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May 2010

7th International Scientific and Technical Conference "Nuclear Power Safety , Effectiveness and Economy " , MNTK -2010. EFFECTIVENESS EVALUATION FOR THE FAST SODIUM- COOLED REACTOR DESIGN SOLUTIONS AND THEIR EVOLUTION IN NEW DESIGNS B.A. Vasilyev. FEDERAL SCIENTIFIC PRODUCTION CENTER

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May 2010

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  1. 7th International Scientific and Technical Conference"Nuclear Power Safety, Effectiveness and Economy", MNTK-2010 EFFECTIVENESS EVALUATION FOR THE FAST SODIUM- COOLEDREACTOR DESIGN SOLUTIONSAND THEIREVOLUTION IN NEW DESIGNS B.A. Vasilyev FEDERAL SCIENTIFIC PRODUCTION CENTER JSC“Afrikantov OKBM” May2010

  2. BN FAST REACTOR TECHNOLOGY STATUS • In February 2010, the Government of the Russian Federation approved the Federal Target Program “New Generation Nuclear Power Technologies for the Period 2010-2015 and for the Futureto 2020” (FTP NGNT) • As part of the FTP NGNT, R&D work is provided for the BN-1200, next generation sodium-cooled fast reactor with the electric power of 1200 MW • BN-1200 is being developed such that the task be resolved for serial construction of the BN-1200 reactors after 2020 • The BN-800 reactor is under construction; the planned completion date for the construction is 2013 • On April 8, it was 30 years since the BN-600 reactor commissioning. The BN-600 is the only operating fast power reactor in the world

  3. PROVEN DESIGN SOLUTIONS. BN-600 DESIGN • Activity on fast reactors in Russia was started in 1960 by designing the first pilot industrial BN-350 power reactor. The reactor was commissioned in 1973 and was in operation until 1998 • In 1980, the next, more powerful BN-600 reactor was commissioned in Beloyarsk NPP • In April 2010, the reactor completed its assigned service life of 30 years. • Its service life extension to 45 years has been validated

  4. BN-600 30-YEAR OPERATION EXPERIENCE

  5. SODIUM LEAKS IN BN-600 • There have been 27 outside leaks (5 of them were radioactive sodium leaks) and 12 SG leaks. Themain reason for them is deviations in the manufacture quality of auxiliary pipelines • An only radioactive sodium leak (~1 m3) resulted in a radioactive substance release into atmosphere below the allowable limits for normal operation of the NPP • The last sodium leak took place in the BN-600 reactor in 1994 • Over the last 24 operational years, only one small leak took place in the SG • Capacity factor reduction due to the leaks is negligibly small • The reliability of design measures to prevent and localize inter-circuit and outer sodium leaks has been convincingly demonstrated

  6. BN-600 CAPACITY FACTOR VARIATION Capacity, %

  7. BN-600 REACTOR CORE MODIFICATIONS

  8. TASKS TO BE SOLVED BY THE BN-800 CONSTRUCTION AND OPERATION • Breeding mode of operation with MOX-fuel • Pilot-scale demonstration of key closed fuel cycle components • Developing innovative technologies for future LMFBR: • advanced fuel and structural materials testing and qualification • MA burn-out technology demonstration • testing novel technical solutions • sustaining competency in the LMFBR technology BN-800– important milestone in evolution to next generation nuclear power technology

  9. THE BN-800 UNIT DESIGN EVOLUTION AND KEY FEATURES • 1984 –initial design–evolutionary up-rated version of the BN-600 • 1994 – updated design approval • much higher unit capacity • passive safety systems • MOX-fuel Distinctive design features:

  10. IMPROVEMENTS IN BN-800 DESIGN SOLUTIONS(1) • Introduce technical solutions to enhance safety, efficiency and reliability of the power unit: • Additional passive emergency protection system is provided for • Emergency decay heat removal system is introduced that utilizes air heat exchangers • A tray is provided for localization of molten core debris in a postulated accident with a failure of all reactor protection equipment

  11. IMPROVEMENTS IN BN-800 DESIGN SOLUTIONS (2) • Hand operations are eliminated from the refueling system to ensure the possibility to handle fresh FAs with highly radioactive MOX-fuel • The design lifetime is increased from30 years (BN-600) to 45 years with the possibility of future extension to 60 years • MOX-fuel burnup is increased through the replacement of ChS-68 austenitic steel (burnup is up to 10% h.a.) byEK-164 c.w. (up to 13% h.a.); and then by ferritic-martensitic steel (up to 15% h.a.)

  12. VIEW OF THE BN-800 CONSTRUCTION SITE. MAY 2010 Vessel bottom Support belt

  13. ECS AHE MCP-1 Refueling mechanism Rotary plugs Intermediate heat exchanger (IHX) CPS column Safety vessel Pressure pipeline Reactor vessel Support belt Core Tray Pressure chamber EVOLUTION OF DESIGN SOLUTIONSIN BN-1200 (1) • Main design solutions, which proved to be successful in BN-600 and used in BN-800: • The primary circuit layout is integral with the safety vessel and lower vessel support • The rotating plugs of the in-reactor refueling system have sealing hydraulic locks based on tin-bismuth alloy • Separate suction cavities for the primary circuit pumps with check valves in the discharge nozzles make it possible to isolate one of the three primary loops without a reactor shutdown in case of equipment failure • There is an in-reactor spent FA storage

  14. Secondary MCP Leak-tight cover for above-the-reactor space Buffer tank Expansion tank Emergency dump tank Steam generator Air heat exchanger Intermediate heat exchanger Autonomous heat exchanger Emergency dump tank Reactor EVOLUTION OF DESIGN SOLUTIONS IN BN-1200 (2) • New Solutions: • Improved reactor and SG designs (reduced materials consumption) • Bellows-type compensators in the secondary circuit pipelines(reduced length and material consumption) • Substantially simplyfied refueling system as compared to BN-600 and BN-800 (reduced materials consumption) BN-1200 RP Layout • The emergency heat removal system uses autonomous heat exchangers in-built into the reactor vessel(enhanced reliability) • Primary sodium cold traps are located in the reactor vessel (pipelines containing radioactive sodium and their auxiliary systems are eliminated)

  15. BN-1200 DESIGN DATA

  16. DESIGN OF THE MAIN EQUIPMENT • Technical solutions for MCP-1, MCP-2, IHX in the BN-800 and BN-1200 are basically the same as those in the BN-600 • The BN-800 CRDM design was upgraded through simplification of the kinematic chain and enhancement of its reliability; the specific metal intensity was reduced. A similar technical solution will be used in the BN-1200 • The BN-800 steam generator design is characteristic of the less number of modules (20 per loop instead of 24 per loop utilized in the BN-600) due to elimination of sodium intermediate steam superheaters. The BN-1200 SGs are substantially enlarged: 2-4 moduls per loop. • Technical solutions for the AHX are the same as those in the BN-800 – finned tubes, heat removal by air natural convection.

  17. NEW SOLUTIONS FOR THE CORE BN-1200 • Enlarged fuel rods (6.9 mm 9.3 mm, reducedaverage fuel heat rating, increased FA life) • Enlarged FA (S=96 mmS=181 mm, reduced number of FAs) • Increased fuel volume fraction (0.43  0.47, increasedbreeding factor) • Increased gas cavityin a fuel rod, Tclad< 670 °C (to ensurehigh fuel burnup) • Use of a single fuel enrichment zone instead of three ones (simplified fuel production) • In-reactor storage areathat ensures2-year fuel delay (simplified refueling)

  18. CORE SPECIFICATIONS • The reactor core design is being developed to ensure possible transition to mixed nitride fuel (breeding factor is up to 1.45)

  19. REDUCTION IN SPECIFIC METAL INTENSITY FOR THE BN REACTORS

  20. COMPARISON OF BN REACTORS TECHNICAL AND ECONOMIC PERFORMANCE • BN-1200 economic performance will be comparable with that of VVERs having the same power. In perspective,the cost of electricity generated by BN-1200 should be lower than that of VVERdue toexpected growth innatural uranium prices.

  21. EVOLUTION OF SOLUTIONS FOR BN REACTOR SAFETY (1)

  22. EVOLUTION OF SOLUTIONS FOR BN REACTOR SAFETY (2) • Thanks to the solutions adopted in the BN-1200 design, safety parameters are planned to be significantly improved: • Core severe damage probability is by an order of magnitude lower than that required by regulatory documents • The exclusion area is within the NPP site for any design accidents • A target criteria has been established: the area for protective measures planning shall coincide with the NPP site boundary for severe beyond-design basis accidents of which occurrence does not exceed 10-7reactor/year

  23. CONCLUSIONS • Experience gained in development and operation of fast sodium-cooled reactors demonstrates effectiveness of basic design solutions adopted in BN-600 reactor, their reliable operation and high safety level • The basic design solutions evolved in the BN-800 and BN-1200 designs. The new design solutions for the BN-1200 will have to be tested by analytical and experimental investigations • The BN-1200 design may be related to Generation IV NPPs due to: • optimal combination of reference and innovative solutions • enhanced safety characteristics • high technical and economic performance • possibility of extensive fuel breeding

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