1

HCCBSummary Supplements

Prepared by Alice Ying Aug. 2005

2

Port Dimensions

Horizontally-divided equatorial port (Port #16 for HCCB TBMs)

A 20 mm gap between the frame and TBM is reserved to grab the TBM during remote handling.

Key

Flexible support

Electrical Strap200710

1208 (mm)

The US HCCB test submodule will be inserted into ITER Equatorial Port #16 for testing.

3

4

Helium-Cooled Ceramic Breeder (HCCB) Blanket/First Wall Concept for TBM

Idea of “Ceramic Breeder” concepts – Tritium produced in immobile lithium ceramic and removed by diffusion into purge gas flowFirst wall / structure / multiplier /breeder all cooled with heliumBeryllium multiplier and lithium ceramic breeder in separate particle beds separated by cooling platesTemperature window of the ceramic breeder and beryllium for the release of tritium is a key issue for solid breeder blanket.

Schematic view of an example ITER HCCB test blanket submodule showing typical configuration layout of ceramic breeder, beryllium multiplier and cooling structures and manifolds

Thermomechanical behavior of breeder and beryllium particle beds under temperature and stress (and irradiation) loading affects the thermal contact with cooled structure and impacts blanket performanceNuclear performance and geometry is highly coupled and must be balanced for tritium production and temperature control

Side Wall

WBS 1.8.2

5

Two collaboration schemes under discussion

Scheme No. 2: Co-Design and fabrication of a half-port TBM with the US contribution to 1/3 of the TBM

Each unit cell size~ 0.2 x 0.2 x 0.4 m3

Scheme No. 1: inserting “US” unit cells into the EU HCPB structural box

WBS 1.8.2

6

Ceramic Breeder Test SubmoduleInserting “US” unit cells into the EU HCPB structural box

Unit (mm)

Electromagnetics/Neutronicsunit cell design

Helium CoolantPressure 8 MPaTemperature, In/Out 100/250 C

Helium PurgePressure 0.1 MPaTemperature, average 225 C

Breeder Min/Max 100/350 CBeryllium Min/Max 100/350 CFS Min/Max 100/300 C

Neutonics Submodule Operating Conditions

WBS 1.8.2

7

EM/NT Unit Cell Design (June, 2005)WBS 1.8.2.1.3

Note that beryllium and ceramic breeder materials in the EM test submodulemay be substituted with simulants (TBD)

8

Detailed dimensions of TBM Unit Cell

FS box with coolant plates

Ceramic breeder pebble zones (single-size, 62% packing)

Be pebble zones (single-size, 62% packing)

T &B Be pebble

zones (single-size,

62% packing)

9

This submodule approach shares the test space with Japan, which features designing the US blanket configurations into one of the three Japan’s submodules

Beryllium (~ 1mm pebble)

1248

402

Helium manifold (to be designed)Ceramic breeder:Li4SiO4- 40% 6Li enriched (single size ~0.4 mm)Li2TiO3- 70% 6Li enriched (single size ~ 0.6 – 0.8 mm)

600

2 of 3 of JA SubmodulesAn example submodule design combines layer and edge-on configurations in one physical unit with its own first wall structural box

402x 350 x 600 mm3 each

WBS 1.8.2.1.3

10

Thermomechanics Unit Cell Design Details

• Helium 8 MPa

• Tin: 350oC

• Tout: 500oC

• Total heat generation inside the unit cell ~ 35.8 kW

• He-coolant flow rate: 0.046 kg/s per unit cell

Skelton View

Demo act-alike design approach:reproducing temperature magnitude and gradient within the blanket pebble bed regions

WBS 1.8.2.1.3

11

Ancillary conditioning equipments and measurement systems for HCCB test submodule are located in the port cell area

• A coordinated test program requires a standardization of the TBM/frame interface and an integrated layout of the port cell equipments.

“US HCCB test submodule”

WBS 1.8.2.2

WBS 1.8.2.1

12

WBS 1.8.2.3 HCCB/ITER System Integration Involving:• to integrate HCCB test submodule (WBS 1.8.2.1) with Host Party’s test

module• to integrate HCCB ancillary equipments (WBS 1.8.2.2) with Port A

Parties’ equipments into Port A port cell area• to connect pipings between ancillary equipments and test submodule

The maximum external size of the container is 2.62 m (W) x 6.5 m (L) x 3.68 m (H).

Port PlugPort Cell

13

Illustration of WBS for HCCB (1.8.2)

Tritium Building

Test submodule(1.8.2.1)

Coolant conditioning components (1.8.2.2)

Measurement systems (1.8.2.2)

Helium coolant system (EU/JA)

Coolant purification system (EU/JA)

Tritium extraction system (EU/JA)

TBM replacement Control

Purge gas conditioning components (1.8.2.2)

Bioshield

Port Cell Area

TCWS VaultHot Cell

TBD

Port Frame

(1.8.2.3)(1.8.2.3)

(1.8.2.3)

14

R&D List

1.8.2.1.2.612. Diagnostics and instrumentation

1.8.2.1.2.711. Blanket non-destructive testing and quality control development

1.8.2.1.410. Blanket component fabrication technology development1.8.2.1.2.39. RAFS material and joint technology development

Beyond 20158. Predictive capability development for performance as a function of fluences

Irradiation test is “pebble” dependent.

1.8.2.1.2.87. In-pile pebble bed assembly tests including irradiation test technology development

1.8.2.1.2.16. Thermal hydraulic and flow distribution performance evaluation

Adopt existing technology /Advanced R&D beyond 2015

5. Tritium recovery and processing technology development

1.8.2.1.2.44. Tritium release, permeation and inventory predictive capability

This R&D is “pebble”dependent.

1.8.2.1.2.23. Pebble bed thermo-physical and –mechanical property characterization and performance evaluation

2. Beryllium pebble fabrication, characterization, and recycling

1. Ceramic breeder pebble fabrication, characterization, and recycling process technology development

Comments WBS R&D Item

15

HCCB ITER Tests and Schedule

Operational Year -2 -1 1 2 3 4 5 6 7 8 9 10 11 122015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

ITER Master Schedule DD# of burn pulses/year 1 750 1000 1500 2500 3000 3000EM Submodule Fabrication/AssemblyInstallationOperation in ITERPost test examinationNT Submodule Fabrication/AssemblyInstallationOperation in ITERPost test examinationTM & T SubmoduleFabrication/AssemblyInstallationOperation in ITERPost test examinationIntegrated SubmoduleFabrication/AssemblyInstallationOperation in ITERPost test examination

HH Low Duty DT High Duty DT

16

Scopes of Characterization on Breeding Elements Thermomechanics

1. Pebble materials• Thermo-physical properties, mechanical

properties, tritium release characteristics, irradiation effects, etc.

2. Pebble bed unit • Effective thermo-physical properties,

effective thermo-mechanical properties, irradiation effects, etc.

3. Breeder unit (with structure) • Stress-strain magnitudes under blanket

operating conditions, temperature profiles, deformation profiles, cyclic effects, etc.

Three main categories: WBS 1.8.2.1.2.2

17

Solid breeder thermomechanics conducted under the frame of IEA collaboration

Primary Variables• Materials• Packing• Loadings• Modes of operation

Irradiation Effect(NRG)

Primary & Secondary Reactants:• Temperature magnitude/

gradient• Differential thermal

stress/contact pressure• Plastic/creep deformation• Particle breakage• gap formation

Goal:Performance/Integrity prediction & evaluation

Partially integrated out-of-pile and fission reactor tests(NRG,ENEA)

Finite Element Code (ABQUS, MARC)

(NRG, FZK, UCLA)

Discrete Element Model (UCLA)

Design Guideline and Evaluation (out-of-pile & in-pile tests, ITER TBMs)

Database Experimental Program(FZK, JAERI, CEA,UCLA)

Thermo-physical and Mechanical PropertiesConsecutive equations

Single/multiple effect experiments(NRG, UCLA)

WBS 1.8.2.1.2.2

18

Test Article Design and Analysis based on the FEM Model developed under WBS 1.8.2.1.2.2

Engineering scaling rules are applied for TBM design in order to achieve DEMO-like operating conditions under a reduced neutron wall load (0.78 vs 2- 3 MW/m2)

75.0314 σxE BC =83.01772 σxE eB =

Elastic modulus (MPa)Temperature profile at 400 s

von Mise’s stresses (focused on beryllium PB region)

Predicted high stress zone (~20MPa) occurs at the corner of the coolant plate

MARC Model

Breeder zone

Beryllium zone

Finite element based pebble bed thermomechanics analysis

WBS 1.8.2.1.3

19

CFD analysis and laboratory experiments are needed to verify helium manifold design

• Multiple parallel paths per flow distributor

• Multiple parallel channels per flow path

• The goal is to ensure that helium flow is properly distributed

EM/S and NT Unit Cells

WBS 1.8.2.1.2.1

20

A “qualified” structural material fabrication technology is also needed for breeder zone coolant plates in addition

to FW box

Layer Design Configuration

Edge-on Design Configuration(2 paths)

WBS 1.8.2.1.2.3 and WBS 1.8.2.1.2.1

21

Tritium permeation: Uncertainties in the database• Permeability / Solubility data and Pressure effect

0.001

0.002

0.003

0.004

0.005

0.006

0.007

0.008

0.009

650 700 750 800 850

F82 H [100 Pa< P< 1000 Pa]

F82H [105 Pa]Eurofer

Temperature (K)

• At higher pressure, the permeation regime appears to be diffusion limited or J~ P0.5, i. e. permeability is governed mainly by hydrogen transport through the bulk. At the lower temperatures and lower pressures (773 K or lower), the pressure dependence of J is somewhat steeper in the low-pressure or J~ P0.63. This can be explained by a more pronounced surface influence on the permeability.

• Note that the tritium partial pressure is < 10 Pa in the purge.

References:E. Serra, A. Perujo, G. Benamati, “Influence of Traps on the Deuterium Behavior in the Low Activation Martensitic Steels F82H and Batman,” J. Nucl. Mater, 245 (1997) 108-114. A. Pisarev, V. Shestakov, S. Kulsartov, A. Vaitonene, “Surface Effects in Diffusion Measurements: Deuterium Permeation through MartensiticSteel,” Phys. Scr, T94 (2001) 121.D. Levchuk, F. Koch, H. Maier, H. Bolt, “Deuterium Permeation through Eurofer & A-alumina Coated Eurofer,” J. Nucl. Matet, 328 (2004)103-106

WBS 1.8.2.1.2.4

22

Summary Table% Tritium permeation versus purge gas condition

1.070.88%0.05 m/sF82H0.524.49%0.1 m/s

1.080.417% 1.016.36%0.05 m/s1.770.716%1.638.18%0.03 m/s4.95 2.21%4.3313.81%0.01 m/sT= 773 K

Eurofer

1.550.56%0.03 m/sF82 H0.471.8%0.1 m/s0.922.55%0.05 m/s

1.56 0.271%1.503.3%0.03 m/s4.46 Pa0.80%4.23 Pa5.62%0.01 m/sT= 673 K

Eurofer

PHT at the 1 m downstream

J3/J1PHT at the 1 m downstream

J3/J1Purge gas velocity

With 100 wppm H2Without H2

Calculated permeation rate appears high and unacceptable without taking into account isotope swamping effects or using permeation reduction barriers.

WBS 1.8.2.1.2.4

23

In-Pile pebble bed assembly test EU HCPB Pebble Bed Assembly Irradiation at

HFR

6.75 cm diameter x 12.5 cm height

WBS 1.8.2.1.2.8

A collaborative effort

Where the nuclear tests be conducted?

24

Design and AnalysisModification to a typical DEMO FW coolant routing scheme is needed in

designing the ITER TBM FW

h=5890 W/m2-K

h=5890 W/m2-K

Max Temp: 523 oC • In general, ITER TBM is smaller in size than a typical DEMO module (short flow path, larger flow area per M2 FW)

• Uncertain ITER surface flux distribution

• Disproportional heat distribution between surface heat and neutron loads: By-pass flow is considered to further increase He velocity (for TM/PI Modules)

ITER FW heat flux at the mid-plane:Nominal: 0.11 MW/m2

Peak: 0.5 MW/m2

Average: 0.3 MW/m2

5 coolant channels per flow path connected in series

WBS 1.8.2.1.3

25

Sophisticated nuclear analysis (2 – 3 D) needed to verify the design that meets test objectives

Top View Showing the two submodules placed in the port with the surrounding ITER basic shielding blanket

0

1 10-5

2 10-5

3 10-5

4 10-5

5 10-5

6 10-5

0 10 20 30 40 50 60 70

d=6.9 cmd=11.6 cmd=16.8 cmd=18.4 cmd=25 cmd=26.6 cmd=34 cmd=36.4 cmd=2.6 cmd=2.6 cmd=2.6 cmd=2.6 cmd=2.6 cmd=2.6 cmd=2.6 cmd=2.6 cmd=2.6 cmd=2.6 cmd=2.6 cm

Toroidal Distance from Frame, cm

4

Breeder unit # 1

Lft. Edge-on Sub-module Rt. Parallel Sub-module

2 3 45

Breeder Layer #

2

34 5

6 7

8

9

1

Toroidal profile of tritium production rate in the two submodules at various radial distance d behind the First Wall

WBS 1.8.2.1.3

26

Design and Analysis:Purge-gas delivery and collection systems are integrated into the bottom

and upper end caps

Bottom end cap

Upper end cap

91 cm First Wall

Not only heat but also tritium produced inside the breeder zone needs to be brought out[more structural fabrication issues]

Purge gas flows vertically and radiallythrough different breeding zones to remove tritium

WBS 1.8.2.1.3

27

DRAFT Cost Estimates for Unit Cell and Submodule

1.7 millions1 millions Total estimated cost

$ 1210 K$ 567 KBreeder + Beryllium cost

$ 540 k$ 189 KBeryllium cost2

$ 670 k$ 378 KBreeder cost 13907700 x 0.0063648 x 3=147Total ferritic steel weight, kg

1850x0.62 x 0.052 =601850 x 0.62 x 0.006167 x 3 =21Total beryllium weight, kg

3450 x 0.9 x 0.62 x 0.035= 673450 x 0.9 x 0.62 x 0.00589 x3=37.8Total breeder weight, kg (Li2TiO3)

0.05060.0063648Total ferritic steel volume, m3

0.0520.006167Beryllium volume, m3

0.0350.00589Breeder volume per unit, m3

13Number of units

0.1330.015115Total breeding volume (0.4 m)

0.402 x 0.71 x 0.60.188 x 0.201 x 0.6Size, m3

Submodule (TM)Unit CellParameters

$ 9K2$ 10K$ 10K1Cost /kg

100%100%98%90%Fabricated density

7700185024003450TD kg/m3

Ferritic SteelBeLi4SiO4Li2TiO3

1. CEA price if purchasing 1 kg. The price per kg may increase for a higher 6Li enrichment and decrease for a large purchase.

2. NGK beryllium pebble price. The price per kg may decrease for a large quantity.

28

Additional cost items (US’ contribution: x%)

– Port Frame– Helium Loop and associated piping system – Port Cell Coolant Conditioning Components – Tritium Extraction System– Diagnostics Control– Special Remote Handling Tools– Hot Cell and PIE– Waste disposal

29

Benefits of a collaborative TBM program

• Provide a scheme for collaboration with China, Korea who are eager to participate

• Japan may wish to collaborate since the water-cooled solid breeder blanket design is her mainline. There is not much difference in terms of issues and configuration between HCPB and WCPB.

• Maintain “leadership” with a minimal investment• Emphasize details of research (but not confirmation

tests)• Built-in flexibility for concept scoping evaluation• A “complete” blanket unit which allows to gain full

development experience • Access to other parties’ R&D through data sharing (fair

participation)

30

EU TBM Helium-cooled (Ceramic Breeder/beryllium)

Pebble Bed

1. Test Blanket Module

2. Example R&D

Content

31

EU HCPB TBM

cap

FW

grid

Breeding unitmanifold

attachment

• Orientation: horizontal (half ITER port)• Dimensions (mm): 740 x 1270 x ~700 (to be updated according to ITER

port frame design optimization)• 18 breeder cells (203 x 222) mm2

• Max. He flow: ~1.8 kg/s• Adapted DEMO He flow scheme

32

First wall

33

CAP

34

Stiffening grid

Dimensions are yet to be updated

35

Breeding unit

Beryllium

canister

ceramicBackplate

Canister/coolant plate for breeder/beryllium

36

Breeding unit

TM/PI-C TM/PI-B NT=DEMO

37

ManifoldPurge gas systemManifold 3Manifold 2Manifold 4

Bypass collector

Manifold 1Bypass outTBM out…..TBM in…….

38

EU R&D Programme

HCPB Project• TBM and DEMO Design• Fabrication Technologies• Out-of-pile testing• Processes and components development • Ceramics R&D• Beryllium R&D• Irradiation Programme• Thermo-mechanics of pebble beds• Modelling of irradiated materialsMaterial Programme• EUROFER and joint technology development

39

Fabrication Technologies(CEA, FZK)

40

Ceramic Breeder Pebbles

Orthosilicate (FZK-Schott, 2003) d = 0.2 - 0.6 mm

Metatitanate (CEA-CTI, 2001)

d = 0.7 - 1.0 mm

41

JA TBM Helium-cooled Ceramic Breeder

1. Test Blanket Module

2. Helium-cooling scheme and Loop

3. Tritium processing system and Measurement system

Content

42

Thickness of Layers in TBMs (Dimensions are based on a 20 cm frame thickness.)

40Rear Wall20Rear Header30Rear Wall

37.14th MultiplierID10, OD13, P456th Cooling Chanel

135.13rd MultiplierID10, OD13, P455th Cooling Channel

353rd BreederID10, OD13, P304th Cooling Channel

91.32nd BreederID10, OD13, P303rd Cooling Channel

23.62nd BreederID10, OD13, P222nd Cooling Chanel

571st MultiplierID10, OD13, P221st Cooling Panel

22.81st Breeder

3(Armor)4/8/6

First Wall(Front/Cool.Ch./Rear)

He Cooled TBM

43

Structure of JA He Cooled Solid Breeder RAFM TBM

1st breeder

1st multiplier2nd breedr2nd multiplier3rd breeder3rd multiplier

3 Sub-module Configuration

Horizontal ViewVertical View

EBW at rear wall

44

45Vertical View

46

Flow Passage of He Cooled Solid Breeder TBM of JapanTBM cooling System outlet pipe 23.8m/s, ID/OD: 120.8/139.8mm

8.0MPa, 300.0℃, 1.80kg/s

First Wall 35.1m/s□8.0×8.0mm, Pitch: 11.0mm

Side Wall 25.9m/s□10.0×10.0mm, Pitch: 22.5mm

373.2℃

389.5℃

Cooling panels 13.8m/sID/OD: 10.0/13.0mm

Pitch: 22.0, 25.0, 28.0mm38.0, 46.0, 106.0mm

Total channel: 75

Back plate 1.87m/sφ28.0mm, Channel: 18

401.1℃

472.2℃, 1.80kg/s

TCWS vault

Coolant inlet pipe 47.6m/sID/OD: 85.4/101.6mm

Port area and transfer cask

Breeding region lower manifold0.17kg/s 0.43kg/s

Back plate upper outlet manifold

500.0℃

Coolant bypass pipe 46.8m/sID/OD: 49.5/60.5mm

TBM

Coolant main outlet pipe 15.3m/sID/OD: 73.9/89.1mm

Heat exchangerPort area and transfer cask

Coolant outlet pipe 61.5m/sID/OD: 85.4/101.6mm

472.2℃, 1.80kg/s

TBM cooling System inlet pipe 21.9m/s, ID/OD: 143.2/165.2mmTCWS vault

From other sub-modules From other

sub-modules

47

Layout of JA TBM Cooling Systems in Vault- He Cooling System including Purification System was assumed to be installed in a given room of TCWS Vault. - Foot print is 25 m2.

48

WSG1 JA He Cooled TBM Coolant Flow Configuration

HXTBM Cooling System

TBM inside V.V. boundary

Common Frame and penetrations

Port Area and Transfer Cask

“Shaft”to TCWS Vault

TCWS Vault

3 Sub-module lines parallelA unified single line to TBM Cooling System

3 independent heat exchangers for 3 sub-module lines

1 pair of He line

49

Major Specification of Heat Exchanger for Mixing By-pass and Outlet Flow for Common Manifold Case

Shell Side (By-pass Flow)

Tube Side (Outlet Flow)

500 / 472 oCTube Inlet / Outlet T.

0.51 kg/sShell Side Flow Rate

1.29 kg/sTube Side Flow Rate

2.2 mShell Length

401 / 472 oCShell Inlet / Outlet T.

13.8 mmTube Diameter

150Tube Number

350 mmShell Diameter

Dimension of a heat exchanger for mixing By-pass flow and Outlet Flow for one sub-module

2200

350

800

2.2m x 0.8m x 0.6 m is necessary for Heat Exchangers in Port Area.

50

Design Conditions for Tritium Recovery System

1265.5180.1070.05060.0056

m3/daymol/daymol/daymol/daymol/day

Throughput in one day (24 h)Purge gas totalH2HTH2OHTO

20.017.4gTotal Tritium production

7230.1

2.795123

7230.1

2.437123

KMPa

Nm3/hCi/Nm3

At TBM OutletTemperaturePressurePurge gas flow rate

Tritium concentration in He purge gas

40014001.230.180He +

1000 ppm H210095/5

40014001.130.156He +

1000 ppm H210095/5

secsec

g/FPD

Tritium ProductionBurnDwellLocal TBRTritium productionPurge gas composition

Purge gas H/T ratioPurge gas HT/HTO ratio

Helium CoolWater Cooled UnitItem

51

Flow Diagram of Tritium Recovery SystemJapanese Tritium Recovery System collect purge gas from both of Water Cool and He Cool TBM.(1) Primary process is Dryer Bed + Cryo-MS Bed.(2) Recovered hydrogen isotopes are purified with Palladium Diffuser.

52

Tritium Measurement System(1) Basic analysis method is hygrometer + micro gas-chromatography +

ionization chamber.(2) One unit is installed in the port area to observe tritium at the nearest place

to TBM.

53

Layout Plan of Tritium Recovery System(1) TRS is assumed to be installed in Tritium Building.(2) Two glove boxes will be used to contain all components.(3) One unit of Tritium Measurement System is installed in a container in the

port area.

54

Space Requirement of Ancillary Systems

1.Cooling System- 25 m2 for He Cooling System in TCWS Vault.- 2m x 2m x 0.4m for heat exchangers of by-pass flow in the port area.

2. Tritium System- One system for Water Cooled and He Cooled TBMS - Two glove boxes (1.2m x 4m x 3m(h) x 2)

3. Tritium Measurement System-TMS for purge gas outlet and inlet is installed in small compartment in port area (about 0.5m x 1m x 0.5m)- Other TMS is contained in two glove boxes.