of FA (TVSA and TVS--2) is developed, 2) is developed, implemented and successfully operated at Russian, Ukrainian and implemented and successfully operated at Russian, Ukrainian and Bulgarian NPPs providingBulgarian NPPs providingSafe and reliable operation cycle of Safe and reliable operation cycle of 66 yearsyearsAssembly burnAssembly burn--up up – up to up to 60 60 GWGW××dd//tHMtHMLoad Follow ModeLoad Follow Mode

2)2) For satisfaction of customer needs regarding nuclear fuel For satisfaction of customer needs regarding nuclear fuel performance the following development of FA design is under performance the following development of FA design is under wayway::Power uprate up to Power uprate up to 104%104% NNnomnom;;Fuel cycles length up toFuel cycles length up to 18 18 monthsmonths

CONCLUSIONSCONCLUSIONS


Thank you for your attentionThank you for your attention

nuclear fuel for vver reactors. actual state and...

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