Review of Research Reactor Fuel Development in KAERI. Jong Man Park

Transcription

1 1 Review of Research Reactor Fuel Development in KAERI Jong Man Park

2 Contents Introduction Localization of HANARO fuel U-Mo development in KAERI KJRR (Ki-Jang Research Reactor) Project in KAERI Global Cooperation 2 2

3 3 3 Introduction Why RR Fuel in Korea?

4 History of Research Reactor in Korea HANARO (1995) KRR-1 (1962) FOUNDATION KRR-2 (1972) GROWTH CHALLENGE JRTR KJRR CNL (2009) TRIGA Mark-II (Pool Type) 250 KW Education & Training RI Production NAA TRIGA Mark-III (Pool Type) 2,000 KW RI Production NAA Neutron Beam Experiments (Open-Tank In-Pool Type) 30,000 KW Cold Neutron Laboratory : 2009 Neutron Beam Fuel/Material Irradiation RI Production / NAA NTD 4

5 5 Major Achievements KAERI has played a major role for nuclear technological independence and now focuses on development of future advanced systems. Localization of CANDU Fuel ( 87) Technology Development Stages 1959~1969 Basic Studies 1970~1982 Import 1983~1996 Localization 1997~2006 Improvement 2007~2016 Innovation Localization of PWR Fuel ( 88) HANARO ( 95) OPR 1000 ( 96) Advanced Fuels for RR, PWR and CANDU DUPIC ( 00) Localization & Standardization SMART ( 12) Improvement JRTR ( 65) APR+ ( 15) New RR ( 17) SFR Pyroprocess VHTR Advancement & Innovation

6 HANARO Driver Fuel Driver Fuel for HANARO : Rod-type LEU U 3 Si Fuel Dispersed in Al Matrix Specifications - Assembly Cylindrical Shape : 18 Fuel Rods (1.26 kg-leu) Hexagonal Shape : 36 Fuel Rods (2.2 kg-leu) - Fuel Rod Enrichment : wt% U-235 (LEU) U Loadings : 3.15 g-u/cc Meat Dimension : L700mm X D(5.49 or 6.35 mm) Fuel Dimension : L760mm X D7.87mm with 8 pins 6

7 7 U 3 Si-Al Dispersion Fuel for HANARO History Need for stable supply of research reactor fuel in connection with the construction of HANARO (middle of 1980s) HANARO driver fuel has been supplied by CANADA (AECL) (1995 ~ early of 2000s) Development of HANARO Driver Fuel Project started at 1987 Development of fabrication process in Lab. scale (1990) Fuel rods by use of DU material were fabricated in early 1990s Study on atomization process to make U 3 Si powder (1987~) Atomization Technology was developed to overcome the difficulties of the comminution process

8 8 Atomization technology in KAERI Disk Motor Powder Production of U-Si and U-Mo Alloys in Commercial Scale Since 1987 Advanced Technology induction melting of U alloys in vac. tech. for ceramic crucible tech. for disc with high rotating speed & wetting

9 9 Centrifugal Atomization Technology Advanced Technology - Key technology for mass production of research reactor fuel powder Superior Fuel Powder Property - Spherical powder to enable easy fabrication - High purity with fewer defects - Excellent irradiation performance Simple and Highly Efficient Process - Directly produced through a single-step process - Short processing time - Very high production yield (~95%) Ground U-Mo Powder Atomized U-Mo Powder

10 Localization of HANARO fuel 10 10

11 11 History ~1992 ~2000 ~Now Developed Atomization Process (U 3 Si powder) HANARO Fuel Localization Program Launched R&D of Fabrication Process Irradiation Test of Atomized Fuel Facility Construction ( 2003) Licensing (2004) Start HANARO Fuel Supply (2005) Fabrication Capacity (55 set/yr)

12 12 Fabrication Process (HANARO Fuel) Conventional Process Atomized Process Melting & Casting U-Si Ingot Heat Treatment U 3 Si Ingot Machining Chip Melting & Atomizing Heat Treatment U-Si powder U 3 Si powder Pulverizing Powder Magnetic Separation Sieving Al powder Powder Assembly Parts Powder Blending & Compacting Extrusion Co-extrusion Welding Assembling Fuel meat Sieving Powder Fuel Rod Fuel Rod Compacts Fuel Assembly 12

13 13 Heat Treatment of Atomized U 3 Si Powder Heat Treatment : 800 o C, 6 hr Before H.T. Uss U 3 Si 2 U 3 Si After H.T. Atomized Fuel Particle *Excessive U 3 Si 2 fraction : less than 8 vol% 13

14 14 Process Equipments 200 TON Vertical Extruder Fuel meat length of 2.5 m long can be produced per one punch three fuel meat rods Better fuel meat surface of atomized fuel Atomized meat Reworked (AECL) AECL meat Extruder Fuel Meat Core after Extrusion 14

15 15 Process Equipments Cladding Co-extruder

16 Process Equipments 16 Eddy Current Test -Objective: to detect surface defect, inclusion, scratch on the fuel surface -Defect size requirement : 0.13 mm -Method Multi Frequency Eddy Current Equipment (MIZ-40A) Detector and Standard : developed by ourselves Scan Example Detector

17 Irradiation Test of U 3 Si/Al Fuel Purpose of Irradiation Test for U 3 Si/Al Nuclear Fuel - To investigate the structural integrity and in-reactor performance of domestically fabricated fuels for localization of HANARO fuel - To compare the irradiation behaviors between comminuted and atomized fuels First Stage Second Stage Object -Normal Linear Power max kw/m - Investigate the In-reactor Behavior in High BU(85at%) -High Linear Power max. 121 kw/m -Investigate the In-reactor Performance at Normal BU(63at%) Fuel Size Mini-size Rod(200mm) Full-size Rod(700mm) Irradiation Dec, Jun, 1999 Jun, Aug,

18 18 Results from 1 st Irradiation Test Relatively uniform Fuel/Al reaction layer Acceptable in the range of ~9 µm in average thickness No breakaway swelling: Stable irradiation behavior ( Relatively low irradiation temperature, low high fission density) Atomized Comminuted

19 19 Results from 1 st Irradiation Test (continued) Fission gas bubble distribution & fuel/al reaction layer thickness: Relatively fine and uniform Stable in-reactor performance: No large and interlinking bubbles Atomized U 3 Si Comminuted U 3 Si

20 20 Results from 2 nd Irradiation Test Vigorous fuel/al reaction layer formed in both type fuels further layer growth after bubble formation ( due to high temperature) No breakaway swelling: : Stable irradiation behavior ( even though at high power condition) Atomized U 3 Si Comminuted U 3 Si

21 21 Construction of the Fabrication Facility The construction of the fabrication facility for HANARO fuel production - decided upon with the permission of government in Dec including R&D space for new nuclear fuel development Design and Construction - Designed by KOPEC (~June 2000) : Anti-seismic design concept - Constructed by DHEC (April 2001 ~ Nov. 2002) All the equipment was moved by early renewed to meet the production scale capability - Atomization system, Co-extruder, EB welding M/C were installed

22 22 Licensing & Capacity of the Facility Licensing Permission to start fuel fabrication (Jan. 2004) Licensing associated with the loading of the atomized fuels into HANARO (April 2004) Annual Production Capacity HANARO Driver Fuel (55 set) Hexagonal Fuel Assembly (36 rods): 33 set Cylindrical Fuel Assembly (18 rods): 22 set Annual LEU metal consumption for HANARO fuel: 100 kg Atomized Powder: 500 kg (~100 Batch) Annual Consumption HANARO Driver Fuel 9 cycles/year (3+2 assemblies/cycle) under 30 MW operation Hexagonal Fuel Assembly (36 rods): 27 set Cylindrical Fuel Assembly (18 rods): 18 set

23 Initiation of the Production of HANARO Nuclear Fuel Two driver (atomized fuel) bundles were fabricated and sent to HANARO - Lead bundle(kfc-001) was loaded in HANARO (March 10, 2005) 23

24 Fuel Production at KAERI 24

25 U-Mo Development in KAERI 25 25

26 Status of Atomized Powder Ato. U-Mo powder has been provided to investigate in-pile & out-of-pile fuel performances Country Year Powder kg France, CERCA 1997, 2000, 2001, 2002 DU 3 Si 2 DU-Mo LEU-Mo 51.5 USA, BWXT 1998, 1999 USA, ANL DU 3 Si 2 DU-Mo LEU-Mo NU-7Mo 1999 LEU-Mo, DU-Mo USA, INL 2007 NU-7Mo 2 Argentina, CNEA 2000, 2001 Belgium, SCK CEN 2009 NU-Mo DU-Mo NU-7Mo LEU-7Mo France, CEA 2010 NU-8Mo 5 Argentina, CNEA 2011 Nuclear Security Summit DU-8Mo LEU-8Mo 2014 LEU-7Mo

27 27 27 Why U-Mo Development in KAERI? Since 2000, KAERI has focused on qualifying rod-type U-Mo fuel with 5-6 gu/cc Objectives of the KOMO irradiation test at HANARO I. Upgrading HANARO research reactor to achieve a more compact core as well as irr. holes II. Development of U-Mo Fuel for a New Isotope Production Reactor (Ki-Jang Research Reactor, 15 MW) III. Solving the back-end options of spent fuel IV. Scientific contribution to understand U-Mo fuel performance

28 KOMO Irradiation Tests Fuel Composition Particle Size (mm) Matrix U- loading (g-u/cc) Max. LP (kw/m) Max. BOL T. ( o C) Max. BU (at% 235 U) EFPD KOMO-1 U-7Mo U-9Mo <150 Pure Al 3.4 and ~8 (27 EFPD) KOMO-2 U-7Mo U-9Mo mostly <150 Pure Al 4.0 and (173 EFPD) KOMO-3 U-7Mo U-7Mo-1Zr U-7Mo-0.2Si Pure Al Al-0.4Si Al-2Si (206 EFPD) KOMO-4 U-7Mo U-7Mo-1Zr U-7Mo-1Ti Mostly Al-2Si Al-5Si Al-8Si 4.5 ~ ~ (132 EFPD) KOMO-5 U-7Mo U-7Mo-1Zr U-7Mo-1Ti Coated fuel < Mostly Al-5Si +B.P. 5.0 ~105 < (228 EFPD) 28 28

29 29 U-Mo Workshop Opening the international U-Mo workshop ( ~13, KAERI) - ANL(USA) 2, INL(USA) 2, CEA(Fra.) 1, SCK-CEN(Belg.) 1, ANSTO(Aus.) 1 - Analysis on KOMO-5 PIE Results International U-Mo Workshop

30 30 Results from KOMO-4 Find out the mechanism of Si effect on IL growth retardation IL thickness in U-7Mo/Al-Si decreases progressively as Si content increases U-7Mo/Al ~40 µm 55.3%BU U-7Mo/Al-2Si ~20 µm 50.9%BU U-7Mo/Al-5Si ~13 µm 49%BU U-7Mo/Al-8Si ~7 µm 48%BU

31 31 Temperature Effect on IL Growth IL Thickness(µm) U-Mo/Al-Si 557-MD3 R5R020 R1R S1 R2R010 R2R030 KOMO-4(200 o C) RERTR-6(120 o C) 676-5S1 R3R S Si wt% in Al-Si Matrix It is noticeable that the higher Si content reduces IL growth further up to 8wt% at irr. T of ~200 o C More Si is required to stabilize IL growth in high T irr. conditions

32 32 Results from KOMO-4 (continued) Find out the mechanism of Si effect on IL growth retardation Reduction of the population of Si precipitates near U-Mo surface (recoil zone) U-7Mo/Al-5Si SEM/Mapping Chemical composition (at%) ~ 10 at.% Si EPMA analysis Distance (µm) Al Si Mo U

33 HANARO full length U-Mo fuel development Qualify full length U-7Mo-(Ti,Zr)/Al-5Si fuels (700mm, 5 g-u/cm 3, with burnable absorbers) Max. Linear Power ~105 kw/m (BOL T <200 o C) at HANARO OR-3 for 228 EFPD 73 rd to 81 st cycle (9 cycles), 30 MW operation Max. U-235 burnup: 87% Results from KOMO-5 After irradiation of U-7Mo-1Ti/Al-5Si SEM Si Cross-section 33

34 Results from KOMO-5 (continued) Coating technique development of U-Mo surface Silicide coated U-Mo dispersion fuel (Pack cementation method) Nitride coated U-Mo dispersion fuel (Gas-Solid reaction) Rotating motor Furnace Gas control Vacuum Nitride-coated U-Mo/Al (61% BU) U-7Mo Non uniform Interaction USi x is a strong barrier Reduced interaction where Si-coating is sound Al Uniform Interaction UN x is Weak Barrier 34

35 35 35 KJRR (Ki-Jang Research Reactor) Project in KAERI

36 36 Research Reactor Projects JRTR Project (Jordan) Jordan Research & Training Reactor (JRTR) Project Period : ~ MW (upgradable to 10 MW), Open-Tank-in-Pool Utilization; Neutron Scattering, RI Production, NAA, NTD, Training & Education KJRR Project (Korea) OYSTER Project (Netherlands) Ki-Jang Research Reactor (KJRR) Project Period: ~ MW th, Open-Tank-in-Pool U-Mo Plate Type Fuel (1st application to RR) Utilization : RI Production (including Mo-99), Silicon & Wafer Doping, R&D Cold Neutron Source for Delft Univ. RR Project Period: ~ Establishment of CNS facility

37 37 37 Construction of Kijang Research Reactor Objectives To provide self-sufficiency of RI demand for people s welfare To enlarge Si doping capacity for power device market growth Features 15MW reactor (2012~2017) Driver fuel : 8gU/cm 3 U-Mo Plate Fuel(1 st in the World) Production and supply of Mo-99 & Si-doping

38 38 Conceptual Design for KJRR Nuclear Fuel Assembly Expansion Joint Assembly Upper Guide Structure RSA Reactor Cover Assembly Reflector Assemblies Core Box Out-core Reflector Out-core Reflector Support Structure Neutron Detector Housing Assembly Grid Plate Outlet Plenum CRDM Support Structure CRDM SSDM SSDM Support Structure

39 1 FNIF 5 NTD Holes Core Configuration CAR1 SSR1 CAR3 CAR2 SSR2 CAR4 FA FM Target 22 FAs, 16 SFA, 6 FFA, 39 39

40 40 Core Condition Reactor Type Open-tank-in-pool Power Thermal Neutron 15 MWth 3 x n/cm2.s Life time(year) 50 Operation day/year ~300 Fuel Assembly SFA(16), FFA(6) - LEU(19.75 w/o 235 U) Fuel - Meat : U-7wt%Mo-Al(5%Si) - Cladding : Al gu/cc : inner 19 FPs Uranium density gu/cc : 2 Outer FPs - Meat : 62 x 600 x 0.51 Fuel dimension - Plate : 70.7 x 640 x 1.27 (mm) - FA : 72.9 x 72.9 x 1010 Flow Gap(mm) 2.35 Coolant Moderator H 2 O H 2 O Heat Flux (MW/m 2 ) - Average = Max = Fq = 3.3 Reflector Beryllium Burnup - FA Average = 65 % Absorber Hafnium (at% of U-235) - (Local Peak 85%) Core Cooling Downward, 6m/sec Coolant Condition - ph 5.5~ Inlet/outlet temp. 37/47 C

41 Failure Criterion of U-Mo/Al IRIS-1 RERTR-2 RERTR-6 Burnup (%) RERTR-6 RERTR-5 IRIS-TUM IRIS-2 E-FUTURE Fission rate (10 14 fission/cm 3 -s) G. Hofman RERTR-3 RERTR

42 42 42 Failure Criterion of U-Mo/Al-Si IRIS-3 70 RERTR-6 Burnup (%) K J R R Threshold curve for fuels without Si Threshold curve for fuels with Si Fission rate (10 14 fission/cm 3 -s) AFIP-1 E-FUTURE IRIS-TUM RERTR-9 RERTR-7 E-FUTURE E-FUTURE-2

43 Fuel Plate & Assembly CAR FFA Meat : 62 x 600 x 0.51 FFA Ext. Shaft Plate : 70.7 x 640 x 1.27 SFA 43 43

44 Fuel Plate & Assembly (continued) Dimension of Fuel Assembly Fuel Plate Meat Composition : U7%Mo-Al(5%Si) Dispersed Cladding material : Al 6061 Fuel Meat Density 8.0gU/cm 3 (19 Inner FPs) 6.5 gu/cm 3 (2 Outermost Fuel Plates) Total U/FA : 3.13kg/FA(3.19kg) Meat thickness : 0.51 Plate Dimension : 1.27 x 70.7 x 640 (meat : 62.0 x 600) FA Dimension SFA : 76.2 x 76.2 x 1010 (76.9 x 76.9 at wear pad) FFA : 76.2 x 76.2 x No Cd wire End fitting : Square Box : 64 x 64 FA structural material : Al 6061-T6 Flow channel gaps : 2.35 ± 0.25 Follower FA Standard FA 44 44

45 45 Roadmap for Development of Plate Fuel in KAERI Present Facility construction for plate fuel fabrication (100 FA /year) Process design, Equipment specifications Installation of plate fabrication facility Utility Supplementation Installation of plate assembly facility Manufacturing License from KINS Qualification test of fuel plate, Supply of fuel plate Supply of KJRR Fuel (1 st ~2 nd core) R&D of Fuel Fabrication Facility Installation Qualification Preliminary research for fab.process development Plate assembly prototype Stabilization of Plate Prototype Manufacturing of fullsize plate FA for process fabrication qualification Design for KJRR Establishment of QA/QC Mini-plate Irradiation test in HANARO Out of-pile test of plate assembly prototype KINS audit & Manufacturing Permission Qualification test of LTA in High-power RR & PIE License acquisition from KINS

46 46 Installation of Plate Fuel Facility in KAERI Project - Purpose: Supply U-Mo plate fuel to KJRR - Period : 2011 ~ 2013 (3 yrs) Facility Installation - Location : Room 230~232 in Sabit building - Capacity for FA fabrication : 100 FA/year - Period : Plate fabrication facility : ~ Inspection facility : ~ Fuel assembly facility : ~ International Cooperation Fabrication Facility for RR Fuel - Argonne National Laboratory (ANL), for set-up the plate fuel facility in KAERI ~10, Send KAERI experts for 3 weeks and training for plate fuel fabrication , Invite ANL engineer (T. Wiencek) - CCHEN, for set-up the plate fuel facility in KAERI and mini-plate irradiation , Send KAERI experts and tour the CCHEN fabrication facility , Invite CCHEN experts (J. Marin, L.Olivares) , Invite CCHEN expert (G. Torres) - Idaho National Laboratory (INL), for set-up the plate fuel facility in KAERI , Send KAERI experts for a week , Invite INL expert (G. Moore)

47 Equipment List for Plate Fuel in KAERI Use Process Equipment Plate Fab. Assembly Fab. Inspection Powder heat treatment 2 Vacuum degassing furnace (10-7 torr) Mixing Compaction 300 ton Press TUBULAR shaker mixer (three dimensional movement) Glove Box Etching & Cleaning Cleaning room with scrubbing system Welding Automatic TIG welder Hot rolling Cold rolling Pre-heat furnace Hot roller (dia. 400mm) Cold roller (dia. 380mm) Leveler Machining CNC milling machine (Cutting & ID marking) Etc. Shearing machine, Laser ID Marking Swaging Swaging machine Welding Electron Beam (EB) welder Machining Machining center Inspection 2 X-rays (CT & location, homogeneity, stray particle) UT (Debonding) 3-dimensional measuring system Gap spacing measuring system MTS for tensile test of swaged side plates 47

48 Fabrication Facility for Plate Fuel in KAERI Cleaning 300ton Press TIG Welder Pre-heat Furnace Shearing machine Cold Roll Hot Roll 48 48

49 Fabrication Flow Chart for U-Mo Plate Fuel Assembly 49 49

50 50 Blending Specification for meat with 8gU/cc Meat Dimension Volume 62.0X0.51X600 mm cc Weight g (163.13g LEU-7Mo, 22.85g Al-5Si) LEU-7Mo : < 150 um Al-5Si : <45 um, degassed at 500 o C for 2hrs at 10-5 torr Mixing condition Blending at 23rpm for 3hrs Glove box at Ar gas atmosphere After Blending

51 Compaction Pressing Pressure : 6 Ton/cm 2 B1401-C8002 Target Size (mm) Compact Size (mm) Compact Weight(g) Theoretical density (g/cm 3 ) Green density (g/cm 3 ) GD/TD (%) (L) x 59.6(W) x 4.3(T) x x

52 52 Assembly & Welding Assembly Welding Automatic TIG Welder

53 53 Hot Rolling Hot Roller Assembly initial thickness : 10.7mm Furnace Temp. : 500 o C, Pre-heating : 60 min. Hot Roll Temp. : 88~90 o C Roll speed : 10 mpm Operation Reduction Reheat Pass 1 20% 10 min Pass 2 30% 10 min Pass 3 30% 10 min Pass 4 30% 10 min Pass 5 30% 10 min Pass 6 30% - After final pass

54 54 Blistering & Bending No blistering & Delamination

55 55 Final Machining Cutting Inscribing

56 Prototype of Full Size Plate Fuel 640± max (600 nominal) 70.7± ±2.2 Plate Length : 640 mm 70.7 mm Fuel meat: mm Location by X-ray U-7Mo/Al-5Si Full-size Plate, 8g U/cc mm 56

57 57 Microstructures of Full Size Plate Fuel 3 8g U/cc

58 58 Cladding Thickness KJS00004 Area 1 : dog-bone min. 0.2mm Area 2 : dog-bone min. 0.2mm Area 3 : Ave. 0.3~0.46mm, min. 0.25mm 1

59 59 Cladding Thickness (continued) KJS00004 Area 1 : dog-bone min. 0.2mm Area 2 : dog-bone min. 0.2mm Area 3 : Ave. 0.3~0.46mm, min. 0.25mm 2

60 Cladding Thickness (continued) 3 KJS00004 Area 1 : dog-bone min. 0.2mm Area 2 : dog-bone min. 0.2mm Area 3 : Ave. 0.3~0.46mm, min. 0.25mm 60

61 61 Fuel Meat Dimension (RT) KJS00002 X-ray Linear Scanner X-ray power : Max. 160KV, Max. 6mA, Tube power 500W

62 62 Non-bonding Indication (UT) UT KJS00002 Micro focus UT sensor & 3 Channel Standard reference : 2 ± 0.02 mm No debonding in plate

63 63 Homogeneity (RT) The tolerance on the U distribution shall be within the following ranges: Area 1 : within ±16% X-ray gray level Area 2 : within +27% / -100% X-ray gray level Area 3 : within +16% / -100% X-ray gray level KJS00002

64 Stray Particle Inspection by X-ray (CT) KJS00002 Detector Jig Specification Power Panel detector CT Resolution 225Kev mm 100um Computer Tomography Detect sray particle Detect pore & defect in welding parts of FA Measure the plate gap 64

65 X-Ray CT on Fuel Assembly 1.11mm 1.11mm 0.75mm 0.75mm 1.11mm 1.11mm 0.75mm 0.75mm 65 65

66 66 INL Audit for KAERI s QA/QC System Period : ~ 17 (for 3 days) Evaluation Team - 2 Auditor and 1 Program Manager Evaluation List (5 categories) - KAERI Quality Manual - Quality System Implementing procedures and work instructions - Objective evidence and QA records of program implementation to evaluation basis - Personnel interviews - Observation of in-process work

67 Cleaning 67 Scrubber Automatic Manual 1 2 3,4 5 6 Degreasing Cleaning Etching Washing, Rinsing Remove Oxide Washing, Rinsing 1 2 3,4 5 6 Chemical fume hood clean Room

68 68 Prepared Plates for LTA (21ea) Calculated Total U wt. : 3,120.57g Calculated Total U-235 wt. : 618.1g

69 69 Swaging 1 st LTA 2 nd LTA

70 Swaging (Cross-sectional View) 70

71 Swaging (Tensile Strength) 71

72 Swaging (Tensile Strength) Swaging T.S. (N/mm) = Max. Load(N) / Plate Number / Plate length (mm) 72

73 73 Assembly of Comb & Comb Pin Gap Measurement

74 Electron Beam Welding filler wire type (ER4047) Side plate End fitting Fixing bars Filler strips filler strip type (AWS BAlSi-4) Insert of fillers using fixing bar 74

75 Electron Beam Welding EB weld parameters beam current : 35mA beam voltage : 60kV travel speed : F1200 EB welder specifications Electron Gun - Type : 3 Triode, Thermionic - Vacuum system : torr. - Focus range : 0-300mm - Max. beam power : 6kW (60kV 40mA) Work chamber : W-L-H (mm) High voltage power supply : 0-75kV D.C Work chamber pumping system : torr

76 76 Electron Beam Welding End fitting GTAW or EBW Side plate

77 77 Electron Beam Welding Fixing Bar Side plate & End fitting

78 Final Machining Machining Process After & Before After & Before After final machining 78

79 D Measurement Measurement of 3-coordinate Area : X 1,000mm, Y 1,600mm, Z 800mm Resolution : 0.1um Temperature: 18 22

80 Inventory for Plate-type Fuel 80 80

81 81 Boehmit Pre-filming Boehmite Pre-filming process Cleaning: The fuel assembly was cleaned by acetone for 5 min, ethanol for 10 min, and blown dry by N 2 gas Pre-filming: The fuel assembly and dummy Al plates were loaded into autoclave (completely submerged in D.I. water) Water Chemistry: ph of the water was remained 7 and 8 during entire process Time and Temperature: Water temperature was elevated and remained 200 for 20 hr, and cooled down to the room temperature in the vessel. Cross-sectional micrograph of the dummy Al plate Boehmite Epoxy Al plate

82 82 82 U-Mo Fuel Qualification Mini Plates Irradiation & PIE 2 full scale FA Irradiation & PIE Plate wise Irradiated data Manufacturing Properties Flow test Mechanical Characteristics Irradiation & PIE at HANARO & INL Input to RERTR Test Report KJRR SAR

83 Licensing schedule: presumably resume HANARO operation in Jan Item Year Fuel Design Licensing Basic Design PSAR Detail Design FSAR CP OL FM 표적조사시험 FM Target HANARO Mini Plate Irradiation Test I (HAMP-1) ~ HAMP-1 (4Cycle 4Mon 10Mon HANARO Mini Plate Irradiation Test II (HAMP-2) 16.1~16.8 5Mon 6Mon HANARO Mini (full length) Plate Irradiation Test I (HAMP-3) LTA Irradiation in ATR/PIE Waste Disposal by DOE ATR-C Criticality Test 16.1~ Mon 6Mon 15.9~16.8 6Mon 8Mon 83

84 KAERI s Efforts on U-Mo Development U-Mo Handbooks publication Volume 1: Material Properties of Constituents of Low Enriched Uranium (LEU) Uranium-Molybdenum (U-Mo) Fuel for Research Reactors (in process of being finalized) Volume 2: Dispersion U-Mo Fuel Behaviour Under the Envelope of Irradiation Conditions Where it is Clearly Recognized that the U-Mo Fuel Performs Properly Volume 3: Dispersion U-Mo Fuel Behaviour Above the Envelope of Irradiation Conditions Where it Performs Properly (This volume will include, inter alia, the use of additives and/or barriers meant to control formation of the interaction layer.) U-Mo Fuel Qualification HANARO: Miniplates Irradiation & PIE INL (ATR): 2 full scale FA Irradiation & PIE Existing Data Base: Plate wise Irradiated Data, Manufacturing Properties Out-of-pile Test: Flow Test, Mechanical Characteristics Licensing Licensing associated with manufacturing U-Mo plate fuel in the nuclear fuel fabrication facility in KAERI (in progress) 84 84

85 CRADA for a U-Mo LTA Irradiation Test & PIE Purpose of the CRADA A comprehensive verification on the U-Mo fuel design, manufacturing and in-pile performance Amassment of Data Base of U-Mo fuel irradiation and PIE for the KJRR fuel license and bilateral free utilization of the DB Scope of Work CRADA Phase Period KAERI INL 1 Jul Jun. 2014(1 Yr) Provides fuel design and test requirements Conceptual design for the tests 2 May 2014 Apr. 2019(5 Yrs) Hardware supply(dtfas, LTAs) Flow test/endurance test Design and safety analysis of the irradiation test LTA irradiation tests and PIE Disposal of materials Schedule Fuel Design LTA/DTFA manuf./delivery Irradiation of LTA (4 Cycles) Cooling (8 Months) PIE and Reports 85

86 86 ATR Irradiation Test ATR Irradiation Test, INL Period : ~ PIE : ~ Fuel LEU : wt% 235 U Meat : U-7Mo/Al-5Si Cladding : Al-6061 Uranium Density - Inner 19 FPs : 8.0gU/cc - Outer FPs : 6.5gU/cc Total U/FA : 3.13kg (19.75% LEU) LTA 2ea (Full-size plate fuel) Advanced Test Reactor

87 The KJRR-LTA ATR/ATRC Insertion (Apr ) 87 87

88 HANARO Irradiation Test Period ~ ~ 2016 ~ Cross-section of the irradiation capsule for HAMP-1,2 and HAMP-3 88

89 HANARO Irradiation Test (continued) Capsule for HAMP-1 Top Housing Bottom Housing Irr. Completed Period : ~ PIE in progress!! KJM8035 KJM8031 KJM6506 KJM6504 KJM8037 KJM8033 Top KJM8036 Bottom KJM

90 Irradiation test condition summary Parameter HAMP-1 and 2 HAMP-3 U-235 enrichment ± 0.2 wt% 10 (8.0 g-u/cm 3 ) 4 (8.0 g-u/cm 3 ) 2 (6.5 g-u/cm 3 ) Number of mini- or full-size plate (uranium density of fuel meat) Fuel meat dimension (mm) (thickness x width x length) Fuel plate dimension (mm) (thickness x width x length) Target burn up (U235 depletion %) Average heat flux at BOC, (W/cm 2 ) FA irradiation (KJRR-FAI) 19 (8.0 g-u/cm 3 ) 2 (6.5 g-u/cm 3 ) 0.51 x 25 x x 25 x x 62 x x 35 x x 35 x x 70.7 x 640 Avg. achieved 60~65 % (HAMP- 1) Avg. 70 % (HAMP-2) Local maximum ~90% Local maximum ~ 85 % 225 (mini-plate #3) ~ (plate #20) Local peak heat flux (W/cm 2 ) 254 (mini-plate mesh (1 4 7) ~ (plate mesh (10 4) Flow rate of fuel channel (m/s) Water gap between plates (mm) 2.13~ ~ Irradiation hole OR-3 (HANARO) OR-5 (HANARO) NEFT (ATR) 90 90

91 4. Fuel performance evaluation of HAMP- 1 Plate #3, KJM8031 (PIE No.5) shows peak heat flux and burnup. Plate #3 also show the highest plate average heat flux history. Fuel performance evaluation and the comparison with NDE of HAMP-1 will be focused on the Plate # C/L

92 Fuel performance evaluation on Plate #3 Fuel centerline temperature and Cladding corrosion (Boehmite layer) Position A : The maximum peak fuel temperature is estimated to be about 155 C at a burnup of around % U235 depletion (20~40 EFPD from MOC of HANARO cycle #92 to MOC of cycle #93). Local corrosion build-up is predicted to be 31 µm at EOL. Position B : The maximum peak fuel temperature is estimated to be about 133 C at a burnup of 10 % U235 depletion (about 15 EFPD). Local corrosion buildup is predicted to be 18 µm at EOL. Position A Position B Peak Temp. Cald. Temp. Boehm. Peak Temp. Cald. Temp. Boehm

93 5. NDE (Non-Destructive Examination) Visual examination on Mini-plates and capsule of HAMP-1 One could not distinguish the identification mark on the mini-plates. It seems that ID mark which was engraved by laser marking in the manufacturing process of the plate didn t have enough depth. (Additional pen vibration graving with sufficient depth will be applied for the plates of HAMP-2 and HAMP-3.) To figure out the ID, matching of X-ray images of the plates as-fabricated and after irradiation was performed

94 KJM8031 (PIE No.5, Neutronics analysis plate #3) : highest heat flux Lower cluster (top) Plate thickness (after irradiation) Lower cluster (top) As-Run Analysis Position (cm) Burnup (%U-235) % 63.4 % 64.5 % 65.8 % % 61.6 % 61.7 % 64.0 % % 59.6 % 58.7 % 63.5 % % 59.3 % 60.9 % 62.2 % % 59.1 % 60.6 % 62.6 % % 60.8 % 60.5 % 63.7 % % 62.7 % 63.5 % 65.9 % (bottom) As-Run Fuel Performance : Plate thickness change of 68~80 µm by fuel swelling 94

95 95 95 Microstructure (KJM8031) BU : ~65% Power density : ~250W/cm 2 Optical EPMA

96 96 Failure Criteria U-Mo/Al-Si, Dispersion Fuel (solid symbols: pillowed and/or large porosity) ATR(LTA) HAMP-3 HAMP-2 HAMP-1 IRIS-3 RERTR-6 AFIP-1 Burnup (%) Threshold curve for fuels without Si Threshold curve for fuels with Si Fission rate (10 14 fission/cm 3 -s) E-FUTURE IRIS-TUM RERTR-9 RERTR-7 E-FUTURE RIAR KOMO SELENIUM HAMP-1 G. Hofman, YS.KIM June 2015.

97 KAERI s Target R & D Project Target Fabrication Atomization of U and UAl x Irradiation Test HANARO Irradiation Test - 2.6gU/cc, commercial-grade - 6gU/cc, high-density LEU Target Supply Kijang Research Reactor HEU Minimization Plate Fabrication Technology Development Material Properties Characterization HANARO Irradiation Test Design/Preparation Post-Irradiation Examination Q.A.System Manufacturing Facility International Cooperation 1 st Phase ( 12-14) 2 nd Phase ( 15-16) Target Supply ( 17~) 97

98 Atomized UAl x Powder U-1wt%Al U-10wt%Al U-20wt%Al For High-density Dispersion Target For Commercial Dispersion Target 98

99 99 Atomized UAl x Powder U-1wt%Al U-10wt%Al U-20wt%Al U Grain refinement, ~ 1 µm Density: 17.8 g/cc Uranium density: 17.6 g/cc 27 vol.% U + 73 vol.% UAl 2 Density: 11.1 g/cc Uranium density: 9.95 g/cc 76 vol.% UAl vol.% UAl 3 Density: 7.8 g/cc Uranium density: 6.26 g/cc U-density (g/cc) Max. U Loading (theoretical fab. limit) U-1wt%Al g-u/cc U-10wt%Al g-u/cc U-20wt%Al g-u/cc

100 100 Commercial UAlx Target Fabrication U-20wt%Al 76 vol.% UAl vol.% UAl 3 Density: 7.8 g/cc Uranium density: 6.26 g/cc Specification (dimension) - Target Plate : 200(L) 48.6(W) 1.57(T) - Meat : 182(L) 40.0(W) 0.79(T) - Meat Dimension : (L) 39.94(W) by X-ray UAlx/Al Dispersion Target, 2.6g U/cc

101 Plan for Extension of Fabrication Facility Current Area for Fabrication Facility (300m 2 ) Fuel Storage Room Area which will be extended (330m 2 ) Aim for fabrication line separation betw. Fuel and Target 101

102 Global Cooperation

103 2012 Seoul NSS To develop high density LEU fuel for high performance research reactors in Europe still using HEU fuel USA-Korea-France-Belgium USA: Provide LEU raw material Korea: Production of 100 kg of U-Mo powder France: Fabrication of fuel assemblies Belgium and France: Irradiation tests at BR-2 and RHF-ILL 2012 Nuclear Security Summit ( ) White House Press Release ( ) 103

104 Current Status after 2012 Seoul NSS USA : Delivery of LEU 116kg from DOE/NNSA/Y-12 to KAERI ( ) Korea: Implementing 2012 NSS Action Plan on the fabrication of 100kg U-Mo powder ( ) Delivery of U-Mo powder to USA Delay of transportation schedule due to the shut down of USA government 98kg U-Mo powder Y-12, USA ( ) 2kg U-Mo powder SCK-CEN, Belgium Ceremony Marking the Delivery of U-Mo Date : (KAERI) Participants - Korea : MSIP, MFA, KAERI - USA : DOE/NNSA, Y

105 105 Current Status after 2012 Seoul NSS Transportation of LEU-Mo Powder(98kg) to DOE/NNSA/Y-12 ( ) Transportation of LEU-Mo Powder(2kg) to SCK-CEN

106 Hague NSS Joint Statement on Multinational Cooperation on High-density Low-enriched Uranium Fuel Development Belgium, France, Germany, the Republic of Korea and the United States, the parties to this joint statement recognize that the ultimate goal of nuclear security is advanced by minimizing highly-enriched uranium (HEU) in civilian use, which is affirmed in the Washington and Seoul Summit Communiqués and is also a key issue on the agenda of the 2014 Nuclear Security Summit. In continuation of the Joint Statement on Quadrilateral Cooperation on High-density Low-enriched Uranium Fuel Production made in Seoul, the original four parties plus Germany are working together to develop and qualify new high-density low-enriched uranium LEU fuels as part of an effort to convert research reactors from HEU fuel to LEU fuel. High performance research reactors use significant quantities of HEU each year and require unique and complex fuels to operate. The five parties are pooling their expertise and resources to develop, qualify and fabricate new high-density LEU fuels with the ultimate goal of converting the remaining high performance research reactors in the world to operate on these fuels when technically and economically feasible. The parties are focusing their efforts on uranium molybdenum (UMo), both as a monolithic fuel foil and as UMo powder dispersed in an aluminium matrix. In the last years the parties have had particular yet not exclusive technical foci. Europe (Belgium, France and Germany) manufactured and tested in-pile full-scale fuel plates based on coated UMo powder technology; the United States manufactured and tested in-pile full-scale fuel plates based on coated monolithic UMo technology. As laid out in the 2012 Joint Statement, the Republic of Korea manufactured and made available to the community UMo powders based on advanced atomization technology, and intends to continue producing and providing such UMo powders for further qualification tests of new high-density dispersion fuel. We express our shared confidence that this international cooperation among Belgium, France, Germany, the Republic of Korea and the United States to develop high density LEU fuels will be strengthened by intensified and coordinated collaboration that will contribute directly to the ultimate goal of minimizing HEU in civilian use. Cooperation and support from the international community are crucial for making available LEU fuel that is suitable for high performance research reactors, and we agree to share the benefits of all technology developed together in this joint effort, with conditions to be set out in due time.

107 Thank you for your kind attention! 107