research and development policy on fbr cycle technology in ... · ¾a feasibility study on...

Research and Development Policy on FBR Cycle Technology

in Japan

Satoru TanakaThe University of Tokyo

Dec. 1, 2008Presentation at IAEA Technical Meetingon Country Nuclear Fuel Cycle Profiles,

Fukui, Japan

Table of Contents

1. History of FBR and its Fuel Cycle Development2. Japanese Basic Policy on FBR Cycle Development3. Development Target in the Feasibility Study4． Promising Concept of FBR Cycle System

4,1 Sodium-cooled Fast Breeder Reactor4.2 Advanced Aqueous Reprocessing4.3 Simplified Pelletizing Fuel Fabrication

5. Future Program

Histry of Fast Breeder reactor Development in Japan

1.History of FBR and its Fuel Cycle Development

Monju

Joyo

DFBR

Confirmation of FBR Basic TechnologiesVerification of Safe and Stable OperationInitial Criticality in 1977Power ： 50MWt 100MWt 140MWt (Mk-III Core)Temperature ： 435ºC 500ºC 500ºC

Demonstration of Reliable OperationEstablishment of Sodium Handling

Initial Criticality in 1994Power ： 714MWt / 280MWeTemperature ： 529ºC

Design Study of Demonstration ReactorDevelopment of Element Technologies

Performed during the 1990sPower ： 1,600MWt / 660MWeTemperature ： 550ºC

System Development as Electricity Generation

Innovative Technology for Economics and Reliability

JSFRDemonstration /

Commercialization

Prototype

Experi‐mental

Design for Demonstration

FBR Cycle Development in Japan

Experimental FR “Joyo” (1977)

Hot engineering test facility

Chemical Processing Facility(since1982)

Engineering Scale Hot Test

Driver Fuel Supply

Pu Recycle(1984)

TRU Recycle(planned)

Pu Fuel Development Facility(Since 1966)

Alpha Gamma FacilityAlpha Gamma Facility

Pu Fuel Production Facility(Since 1988)

Pu Recycle

TRU Recycle

Labo.Scale

Eng.Scale

Tokai Reprocessing Plant(Since 1977)

Red ; In the Nuclear Fuel Cycle Engineering Laboratories


Prototype FBR “Monju”(1994)

Stepwise R&D & Facilities for Aqueous Reprocessing

Non radioactive

EDF-IEDF-IProcess Equipment.

U/RI

H E T F

Actual Spent Fuel

Pu

Basic test Small Scale testFuel pin scale

Engineering scale testFuel assembly scale

EDF-IIIEDF-IIIRemote handling

EDF-IIEDF-II

Basic Chemical Test Lab.

Basic Chemical Test Lab.

Process Equipment.

Flow sheet Study

CPFCPF

TRPTRPLWR Reprocessing

Demonstration Plant

CPF ; Chemical Processing Facility HETF ; Hot engineering test facilityEDF ; Engineering Demonstration Facility


Framework for Nuclear Energy Policy by Atomic Energy Commission (AEC) of Japan (Oct. 2005)

It is necessary to promote R&D toward commercialization of FBR cycle technology, which can enable long-term energy security and reduction in radio-toxicity of radioactive waste.A Feasibility Study on Commercialized FBR Cycle Systems aims to establish the FBR cycle technological scheme by around 2015.Development of FBR cycle aims at its commercial introduction around 2050.

“Basic Policy on Research and Development of Fast Breeder ReactorCycle Technologies over the Next Decade” was decided by AEC (Dec. 2006)

Report on Nuclear Energy Policy of MEXT (Jul. 2006) and METI (Aug. 2006)

A council was set up to investigate demonstration processes of FBR cycle technology by MEXT, METI, JAEA, electric utilities and plant vendors.Development of a demonstration FBR aims at its introduction by around 2025.

Science and Technology Basic Plan by Council for Science and Technology Policy (Mar. 2006)

FBR cycle technology was selected as one of the key technologies of national importance.

FBR Cycle Development Policy in JapanFBR Cycle Development Policy in Japan2. Japanese Basic Policy on FBR Cycle Development

Outline of the Feasibility StudyOutline of the Feasibility Study

2000 2005

Phase 1Evaluation of

Phase I• Assessment of

various options• Screening of

promising candidates

Phase II• Application of

innovative technologies

• Conceptual design & fundamental tests of key technologies

• R&D planning• Selection of a few

promising candidates

C&R

Design Studies

ExperimentalStudies

Example

TechnologicalOptions

InnovativeTechnologies

Reprocessing- Advanced Aqueous- Metal Electrorefining- Oxide Electrowinning

Fuel Fabrication- Simplified Pelletizing- Vibration Compaction - Casting

Promising candidates-First Priority = MOX

advanced aqueous repro. + simplifid pelletizing

-Second Priority = Metalelectrorefining repro. + injection casting

1998

Monju Accident(1995)

FBR Na coolant

Japanese Fiscal Year

3. Development Target in the Feasibility Study

8

Safety• Risks caused by introduction of FBR cycle should be small compared with

risks that already exist in society.Economic Competitiveness

• Achieve power generation cost comparable to that of future LWRs and other energy resources.

• Ensure cost competitiveness in the global market.Reduction of Environmental Burden

• Reduce the amount of radioactive waste generated in the course of plant operation and maintenance as well as decommissioning.

• Reduce the radiotoxicity of radioactive waste by means of burning or transmuting long lived nuclides.

Efficient Utilization of Nuclear Fuel Resources• Produce sustainable nuclear fuel.• Respond to diverse needs for energy resources.

Enhancement of Nuclear Non-Proliferation• Reduce burden of nuclear Physical Protection and safeguards (no pure

plutonium in any FBR cycle process and increase radioactivity of fuel materials).

• Effectively operate non-proliferation system (remote process and monitoring system.)

Development Targets in the Feasibility Study3. Development Target in the Feasibility Study

Candidate FBRs using Various Coolants4. Promising Concept of FBR Cycle System ～ 4.1 Sodium-cooled Fast Breeder Reactor

Advanced Sodium‐cooled FBR

Lead‐Bismuth‐cooled FBR

Helium Gas‐cooled FBR

Light‐water‐cooled Boiling FBR

○Compacted design○Integrated components○Reduction of loop number○Shortening of piping▲ODS cladding steel

○Higher thermal efficiency○Helium gas turbine○Multi‐purpose usage▲TiN coated nitride fuel particle

○No need of intermediate loop○Chemically inactive▲Need for 3D seismic isolation▲Material corrosion behavior

○BWR operational experiences▲Restriction on FR performance▲New cladding for fast neutron

and water environment▲Consideration of CDA

Design studies were conducted on candidate FBRs for various coolants.

○: advantages ▲: crucial issues

Japanese Sodium-cooled FBR (JSFR)

Secondary pump

SG

Integratedpump‐IHX

Reactor VesselReactor Core

Items Specifications

Output 3,570MWt / 1,500MWe

Number of loops 2

Primary sodium temperature and flow rate

550 /395 degree C3.24 x 107 kg/h/loop

Secondary sodium temperature and flow rate

520 / 335 degree C2.70 x 107 kg/h/loop

Main steam temperature and pressure

497 degree C19.2 MPa

Feed water temperature and flow rate

240 degree C5.77 x 106 kg/h

Plant efficiency Approx. 42%

Fuel type TRU‐MOX

Breeding ratio Break even (1.03), 1.1, 1.2

Cycle length 26 months or less, 4 batches

4. Promising Concept of FBR Cycle System ～ 4.1 Sodium-cooled Fast Breeder Reactor

Cost Reduction from Monju to JSFR

1000$ line

Target of FS0.2M

0.4M

0.6M

2.0M

Unit C

onstruction Co

st (JP Yen / kW

e)

MONJU:280MWe

JSFR :1500MWe×2(FOAK)

~0.18

Scale Merit(to 1500MWe)

Twin Effect

2.0 Innovative Technologies

0.48DFBR:670MWe

Breakdown list

0.1M

0.3M

0.5M

The unit construction cost of Monju is expressed as the construction cost divided by electric power.The unit construction costs of DFBR and JSFR are evaluated values.

Others, 17%High Cr Steel,14%

Compacted R/V,24% 2 loop heat

Transport system,34%

Integrated IHX withPump, 10%

Cost Estimation by NOAK and Overnight Cost, taking into account Learning Effect


Innovative Technologies for JSFR4. Promising Concept of FBR Cycle System ～ 4.1 Sodium-cooled Fast Breeder Reactor

Core safety

Seismic reliability

Reduction of Mass & Volume

Long operation by high burn‐up fuel

1) Shortened piping with high chromium steel

3) Seismic reliability in core assemblies

4) Compact reactor vessel

7) Advanced fuel material

2) Two loop cooling system

2) Re‐criticality free core

1) Passive shutdown and decay heat removal

Economic CompetitivenessEconomic Competitiveness Higher reliabilityHigher reliability

Higher safetyHigher safety

5) Simplified fuel handling system

6) CV with steel plate reinforced concrete building

Sodium technology

3) Higher maintenance ability inside of sodium boundary

1) Sodium leak tightness with double wall piping

3) Integrated pump‐IHX component

Secondary pump

SG

Integrated pump‐IHX

Reactor Vessel

2) Higher reliable SG with double wall tube

The large scale sodiumtest complex

Plant design study

R&D Programs Using Monju

Power operationSystem start-up tests

R&D using Monju

Oper/maint experiences

Original missions• Demonstration of safe and reliable operation• Sodium handling technologies

Site of international/local collaboration

2009

Validation of design tools

Demonstration of FR corePerformance (breeding/burning)

Demonstration irradiation ofAdvenced fuel (MA-bearing)Reflection to JSFR

Core upgrade

Utilization as an R&D facility

Demonstration of advanced technol.• Advanced fuel (TRU-MOX)• Longer operation cycle• Higher burnup• Irradiation bed in larger scale, etc.

2015


Entire system function test /Pre-start-up Confirmation

U Product Pu Product

Conventional PUREXSpent fuel

U/Pu Co-extraction

U Stripping

High levelLiquid waste

U-Pu-Np

MA Recovery

Am-Cm

NEXT

Co-extraction

Co-Stripping

U-Pu-MA Product

Single cycle co-extraction

Pu Stripping

Pu PurificationU Purification

Clarification

Under R&D in CPF

U Product

U/Pu/Np

Spent fuel

Dissolution

Adjustment

Dissolution

ClarificationAdjustment

Crystallization

High levelLiquid waste

Advanced Aqueous Process “NEXT”(New Extraction System for TRU Recovery Process)

4. Promising Concept of FBR Cycle System ～ 4.2 Advanced Aqueous Reprocessing

Development of Development of Advanced Aqueous ReprocessingAdvanced Aqueous Reprocessing

Engineering Scale Crystallizer and UNH Crystal

4. Promising Concept of FBR Cycle System ～ 4.2 Advanced Aqueous Reprocessing

Laboratory Scale Centrifugal Contactors SystemAt CPF ( U-Pu-Np co-recovery test )

Advanced Centrifugal Contactor Test System

Continuous Rotary Dissolver

<FBR>MONJU : 285 FAsJOYO : 636 FAs

<ATR>FUGEN : 773 FAs

<BWR>Tsuruga No.1 : 2 FAs

Others : 2 FAs

TOTAL : 1698 FAs

JOYO

MONJUBWR

PWR FUGEN

Fabrication Achievements

4. Promising Concept of FBR Cycle System ～ 4.3 Simplified Pelletizing Fuel Fabrication

2.0cmφ

Simplified Pelletizing Process (SPP)

Simplified Pelletizing Process (SPP)Present MOX Pellet Fabrication Process

MOX or PuO2 Powder

Ball Milling

UO2 Powder

Transfer

Inspection

Inspection by Gov.

Product

Grinding

Binder MixingGranulation

Pressing

Sintering

Recycled MOX

Weighing Lot Mixing

Lubricant Mix.

De-waxing

De-gassing

Effect by PuEAS*

Effect by organic binder-less granulation

Effect by die-lubrication pressing

Effect by other factors

* Pu Enrichment Adjustment in Solution

Transfer

Broth makingMH conversionHeat Treatment

PuEALS* MOX Powder

CompactionSintering

InspectionInspection by Gov.

Product

PuEAS*

MH conversionBinder-less Granulation Wet Recycling

Heat Treatment

To realize MA-MOX fuel fabrication in a commercial scale, a simple, dust minimum process without organic additives is necessary.

-Reduction of fabrication cost, human exposure -Adoption to automation, remoteness-Resistance against higher heat generation

Milling

4. Promising Concept of FBR Cycle System ～ 4.3 Simplified Pelletizing Fuel Fabrication

Fast Reactor

2050～20252015

Fuel Cycle S

ystemStage

20452035

Fast Reactor

2050～20252015

Fuel Cycle S

ystemStage

20452035

Commercial Reactor(1,500MWe)

Acquisition of ExperienceDesign, Construction

Engineering Test Facility

Design, Construction

Start of Test

Design, Modification Advanced Aqueous Tech.(Component test / System test)

Scale: 1-10kgHM/hHandling Amount: around 1tHM/y

Modification Supply MOX fuels to fast reactor(and demonstration test of mass production tech.)

Demonstration Facility Design, Construction Operation

Design, Modification Remote Handling TRU Fuel Fabrication Tech.(Place with above Engineering Test Facility) (Fuel Fabrication: 1tHM/y)

Research &Development Demonstration & Commercialization Full-scale deployment

Design Study Optimization

R&D of innovative tech.



“Joyo” and “Monju”“Joyo” and “Monju”

Test Facility

DemonstrationReactor

Design,Construction Experiment Start of Operation

Start of Operation

Design, Construction Operation





CPF, AGF, etc.

MOX Fuel Fabrication Facility

Start of Operation

Commercial Facility

Start of Operation-Reprocessing-Fuel Fabrication for FR

R&D Roadmap toward commercializationR&D Roadmap toward commercializationR&D Roadmap toward commercialization

5.Future Program

Fast Breeder R

eactor

As of 2006

FBR Research and Development FrameworkFBR Research and Development Framework5.Future Program

・Checking functions・Advice for advancing the project

Ministry of Economy, Trade and Industry

(METI)

Advisory committee

Electric Utilities

ManufacturerManufacturer

Core company

Universities, Research Organizations, etc.

・Bundling orders

・Partial injection of capital

・Loaning of engineers

Ministry of Education, Culture, Sports, Science and Technology

(MEXT)

・Provision of R&D results・Loaning of engineers

・The core companyinjects most of capital

・Places orders with manufacturers, universities, research organizations,etc.

MFBR MHI

JAEA

FBR Development Company

Core Company

Atomic Energy Commission

(AEC)

Council for Science and Technology Policy

(CSTP)

・National Policy of FBR Cycle Technology Development

Overall schedule• Phase 1 (2006-2010): Design study and key technology R&D.• Phase 2 (2011-2015): Establishment of FBR cycle technology with

conceptual design

5-Party council to discuss processes of demonstration and commercialization of FBR cycle systems in Japan.

5-Party： MEXT, METI, Electric utilities, manufacturers, and JAEA

Leading Engineering Company was selected in April , 2007Mitsubishi Heavy Industries (MHI) was selected as a “core enterprise”of FBR development program. MHI established the a company “Mitsubishi FBR Systems Inc.(MFBR)” for designing and engineering of FBR.

International cooperation such as GIF, GNEP, INPRO etc.

Overview of the Overview of the FaCTFaCT ProjectProject5.Future Program

2100

Inst

alle

d ca

paci

ty

2000

LWR FBRPu utilization in LWR

RokkasyoReprocessing Plant

Spent Fuel of LWR-UO2

Spent Fuel of LWR-MOX

Spent Fuel of FBR

Interimstorage

Spent Fuel of LWR UO2

Pu

Next Reprocessing Plant

PuPu

Transition from LWR cycle to FBR cycleTransition from LWR cycle to FBR cycle5.Future Program

Concluding Remarks

Most Promising Concept was identified trough the Feasibility Study.・Sodium-Cooled Fast Breeder Reactor・Advanced Aqueous Reprocessing・Simplified Pelletizing Fuel FabricationIntensive R&D on the promising concept is now on the way as FaCT program. Major milestone of development plan:2010: Decision on Adoption of Innovative Technologies 2015: Establishment of Conceptual Design of Commercial and Demonstration FacilitiesSmooth transition from LWR cycle to FBR cycle is quite important issue.

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