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H2-MHR Conceptual Designs Basedon the SI Process and HTE
Matt Richards, Arkal Shenoy, Ken Schultz, Lloyd Brown – General AtomicsEd Harvego and Michael McKellar, Idaho National Laboratory
Jean-Phillippe Coupey and S.M. Moshin Reza, Texas A&M UniversityFutoshi Okamoto – Fuji Electric SystemsNorihiko Handa – Toshiba Corporation
Third Information Exchange on theNuclear Production of Hydrogen
andSecond HTTR Workshop on Hydrogen Production Technologies
Japan Atomic Energy AgencyOari, Japan
October 5 – 7, 2005
Presented by���������
General Atomics, San Diego, CA, [email protected]
H2-MHR Conceptual Designs are Being Developed
• 3 year DOE NERI project with GA, INL, TAMU, & Entergy– Develop conceptual designs of “H2-MHR” hydrogen production plants– Initial focus on integration of MHR and Sulfur-Iodine-based hydrogen
production plant– Conceptual design also being developed for integration of MHR with High
Temperature Electrolysis– FY-05 is last year of project
• Participation in Related NERI/I-NERI Projects:– Centralized Hydrogen Production from Nuclear Power: Infrastructure Analysis
and Test Case Design Study (SRNL, GA, Entergy, ANL, Univ. S. Carolina)– High Efficiency Hydrogen Production from Nuclear Energy: Laboratory
Demonstration of S-I Water Splitting (SNL, CEA, GA)
• Additional Cooperation/Coordination with Various other Projects– UNLV High Temperature HX Project– Private collaborations with Fuji Electric / Toshiba– HTE Technology Development at INL
GT-MHR Provides Springboard to the H2-MHR• MHR coupled to a direct-
cycle Brayton power-conversion system
• 600 MW(t), 102 column, annular core, prismatic blocks
• Concept developed initially in the U.S.– Technology transferred to
Russia to further develop design for Pu disposition
– Similar concept being developed in Japan (JAEA GTHTR300)
ControlRods
PCS
Generator
Turbocompressor
Recuperator
Precooler
AnnularCore
Intercooler
MHR
The MHR is a Passively Safe Design
Passive Safety Features• Ceramic, coated-particle
fuel– Maintains integrity during loss-
of-coolant accident• Annular graphite core with
high heat capacity– Helps to limit temperature rise
during loss-of-coolant accident
• Low power density– Helps to maintain
acceptable temperatures during normal operation and accidents
• Inert Helium Coolant– Reduces circulating and
plateout activity
ControlRodDriveAssemblies
ReactorMetallic Internals
ReplaceableReflector
Core
Reactor Vessel
Shutdown Cooling System
Hot GasDuct
ControlRodDriveAssemblies
ReactorMetallic Internals
ReplaceableReflector
Core
Reactor Vessel
Shutdown Cooling System
Hot GasDuct
Ceramic Fuel Retains its Integrity Under Severe Accident Conditions and is an Ideal Waste Form for Permanent Disposal
Uranium OxycarbidePorous Carbon BufferSilicon CarbidePyrolytic Carbon
PARTICLES COMPACTS FUEL ELEMENTS
TRISO Coated fuel particles (left) are formed into fuel rods (center) and inserted into graphite fuel elements (right).
Reactor Design is Being Optimized for Higher Temperature Operation
• Optimize Power Distributions– Fuel placement or sandwich shuffling refueling schemes to reduce
“age” component of power peaking– Improved zoning of fissile/fertile fuel ratio and burnable poison– Use control rods in inner and outer reflector
• Reduce radial component of power peaking• Temperature limitations may require C-C clad rods
• Optimize Thermal Hydraulic Design– Reduce bypass flow
• Core restraint and sealing devices to minimize gaps• Reduce or eliminate flow in control-rod channels using C-C rods• Goal is to reduce bypass flow fraction from about 0.2 to about 0.1
– Alternative Inlet Flow Configurations• Reduce vessel temperature• Route flow through inner and/or outer reflector
• Use Higher-Temperature Metals, C-C Composites for Reactor Internal Components
Alternative Inlet Flow Configurations Can Reduce Vessel Temperatures
Reference GT-MHR(channel box)
(a) (b)
InnerReflector
Permanent SideReflector
ATHENA code used to assessalternative flow configurations
Inner reflector configuration removes significant heat capacity, resulting in higher fuel temperatures during accidents
H2-MHR Point Design Options Have Been Evaluated
GT-MHRH2-MHR
Orificed CoreH2-MHR
Optimized Core
Power Level (MWt)
600 600 600
Helium Inlet Temperature (°C)
490 490 590
Helium Outlet Temperature (°C)
850 1000 950
Coolant Flow Rate (kg/s)
320 226 320
Core Pressure Drop (kPa)
~50 ~50 >50
Orificed Core: Use of fixed orifices in upper/lower reflectorOptimized Core: Possible limited use of fixed orifices on “cold”
columns for additional design margin on fuel temperatures
Core Nuclear / Thermal Hydraulic Optimization – Scoping Studies
Fuel Temperatures
0.0 0.2 0.4 0.6 0.8 1.0
Volume Fraction
500
600
700
800
900
1000
1100
1200
Fuel
Tem
pera
ture
, °C
Reference GT-MHR491°C Coolant Inlet Temperature850°C Coolant OutletTemperature
H2-MHR491°C Coolant Inlet Temperature1000°C Coolant OutletTemperature
Irradiation Time, Effective Full Power Days0 100 200 300 400 500 600 700 800
SiC Layer Failure Probability
10-7
10-6
10-5
10-4
10-3
10-2
10-1
100
1350°C
1300°C
1250°C
Fuel Performance
Sulfur-Iodine CycleI-NERI Demonstration
Sandia
CEA
GA
MHR Coupled to S-I Thermochemical Water Splitting
H2O
SO2+H2O
H2SO4
HI
I2
BunsenReactor
High Temp HX -H2SO4 Decomposer
O2
High Temp HX -H2SO4 Decomposer
O2O2
H2Low Temp HX-HI Decomposer
H2Low Temp HX-HI Decomposer
H2Low Temp HX-HI Decomposer
565ºC
Inte
rmed
iate
HX
900ºC
950ºC590ºC
600MWthermalModularHelium Reactor
565ºC
Inte
rmed
iate
HX
900ºC
950ºC590ºC
600MWthermalModularHelium Reactor
Aspen flowsheet evaluations show efficiencies of about 45% based on HHV of H2
Conceptual IHX Design has Been Developed Based on HEATRIC Printed Circuit Heat Exchanger (PCHE)
Stacked Plates with Counterflow Diffusion Bonding Restores Properties of Base Metal
Shell and Tube: 100 tonnes
PCHE: 15 tonnes
High Temperature and High Pressure Capability
Compact, Lighter-Weight Design
PCHEs using higher temperature alloys are currently being developed by HEATRIC.600 MW(t) IHX would consist of 40 15-MW(t) modules.
MHR Coupled to High-Temperature Electrolysis
MHR 600 MW(t)
CIRC
Turbine
Separator
Gen
Electrolysis
Recuperator
Pre-Cooler
Helium
Helium
Helium
SteamGenerator
Steam
Hydrogen
Oxygen
Water
Electricity
Inter Cooler
IHX
HPComp
LPComp
CIRC
85%
15%
HTE-Based H2-MHR FlowsheetWater Supply System
Heat Transfer System
SecondaryHelium
H2 startuptank
Condensate
Primary Side Circulator
FLOWSHe primary (HOT)He secondary (cold)He primary in PCS
H2H2 mix
steam mixliquid waterwater steam
O2 with sweepO2 with negligible sweep
Brayton CyclePower Conversion System
(PCS)Secondary Side Circulator
H2 recirculator
Hydrogen Production System
Electric heater
H2 / waterknockout tank
Feedwater pump
O2 withsweepSweep steam
WaterPurification
System
H2 mix
steam mix
Inte
rcoo
ler
(Wat
er C
oole
d)
600C
112C
94C
582C
858C
444C
210C
22C
280C
858C
22C 141C
168C
27C
H2 product
IHX
950C 925C
351C637C
38.0 kg/s
2.6 kg/s
14.4 kg/s
23.6 kg/s 0.3 kg/s
26.4 kg/s
Prim
ary
Hel
ium
Sweep water fromwater storage
Generator
Bypa
ss V
alve
Pre
cool
er(W
ater
Coo
led)
Recuperator
Turbine
Low PressureCompressor
High PressureCompressor
Water tosweep system
Steam Generator
Super Heater
72C582C
Reactor System
Mod
ular
Hel
ium
Rea
ctor
600
MW
(t) 950C
26C
26C
590C
590C
642C
450C
832C
347C
827C
H2O / O 2knockout tank
Sweep condensate
27C
29C
27C
22.0 kg/s
17.0 kg/s
5.0 kg/s
827C
23.9 kg/s
water fromsweep condensate
Waterstorage
22C
14.4 kg/s 33.0 kg/s
Electricity fromPCS
Power Supply
Solid OxideElectrolyzer
Cathode
Ele
ctro
lyte
Anode
5.3 kg/s
2.4 kg/s
41.7 kg/s
321.1 kg/s
279.4 kg/s
160C
266C
257C
536C
41.7 kg/s 22.0 kg/s
925C
925C
21C 7.5 kg/s
02 / steam expander
POWER
210C
210C
6.6 kg/s
14.4 kg/s
2.7 kg/s27C
5.3 kg/s
27C
27C
O2 output21C
18.9 kg/s
Results of HTE Flowsheet Using HYSYS Process Simulation Software
MHR Module Thermal Power 600 MW(t) MHR Coolant Outlet Temperature 950°C
PCS Power Generation 312 MW(e)
PCS Thermal Efficiency 52%
Thermal Power Supplied for Hydrogen Production 68 MW(t)
SOE Process Temperature 827°C Power Supplied to SOE Modules 292 MW(e) Hydrogen Production Rate 2.36 kg/s Hydrogen Production Efficiency (based on HHV of H2) 55.5%
Auxiliary Power Generation 9.3 MW(e) Overall Process Efficiency 59.9%
Solid Oxide Electrolyzer Technology Has Been Successfully Tested
10-Cell Stack Tested at INL
4-MW(e) Trailer Module
Hydrogen Plant Will Not Impact Passive Safety
• Licensing issue of most concern is co-location of MHR and Hydrogen Plant– Passive safety of MHR allows
co-location– Earthen berm provides
defense-in-depth• Other reactors located in
close proximity to hazardous chemical plants and transportation routes– NRC allows risk-based
approach– INL recommends 60 to 100 m
separation distance
Economics for Nuclear Hydrogen Production are Competitive With Steam-Methane Reforming
SI-Based PlantHTE-Based
Plant
Capital Costs ($M)Reactor System
1030 1284
Hydrogen System
738 TBD – Depends on SOE unit
costsO&M Costs ($M/yr)Reactor System
27.8 34.6
Hydrogen System
70.9 TBD – Probably less than SI
plantHydrogen Cost ($/kg)
1.65 TBDNatural Gas Cost ($/MMBTU)
0.0 2.0 4.0 6.0 8.0 10.0 12.0
Hyd
roge
n C
ost (
$/kg
)0.50
1.00
1.50
2.00
2.50
Nuclear (SI Process)
Methane Reforming w/o CO2 Capture
Methane Reforming withCO2 Capture
Current Price
H2-MHR 4-Module Reference Design
• Standard MHR (850°C) or VHTR (950°C - 1000°C)reactor
• Intermediate Heat Exchanger (IHX) in adjacent cavity
• Intermediate heat transport loop
• MHR Passive Safety maintained
• H2 plant separation by berm• Non-nuclear H2 plant• 600 MWt ⇒ 200 tons/day
hydrogen production
4 MHR Modules, each with IHX
Earthen Berm
Hydrogen Production Plant
Cooling Towers
CONCLUSIONS• MHR is well suited for
hydrogen production– Passively safe reactor
design– Produces high
temperature heat needed for SI process and HTE
– Proof of principle for both SI process and HTE have been demonstrated
– Both SI process and HTE show potential for economical production of hydrogen without producing carbon dioxide
• MHR technology can be applied to other missions
LEUTRISOLEU
TRISO
LWRSpent Fuel
TRISO
LWRSpent Fuel
TRISO
WeaponsPlutonium
TRISO
WeaponsPlutonium
TRISO
TRISO Fuel in fuel blocks
Electricity
Hydrogen
One Reactor Design can be used for Multiple Applications
Er-167 burnable poisonPure W-Pu, small kernelTRISO coated 750,000 MWd/HMt burnup
Minor Actinides burnable controlLWR Actinides, small kernelTRISO coated 700,000 MWd/HMt burnup
Conventional burnable poisonLEU large kernel - fertile fuelTRISO coated 100,000 MWd/HMt burnup
��������������
Thank you for your kind attention.
Solid Oxide Electrolyzer Technology Has Been Successfully Tested
Requirements for a 600 MW(t) MHR Module10-Cell Stack Tested at INL
Cell Area Individual Cell Width 10 cm Individual Cell Active Area 100 cm2
Total Number of Cells 12 x 106
Total Active Cell Area 120,000 m2
Cell Thickness Electrolyte 10 µm (Scandia Stabilized
Zirconia) Anode 1500 µm (Strontium Doped
Lathanum Manganite) Cathode 50 µm (Nickel Zirconia
Cermet) Bipolar Plate 2.5 mm (Stainless Steel) Total Cell Thickness 4.06 mm Stack Dimensions Cells per Stack 500 Stack Height 2.03 m Stack Volume 0.0203 m3
Stack Volume with Manifold 0.0812 m3 Number of Stacks 24,000