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Babcock & Wilcox Cost & Yield Review NAS
Research Test Reactors May 21 , 2015
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B&W Cost Analysis Cost Analysis in 2012 for Projected Costs in 2019
Purpose: Utilize the current LEU information and process knowledge to develop a steady-state cost for HEU & LEU fuel Goal: To develop a process which is cost neutral from HEU to LEU Maintain HEU Manufacturing capability until LEU manufacturing is demonstrated for all 5 reactors. 2010 DOE funded independent study estimated an increase of 37% GSA Cost based on a Set of Assumptions LEU Steady-State utilizing what we defined as a “Base-line Process” Compared LEU to HEU in 2019 $$
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Fabrication Processes
Fuel Powder Process Compact Process Plate Process Element Process HEU Process B&W fabricates Powder for ATR, MURR, and MIT Y-12 fabricates Powder for HFIR and NIST The conversion from HEU to a LEU transitions from a cermet to a metal plate fabrication process Processing Unchanged LEU Process Coupon/ Ingot Process Foil Process Plate Process Element Process Y-12 fabricates Coupons/Ingot
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Current HEU Processes Fuel Powder Fabrication Compact Fabrication
Issue Material Weight Charges Arc Melt Crush Blend Weight Inspect Compact Fabrication Compact Anneal Plate Fabrication Pack & Weld Hot Roll Blister Anneal Inspect Cold Roll Machine to Length and Width NDT & Dimensional Inspection Form Processes eliminated TBD TBD TBD Processes eliminated
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“U-Moly Base-line Process”
U-Mo Coupon Can Assembly U-Mo HIP Can Assembly U-Mo Foil U-Mo Plate 0.015” Thick With ~ 0.001” Thick Zr Layer on Both Sides 304 SS Al 6061 U-Mo Coupon: 19.75% U-235 ~6” x 6” x 0.125” Mild Steel Foil Processing Receipt Inspect Coupon Can Coupon Hot Roll Coupon Into Foil Cold Roll Foil Size Foil HIP Processing Fabricate HIP Can Parts Can Foil and Al Cladding Remove Plates From Can Plate Processing Radiography Minclad UT Machine Plates to Thickness Machine Plates to Size QC Plates (Normal)
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Assumptions What’s not Included Coupon Costs (GFM – Y-12) Burnable absorbers cost Manufacturing of burnable absorbers (ATR, HFIR) Shipping Costs Waste Costs Costs associated with transition from HEU to LEU Low Impact Estimate is at full LEU production, no HEU fabrication Steady State Production Rate ~8000 plates per year Facility will include storage for 3 years worth of coupons/Ingots (backlog inventory) HEU and LEU Equivalent Operations New Rates for 2019 High Impact U-Mo Coupons LEU Process Yields ~ 1000 kgs of Zr coded scrap generated per year Uranium recovery could be performed at NOG-L in existing facility Waste Costs: Non-uranium Scrap recycle (HIP cans) & Uranium waste disposal Rates: Increased manpower and labor hours, added capital depreciation, Rate reduction due to increased hours and reduced security requirements Coupons: GFY from Y-12, Size, Defect Free, # of foils per coupon, HFIR design 2 ATR, 1 HFIR, 4 MIT, 4 MURR, 10 NIST
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Yields Yields have not been demonstrated
HEU Process Yields Compacts ~ 99% Plates ~ 93% Projected LEU Process Yields Foils ~ 88% Plates ~ 90% Foils: Edge Cracking, ZR Blistering on U-Moly Foil, Yields have not been demonstrated
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Created Cost Estimating Tool
Process flow Diagram WBS Time Standards Equipment List Rates (variable based on many factors) Cost per Assembly Assemblies per year Annual Operating Cost
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Total Manufacturing Hours/Plate
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% increase in Cost of HEU Assembly
2012 U-Moly Cost Summary Contract % increase in Cost of HEU Assembly ATR 17% HFIR 115% * MIT 13% MURR 49% NIST 60% * Due to the complex geometry of the HFIR fuel and the lack of manufacturing development, it is estimated that HFIR foil manufacturing will take 2X longer
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Program R&D Projects National Labs (LANL & PNNL) Casting Optimization
Optimize HIP Process operations (HIP Can) Develop an alternate process for Zr Application Foil Rolling and Anneal Studies Demonstration of Complex Shape Fabrication (HFIR) Coupon/Ingot Size Optimization Y-12 Demonstrate LEU Manufacturing Cycle B&W Demonstrate complex fuel process Develop a Foil Process with less Scrap HIP Processing Parameters
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Program LEU Manufacturing Cycle
LEU Metal Alloying Coupon Foil Plate Element ZR HEU Metal DU or NU Metal Mo Reduce to LEU Metal Recovery Recovery Yellow – Y-12 Blue – B&W Clear – Unknown
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B&W Current Manufacturing Development Efforts
Foil Processing Receipt Inspect Coupon Can Coupon Hot Roll Coupon Into Foil Cold Roll Foil Size Foil HIP Processing Fabricate HIP Can Parts Can Foil and Al Cladding Remove Plates From Can Plate Processing Radiography Minclad UT Machine Plates to Thickness Machine Plates to Size QC Plates (Normal) Development Focus
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Foil Standard Process Flow Development Efforts
Coupon Process Hot Roll with Zirconium Decan and Clean Vacuum Anneal Cold Roll Sizing Homogenize Coupon or Ingot Pack & Weld (Coupons or Ingots) Additional Process Steps Hot Roll without Zirconium Decan and Clean Sizing Cold Roll Pack & Weld Ingot Process Alternate process being developed to minimize Zr Coded Scrap Vacuum Anneal Decan and Clean Hot Roll with Zirconium Sizing Cold Roll
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B&W Cost Analysis 2014 Update
Reviewed 2012 analysis to update assumptions Determined change to 2012 estimate Update was Changed to Hours Based New Conversion dates beyond 2030 Rates too hard to predict Compared reduction in hours from 2014 to 2012 Same assemblies / year No Yield Changes Compared Mfg & Total Hours Mfg hours = Shop & QC
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Assumptions for 2014 Update
What’s not Included Coupon Costs (GFM – Y-12) Burnable absorbers cost Manufacturing of burnable absorbers (ATR, HFIR) Shipping Costs Waste Costs Costs associated with transition from HEU to LEU Low Impact Estimate is at full LEU production, no HEU fabrication Steady State Production Rate ~8000 plates per year Facility will include storage for 3 years worth of coupons/ingots (backlog inventory) HEU and LEU Equivalent Operations New Rates for 2019 High Impact U-Mo Coupons LEU Process Yields ~ 1000 kgs of Zr coded scrap generated per year Uranium recovery (could be performed at NOG-L in existing facility) Foil Fab increase - 26% Coupon size change - increased foil fabrication
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2014 Assumption Changes Foil Processing HIP Processing
Receipt Inspect Coupon Can Coupon Hot Roll Coupon Into Foil Cold Roll Foil Size Foil HIP Processing Fabricate HIP Can Parts Can Foil and Al Cladding Remove Plates From Can Plate Processing Radiography Minclad UT Machine Plates to Thickness Machine Plates to Size QC Plates (Normal) 2014 Assumption Changes HIP development reduced plate fabrication by 40% Optimized Pre-formed Hip Can (Not yet Demonstrated) Capacity change Eliminated Internal HIP Can Fabrication Eliminated Plate Thickness machining & UT for Support Thickness Machining
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Total Manufacturing Hours/Plate
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% Reduction from 2012 Estimate
2014 U-Moly Cost Summary Contract % Reduction from 2012 Estimate ATR 15% HFIR 16% MIT MURR 14% NIST 25% Overall Reduction 17%
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Conclusions Still in Development
Dedicated Team working on U-Moly Program Concerted effort between all Organizations Y-12, PNNL, LANL, INL & B&W Our Focus is two-fold Manufacturing capability Cost Consciousness (Cost neutral between HEU and LEU)
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