1. Sustainable Energy Security from Fast Breeder Reactors
P. Puthiya Vinayagam and P. Chellapandi
Indira Gandhi Centre for Atomic Research
Kalpakkam, India
6th Nuclear Energy Conclave
Organised by India Energy Forum at New Delhi on 14th October 2014

2. FBR : A Vital Stage in Indian Nuclear Power Program
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
Nat U
Pu &
Depleted U
U233 Th
Stage I
Stage II
Stage III Pu
FBRs : Inevitable for long term security & sustainability of nuclear power

3. Growth and Waste Minimization Strategy
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)

4. 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

5. 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
40 MWt
13.5 MWe
Loop type
(Pu-U)C fuel
Major Achievements
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

6. Evolution of SFR Power Reactor Concepts
Adopting Innovative Features
Improved Economics and Enhanced Safety
MFBR
1000 MWe
FBR 1 & MWe
MOX, Pool, Twin units, Indigeneous
Metal fuel Demonstration Fast Reactor – 500 MWe
Same reactor concepts, Indigeneous
Design, Mfg. and Safety review Experience
Proven Prototype Concepts
FBR-600 MWe
Preliminary Conceptual Design options worked out
Power : 600 MWe with expanded core
Targets : Higher breeding ratio compared to PFBR
Vessel size : same as PFBR
Reactor Assembly design concepts : same as FBR1&2
Core type: Heterogeneous as an option
Advantage : Existing MOX technology & economy
PFBR MWe
MOX , Pool type, Indigeneous

7. Design Approach for Future FBRs
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
No major R&D requirement for Design as well as Technology development beyond those planned for 500 MWe reactors

8. FBR-600 MWe : Plant Parameters
PFBR
FBR-600
Power, MWe
500
600
Fuel
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
No. of Primary Sodium Pump 3
No. of IHX 4
No. of Secondary Sodium Pump
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
Load factor, % 75 85

9. 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 MWe plants

10. 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)
Substantial Core Metallic
Fuel in FBTR
Pin Irradiation
in FBTR
Subassembly
Irradiation in FBTR
Experimental Fast Reactor
Metallic Fuel Design
1000 MWe Units
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

11. 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
Parameter
Sodium Bond
Mech Bond
10 % Zr
6 %Zr
0 % Zr
LHR, W/cm
Breeding Ratio
(including ext. blanket )
1.2 – 1.25
1.30 – 1.35
1.4 – 1.45
Burnup, GWd/t
Sodium Void Reactivity coeff, $
4.5 – 5.0
5.0 – 5.5
5.5 – 6.0
Fissile enrichment zones (500/1000)
2 / 3
No of SA (500 MWe)
180
195
220
Na outlet temp oC
Spent fuel storage
Sodium
Water
Reprocessing
Pyro
Purex

12. Plant Parameters : A Comparison (MOX & Metal)
Unit
PFBR
MDFR-500
Reactor thermal power
MWt
1253
1350
Electrical output (Gross)
MWe
500
Gross thermal efficiency -- 40
37.5
Fuel
PuO2-UO2
U-Pu-6%Zr
Coolant
Sodium
Concept of Pri. Na circuit
Pool
Reactor coolant inlet temp.
K (oC)
670 (397)
633 (360)
Reactor coolant outlet temp.
820 (547)
783 (510)
Steam temp. at SG outlet
766 (493)
736 (463)

13. 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

14. Sustainability Consideration Minor Actinide Management – A scenario
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
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

15. Summary
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.

16. Thank You for your attention