1. Nuclear Energy R&D in India for FBR
P. Mohanakrishnan
IGCAR, Kalpakkam, India
Nuclear Energy R&D
14 Jan 2011

2. Indira Gandhi Centre for Atomic Research and FBR Programme in India
CONTENTS
Indira Gandhi Centre for Atomic Research and FBR Programme in India
40 MWt FBTR and 500 MWe PFBR
R&D for Future FBR
R&D for Closed Fuel Cycle
R&D for Metal Fuel FBR
Nuclear Energy R&D
14 Jan 2011

3. INDIRA GANDHI CENTRE FOR ATOMIC REASEARCH (IGCAR) KALPAKKAM
Centre Dedicated for Development of FBR and Its Closed Fuel Cycle with Activities
Reactor Design
Fast Breeder Test Reactor (FBTR)
Sodium Technology
Materials Science
Chemistry and Physics of Fuel Cycle
Participation in construction of PFBR
Fuel Cycle Facilities
Waste Management
Nuclear Energy R&D
14 Jan 2011

4. Utilisation & Growth Potential with Fast Reactors
Most neutrons in FBR have energies near here
Neutrons produced per neutron absorbed (η) for different isotopes in Thermal and Fast Reactors
Neutron Spectrum
233 U
235 U
239 Pu
Thermal Reactor spectrum
2.26
2.04
2.06
Fast Reactor spectrum
2.35
2.20
2.75
Nuclear Energy R&D
14 Jan 2011

5. Fast Reactors - Sustainability and Capabilities
Full utilisation of U resource
Minor actinide burning - reducing the quantity and toxicity of radioactive waste requiring ultimate disposal
Can provide critical liquid metal technology and high temperature design inputs for ADS, fusion and HTR
Effective utilisation of thorium to convert into U233
Nuclear Energy R&D
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6. Thorium Based Reactors
Three Stage Nuclear Power Programme of India : Status
Stage – I
PHWRs
17- operating
2 - under construction
Scaling to 700 MWe
Construction period
reduced
POWER POTENTIAL  10,000 MWe
LWRs
2 BWRs operating
2 PWRs construction
Stage - II
Fast Breeder Reactors
40 MWth FBTR - Operating
Technology Objectives realised
500 MWe PFBR-
under construction
POWER POTENTIAL  500,000 MWe for 100 y
Stage - III
Thorium Based Reactors
30 kWth KAMINI- operating
300 MWe AHWR- under regulatory examination
POWER POTENTIAL  Very large.
Availability of accelerator
driven neutron sources can
covert Thorium
Participation in ITER for
fusion technology
development
Nuclear Energy R&D
14 Jan 2011

7. FBTR today
FBTR, in operation since 1985, is the flag-ship of IGCAR and is the test bed for fast reactor fuels and materials. It has completed 16 irradiation campaigns with very high availability factors in the recent campaigns. Its unique carbide fuel has set an international record in burn-up (165 GWd/t).
The performance of sodium systems for the past 25 years has been excellent. Steam generators have performed without a single leak incident
PFBR test fuel is under irradiation at FBTR and seen design burnup of 100 GWd/t burn-up
India is one of the leading countries in the world among a select group pursuing FBR technology
Nuclear Energy R&D
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8. Carbide Fuel Cycle of FBTR
Fuel fabricated at BARC
Comprehensive PIE of FBTR fuel at 25, 50, 100 and 155 GWd/t in hot cells under inert atmosphere: destructive as well as non destructive techniques employed
FBTR Mark I Fuel has now reached GWd/t without fuel pin failure in the core
Fuel discharged at 25, 50, 100 and GWd/t reprocessed in CORAL facility
Nuclear Energy R&D
100 GWd/t
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9. Performance of FBTR Carbide Fuel
Microstructure of fuel pin cross section after different burn-ups
155 GWd/t – CENTRE of the fuel column
25GWd/t
50GWd/t
100GWd/t
Micrographs of fuel pin cross section at the centre of fuel column after 25 & 50 & 100 GWd/t burn-up
155 GWd/t – END of the fuel column
Radial cracking at low burn-ups in free swelling regime
Progressive reduction in fuel clad gap with burn-up
Cracking pattern changes from radial to circumferential
cracking with closure of fuel clad gap
Complete closure of fuel-clad gap along the entire fuel
column at 155 GWd/t burnup
Porosity free dense zone at the outer rim of the fuel
Swelling of fuel accomodated by porosities & clad
swelling
Nuclear Energy R&D
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10. Successful Demonstration of Reprocessing
16 Stage Centrifugal Extractor Bank
CORAL facility operation area
Mixed carbide fuels with high Pu with a burn up of 155,000 MWd/t reprocessed for the first time
CORAL facility demonstrated the successful reprocessing of this high burn up fuel
Centrifugal extractors used in solvent extraction in CORAL facility for reprocessing of FBTR fuel
Modifications carried out in extractor bowl resulted in the improved performance
Progressive hotter fuel
reprocessing
Nuclear Energy R&D
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11. Prototype Fast Breeder Reactor (PFBR) – a sequel to FBTR
IGCAR has designed and developed the 500 MWe PFBR and has played the lead role in obtaining safety clearances for the reactor.
The construction of the reactor is in progress at Kalpakkam, by BHAVINI. IGCAR in association with BHAVINI has contributed to successful indigenous production of reactor components. This will demonstrate the second stage of the Indian Nuclear Power Program & techno-economic viability on an industrial scale.
Nuclear Energy R&D
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12. Prototype Fast Breeder Reactor (PFBR) Erection of Safety Vessel
Roof Slab: Fabrication at Site Assembly Shop
Erection of Safety Vessel
Primary pipe with Grid Plate
Primary Sodium Pump
Steam Generator
Secondary Sodium Pump
Nuclear Energy R&D
14 Jan 2011 12

13. Challenging R&D for PFBR
Seismic testing of reactor assembly
Minimising risk of sodium fire
Prototype testing of components under actual environment (sodium & temperature)
Minimising risk of steam generator tube leaks
In-service Inspection
Testing of components in sodium
Transfer arm
Control & safety rod drive mechanism
Diverse safety rod drive mechanism
Nuclear Energy R&D
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14. STRUCTURAL MATERIALS FOR PFBR
Structure Materials
Clad & Wrapper Tubes 20 % cold-worked D9 steel
Grid plate SS 316L(N) [Though temp < 700 K]
Steam Generator Ferritic steel (Modified 9Cr-1Mo)
Top Shield (Roof-slab) Sp. Grade Low carbon A48P2 steel.
Other structural components Low carbon Austenitic SS alloyed with nitrogen up to 0.08 wt%
< 700 K: SS 304L(N)
> 700 K: SS 316L(N)
Nuclear Energy R&D
14 Jan 2011

15. Boron enrichment & elemental boron production
Boron Enrichment Plant
Electro-winning facility
Enriched boron carbide for control & safety rod material for produced in IGCAR
Technology is being used by
Heavy Water Board to produce
the material for PFBR
Enrichment of 65% in Boron-10 achieved
Boric acid converted to elemental boron
Nuclear Energy R&D
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16. In-Service Inspection of PFBR Main-Vessel
Collaborative effort between DRHR, BARC & IGCAR
ISI vehicle and its accessories – DRHR
On-board NDE modules – IGCAR
NAVIGATION CAMERA
VISUAL
EXAMINATION
SYSTEM
3-D Model of ISI Vehicle
UT MODULE
3-D animated model of ISI developed in collaboration with IISc, Bangalore
ISI vehicle deployed in the interspace between MV & SV
Nuclear Energy R&D
14 Jan 2011 16

17. R&D Challenges for Improved Safety and Economics of Future FBRs - CFBR
Construction of 6 more reactors (CFBR) (2x500 MWe at Kalpakkam & 4x500 MWe at a new site) – Commissioning by 2023, based on improved PFBR design
Enhance safety and improved economics are twin objectives
Need for optimized design
Substantial R&D needed to experimentally validate any new design
Nuclear Energy R&D
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18. Increased Reliability in Future
PFBR
CFBR
Shutdown Systems
SDS-1: CSRDM Testing of 1:1 Prototype
SDS-2: DSRDM testing in Na
Nuclear Energy R&D
14 Jan 2011
Increased Reliability in Future

19. In-vessel Purification
Sodium Purification
In-vessel Purification
Primary Sodium is contained within main vessel
No risk of siphoning of sodium
In-Vessel Purification
Ex-Vessel Purification
PFBR
CFBR
Nuclear Energy R&D
14 Jan 2011

20. Feedback from PFBR - Steam Generators for CFBR
For SG of future FBRs 30m long tubes with 3 modules per loop concept is chosen as against 23m tubes with 4 modules per loop in PFBR
Salient Improvements
Reduction in number of tube to tube sheet joints by about 40%.
27% Savings in material of construction.
Associated reduction in piping, number of rupture discs and other systems.
Enhanced overall reliability of SG units of the plant.
For PFBR, 19 tubes model tested at 5.5MW steam generator test facility (SGTF)
For CFBR, 7 tubes model
testing planned in SGTF

21. Development of Sensors
In-Sodium Electrochemical Hydrogen Meter
For monitoring [H]Na under normal operating conditions of reactor : Possesses a resolution of 13 ppb at a background conc. of 50 ppb
Tested in the Steam Generator Test Facility (SGTF) by steam injection
Cover Gas Hydrogen Meter
For monitoring [H]Na under low power operating conditions or start up of reactor
(Tna ~ 250oC) : detection limit 30 ppm
Oxygen sensors based on yttria-doped thoria
Sensors based on nanocrystalline materials
Nuclear Energy R&D
14 Jan 2011
Thin film H2 sensor 21

22. Simulation of Radiation Damage
Experiments using Heavy ion Beams from 1.7 MV Tandem Accelerator
Material for Present core of PFBR - 20% CW D9 Alloy: Target burnup MWd/t (85 dpa)
Materials for future core of PFBR D9I – Target burnup MWd/t (130 dpa)
Development of material D9I rely on increasing the incubation dose by adding minor alloying elements Ti, Si, and P.
Experimental Techniques
Surface Profilometry
TEM
Positron Annihilation
Studies on D9 alloy, 5 MeV Ni Beam, Pre implanted with He
Damage Rate ~ 15 dpa/hr,
Dose range upto 150dpa,
Irradiation temperature 300C – 750C
Nuclear Energy R&D
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23. Atmospheric Dispersion Modelling
Mesoscale Atmospheric Model (MAM-I) for Coastal site validated with local and RISÖ data.
Improved dispersion code System for Prediction of Environmental Emergency Dose Information (SPEEDI) developed.
Realtime nested dispersion modeling system for local, regional and national scale- applied for accident analysis. y
Kaiga
Narora
Manuguru
Kalpakkam
Simulation of plume dispersion at four nuclear sites on a day
Inner blocks: Topography
Outer blocks: The plume
Nuclear Energy R&D
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24. FBR Fuel Cycle MOX Fuel U & Pu FBR Power Station Spent Fuel
Pu (PHWR)
FBR Power Station
Fabrication Plant
FBR Fuel Cycle
Spent Fuel
U & Pu
Bred Pu
& U233 for new reactors
Reprocessing Plants
for FBR
Radioactive
High level Waste Disposal Site
Nuclear Energy R&D
14 Jan 2011

25. FRFCF facility – Bird’s eye view
Fuel Cycle for PFBR
Initial fuel requirement of PFBR will be met from Plutonium obtained from the PHWRs (planned to be used for the first series of FBRs)
The fuel cycle of PFBR would be closed by constructing a Fast Reactor Fuel Cycle Facility (FRFCF) at Kalpakkam.
Co-location of the facility with reactor would reduce cost due to transport and also avoid security issues
Basic technology required for the facility is available
FRFCF facility – Bird’s eye view
Layout has been planned in such a way that expansion is possible to meet the requirements of two more 500 MWe FBRs to be built at Kalpakkam at later date.
Nuclear Energy R&D
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26. Closed PFBR Fuel Cycle In vessel cooling period – 240 d
Reprocessing period – 240 d
Fabrication period d
Pu-239 reactivity equivalence used to judge quality of Pu after each recycle
Pu isotopic composition change small with recycle of FBR fuel
Net Pu enrichment change over 10 fuel cycles (life of reactor) is less than 3%
Radio-active source is higher than PHWR re-processed fuel necessitating more automation
Nuclear Energy R&D
14 Jan 2011

27. Advantages of FBR for Minor Actinide (MA) Incineration
Hard neutron spectrum reduces capture to fission ratios compared to thermal
Penalty on core parameters with homogeneous mixing of MA (< 5%), is mild in FBR compared to thermal reactor –(eg. required Pu enrichment reduces)
Existing fuel fabrication facilities handling Pu for FBR fuel cycle can accommodate MA bearing fuel
MA produced in life time of 540 MWe PHWR can be incinerated in 3 cycles of 500 MWe FBR
Nuclear Energy R&D
14 Jan 2011

28. By Product - Valuable Fission Products from FBR Fuel Cycle
1 GWe for 1 y
(75 % capacity)
Element/Isotope kg
Cs (Cs-137)
143.7 (44.6)
Sr (Sr-90)
16.8 (10.2) Ru
108.2 Rh
39.1 Pd
83.0
Rh and Ru become inactive few tens of years after separation
Nuclear Energy R&D
14 Jan 2011

29. R &D for Cost Reduction of Fuel Cycle
Road map for higher fuel discharge burnups
Aim for 200 GWd/t peak burnup with right choice of structure material - Radiation damage models and micro-structure characterization of materials
Ferritic martensitic steels and Oxide Dispersion Steels (ODS) are the viable choices
Parameter
PFBR
High burnup
Cycle length (calendar days)
240
360
Fuel enrichment (Pu %)
21/28
24.5/29.5
Number of Fuel SA
181
199
Fraction of core discharged
1/3
1/4
Peak burnup (GWd/t)
100
200
Nuclear Energy R&D
14 Jan 2011

30. Co-located Fuel Cycle Facilities for Multiple Units
Multiple units at a given site
(a) Sharing of facilities outside nuclear islan
(b) Sharing of fuel handling facilities of two units
(c) Sharing of operation and maintenance
Co-located fuel cycle facilities provide
(a) higher physical protection
(b) favourable economics
(c) proliferation resistance (eg. co- processing of
U, Pu and MA)
In a 4 x 1 GWe fuel cycle facility compared to 2 x 1 GWe facility, per GWe
(a) capital cost per GWe is lower
(b) operation and maintenance cost per GWe is lower
Nuclear Energy R&D
14 Jan 2011

31. Beyond 2020 – Development of FBR-M
Fast reactor programme will be based on metal fuel to achieve faster growth of nuclear power
The target of nuclear energy production of 25% by 2050 cannot
be achieved without establishing metal fuel reactors on a commercial scale
Involves R&D in lab scale, setting up of a metal fuel test reactor and designing the commercial scale reactor based on metal fuels
This requires substantial efforts in design, materials development and fuel cycle technologies
Nuclear Energy R&D
14 Jan 2011 31

32. Metal Fuel Pin for 1000 MWe Reactor
CLAD
LINER
FUEL
U-Pu U
2950
300
1000
140
1150
Metal Fuel Pin for 1000 MWe Reactor
U-Zr
FUEL
300
1000
1440
UZr
Sodium bonded
75 % smeared density
Plenum at top
Plenum/ Fuel ratio: 1.44
Pin height- 3.1 m
Linear power at 2 at % BU governs
BR = 1.47
Na FREE LEVEL
Mechanical bonded
85 % smeared density
Plenum at bottom
Plenum/ Fuel ratio: 1.28
Pin height m
Linear power at BOL governs
BR = 1.56
CLAD
3100
1000 MWe, 8 mm  pin, 2 rows of blanket
Peak Linear Power W/ cm
Burn-up – GWd/t
Sodium inlet/ outlet 360/ 510 oC
Max clad inside T 650 oC
T91 structural material
Sodium bonded
(U-Pu-6%Zr)
Nuclear Energy R&D
14 Jan 2011
Mechanical bonded

33. Metal Fuel Development Fuel Doubling time : About 10y
Road Map
Pin irradiation in FBTR
Subassembly irradiation in FBTR
Full core metal fuel in FBTR
Experimental metal fuel reactor (320 MWt)
Metal Fuel
1000 MWe Design
Linear Power W/ cm
Clad - T91
Capsule irradiation – 3 pins
SA irradiation – 37 pins
Prototype scale -217 pins
Target Burnup GWd/ t
Salient Features of Irradiation Plan
Experimental Pin Schematic
Nuclear Energy R&D
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34. Research on Safety Aspects of FBR-M
Compared to MOX core , metal core has lower Doppler constant and significantly higher Na void worth
Concern of reactor safety under unprotected loss of flow accident (ULOFA)
IGCAR study show that despite the high Na void worth, ULOFA of metal core is realtively benign
Na voiding is low and happens only on reactor top – net reactivity is –ve after 30 minutes
A passive safety grade heat removal system can maintain the reactor a safe shutdown state at a elevated Na temperature with adequate heat removal
Nuclear Energy R&D
14 Jan 2011

35. Metal Test Fuel Pin Fabrication Facility
Fuel Fabrication facility
Glove Box Train arrangement
Purification tower arrangement
Co-swaged fuel rod with clad / liner
INJECTION-CAST, SWAGED & MACHINED URANIUM RODS (demonstrated at BARC)
Length = 160 mm, Diameter= 4.67±0.04
Nuclear Energy R&D
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36. Metal Fuel Sodium Bonding Facilities
Sodium wire extruder
Argon Glove Box for Sodium Handling
Dummy Fuel Pin
Developmental Facilities established in BARC and IGCAR to demonstrate the technology
Pin welding fixture
Sodium Bonding Furnace with Vibrator
Nuclear Energy R&D
14 Jan 2011

37. Thank you
Nuclear Energy R&D
14 Jan 2011