ORNL-4119
MOLTEN-SALT REACTOR PROGRAM
SEMIANNUAL PROGRESS REPORT
For Period Ending February 28, 1967
9. Molten-Salt Breeder Reactor Design Studies
9.1 GENERAL
The Breeder Reactor design has been considerably narrowed in
scope during this period. A modular concept has been adopted as the basic
design, and our effort has been concentrated on more clearly defining the
features of one 250-MWe module. No work has been done on overall plant design
during this period, and no attention has been given to the steam system.
With minor exceptions, all design effort has been concerned
with components and layout within the reactor cell. A layout was made of the
drain tanks with interconnecting piping for all three salt circuits. Figure 9.1
is a plan view of the general arrangement. This preliminary layout was made to
get an idea of the magnitude of the "tank farm" problem, and it
appears that a satisfactory solution to this question will not be overly
difficult.
Again, in order to get a preliminary evaluation of the
nature of the communication problem between reactor plant and chemical
processing plant, one method of effecting this interconnection was developed.
Basically this plan involves a batch transfer between plants, the batches being
moved between the two plants by gas pressure. Transfer to and from the chemical
plant is in control of the reactor plant operator. Although the system of
communication between reactor and chemical plant has not been worked out in any
detail, it appears that the communication scheme can be done with certainty and
safety.
We believe that the optimization of the reactor is now
accurate enough to warrant serious detailing of the design. A basic concept of
fuel cell, blanket, plenum chambers, and reflector thickness for a reactor with
an average power density of approximately 40 kW/liter
has reached a firm status. It is this module which will receive detailed
attention. For comparison purposes a module of equal power but having twice the
average power density was calculated. Table 9.1 shows the comparison between
these two reactors regarding performance and economy.
The blanket and fuel heat exchangers are also considered to
be in a sufficiently firm design to justify detailing of these components. Both
heat exchangers have undergone significant changes in physical arrangement and
will be discussed in some detail later.
The arrangement of components in the reactor cell as
previously reported posed some very difficult stress problems. A new
arrangement of these components appears to have removed or greatly lessened
these problems. Analyses are currently in progress which will indicate whether
or not further changes are required.
Operational experience with the MSRE has indicated clearly
that the handling of fission gases from a molten-salt reactor requires very
careful design. The gas system for the breeder reactor is a most important part
of the plant, and a start has been made in the design of this system. A
flowsheet which seems to describe this system has been developed. Also,
analytical studies of gas stripping efficiencies and parameters which determine
or define the nature of the gas sparging system have been initiated.
Associated with the gas handling problem is the matter of
draining the reactor in the event of a pump stoppage. Modifications in the
primary heat exchanger indicated by the sparge gas handling and core drainage
influenced us to put an overflow line from the sump tank of the pump into a
fuel dump tank. These changes in the primary heat exchanger have been rather
extensive, although the basic heat exchanger remains very much as the original
concept.
9.2 FLOWSHEET
Since the reference design is based on the modular reactor
concept, the flowsheet of Fig. 9.2 is for one module. The number of the various
components in this module is shown. The steam system is shown very sketchily
for the 1000-MWe plant, and an indication of a steam header fed by the four
modules is shown.
It will be noted that the maximum coolant-salt pressure is
somewhat higher than has been reported previously. This pressure occurs at the
discharge of the coolant pump, and, of the 260 psi at this point, 110 psi comes
from a gas overpressure at the suction side of the coolant pump.
We believe it to be imperative that, in the event of a
failure in any part of the salt systems, the pressures should be such that
blanket salt would flow into fuel salt, and coolant salt would flow into
blanket and fuel salt, depending on the location of the failure. This made it
necessary to put a high bias pressure on the coolant salt. The pressures shown
on the flow diagram represent design-point pressures and take into account static
heads and dynamic pressure drops in all cases.
In previous flowsheets a separate coolant pump circulated
salt through the reheater. We now bypass the discharge of the main coolant pump
through a salt-flow regulating valve to the reheater. This valve is little more
than a variable orifice, and we believe the use of such a valve is justified.
9.3 REACTOR CELL COMPONENT ARRANGEMENT
Because of the relatively high melting point of the blanket
salt, it is desirable to connect the coolant circuits of the fuel heat
exchanger and the blanket heat exchanger in series. Coolant salt leaving the
fuel heat exchanger at a temperature of 1111°F enters the blanket heat
exchanger, where it picks up 14°F to attain the design-point temperature of
1125°F. The coolant-salt line, carrying 37.5 ft3/sec,
is a large pipe (~20 in. in diameter) and therefore rigidly connects these two
heat exchangers. Since the blanket heat exchanger is located high in the
reactor cell while the fuel heat exchanger must be located below the bottom of
the reactor vessel, there is a shift in the center of gravity of the coupled
heat exchangers when they are filled with salt.
In the original layout of the reactor cell which had the
reactor, fuel heat exchanger, and blanket heat exchanger in a triangular array,
a twisting moment resulted about the axis of the fuel connection between the
reactor and the fuel heat exchanger. Also, the method of suspension mounting of
the heat exchangers from constant load cells could not provide accommodation
for the differential thermal expansion of the system under all conditions.
A new layout of the reactor cell shown in Fig. 9.3 was made.
In this configuration the three components, reactor, fuel heat exchanger, and
blanket heat exchanger, are mounted in line. The coolant lines connecting the
fuel and the blanket exchanger are made concentric, and the shortest possible
spacing between exchangers is used. The connection from fuel heat exchanger to
reactor is as short as possible, using concentric piping for this as we have
been doing previously.
The connection from the blanket heat exchanger to the
reactor vessel has been changed. Instead of the short concentric pipe used
previously, the inlet and outlet lines from reactor vessel to blanket exchanger
are run independently. These lines are purposely made long and flexible by
running them through four 90° bends. Thus we intend to decouple the
interconnection between the reactor and the blanket heat exchanger by use of
flexible piping.
The three components, reactor, fuel exchanger, and blanket
exchanger, are rigidly interconnected then by only one link for each; the
reactor connects by the concentric fuel line to the fuel exchanger, which
connects by one concentric coolant line to the blanket exchanger. At design
point these connecting lines are very near the ambient cell temperature of
1000°F. The fuel line is actually at 1000°F, and the coolant line is very near
850°F. With the three cell components in line, a different plan of support is
now proposed. Let us point out that this arrangement has not yet been analyzed
for stresses, so we cannot be sure it is satisfactory in its present
conception.
The plan now involves mounting a stainless steel bed plate
in the reactor cell in such a way as to be tied at one end but free to expand
with cell temperature. This bed plate is located horizontally below the bottom
of the reactor vessel and is mounted through necessary insulated supports to
the load-bearing concrete of the cell. The reactor vessel and both heat
exchangers are mounted rigidly to the plate as shown in Fig. 9.4. We believe
that this general arrangement will work and that any overstressing found by
analysis of the system can be corrected without departing drastically from the
concept.
Vertical growth of all components can take place
independently, and the only accommodation needed is a low-temperature sealing
bellows at each pump-drive penetration through the cell membrane. Any
control-rod drive mechanism would involve a similar bellows seal.
The treatment of the reactor cell has not received any
attention, but it is certain that some form of radiation shield must cover the
structural concrete and this shield must have cooling. Inside the radiation
shield, between it and the furnace of the cell, there must be some thermal
insulation.
9.4 COMPONENT DESIGN
Reactor Vessel
The reactor is shown in the elevation drawing of Fig. 9.5.
The reactor vessel has a cylindrical body 12 ft in diameter and approximately
17 ft high with dished heads on top and bottom. A heavy supporting ring
essentially the diameter of the core carries legs which weld to the bed plate
and provide the mechanical mounting for the vessel. From the center of the
bottom head a concentric fuel line communicates with the fuel heat exchanger.
This fuel line has an outside diameter of 24 in. with a concentric return line
16 in. in outside diameter. Fuel flows in these lines at a rate of
approximately 18 fps.
Inside the reactor vessel are dished heads forming plenum
chambers for distribution of the fuel cells which rise from these heads. These
plenum chambers are removable from the reactor vessel, being held in place by a
flanged mounting ring equipped with clamps. This flange has not been completely
designed, but we are considering the use of flat graphite gaskets to prevent
bonding of the flange surfaces under the high temperature and rather high
loading pressure obtained at design conditions. The inner head communicates
with the inner concentric line through a slip joint which permits movement of
the head relative to the pipe. Such movement results from thermal expansion and
must be accommodated. In addition, the slip joint allows removal of the core
when the flange seal is broken.
The core of the reactor is made up of 336 cylindrical
graphite fuel cells mounted as close together as tolerances permit to form
essentially a cylindrical array approximately 8.3 ft in diameter. The graphite
cells are extruded cylinders with center holes 1 1/2 in. in diameter,
surrounded at 120° angles with three 7/8-in.-diam holes. At the top of each
cell there is a graphite cap machined to provide a smooth communication between
the four holes of the cell. Figure 9.6 shows the arrangement of one of these
cells.
At the bottom of a cell, the graphite cylinder is joined to
a transition nipple. This joining is done by a combination of a short threaded
engagement for mechanical attachment and a rather longer brazed joint for
leak-tightness. The connection to this nipple is a matter of development, and
work is proceeding to establish the best practice for effecting this
connection. The lower end of the nipple is threaded to screw into tapped holes
in the upper curved head.
From smaller holes in the inner head, concentric with the
upper one, smaller nipples extend through the upper head. These nipples are
also attached to the inner head by a pipe thread, each one being screwed into
place before attaching the fuel cells above.
As a fuel cell is put into place, the 1 1/2-in. center hole
is slipped over the inner nipple. This engagement is a slip joint and allows
for screwing the cell into place, and in operation it permits the necessary
differential expansion between the cell and the inner nipple. After all cells
are in place, the entire core can be leak-tested, the graphite-to-metal transition
joints having previously been tested individually. When the assembled core has
been tested, it can be lowered into the reactor vessel and the flanged joint
can be clamped.
Just inside the reactor vessel there is a graphite reflector
6 in. thick. This reflector is only on the vertical walls; there is none below
or above the core. It is made of rectangular-shaped pieces with mortised joints
to form a self-supporting wall resting on a ledge at the bottom of the vessel.
The volume between the reflector and the vessel provides a flow passage for the
blanket salt as it discharges through holes in the bottom of the distribution
ring located near the top of the vessel.
We are considering the use of 4-in.-diam graphite balls in
the region between the core and the reflector. These balls have holes in them
so that graphite occupies 40% of the volume in this 1 1/2-ft-thick region. A
retainer of perforated metal prevents the balls, which float in the blanket
salt, from crowding into the top head of the reactor vessel. Instead, by
floating up against this retainer, a measure of support is afforded the core
structure, the floating balls tending to exert a considerable force on the fuel
cells.
With this core configuration a two-fluid reactor is
achieved. Fuel salt enters the outer concentric pipe at the bottom of the
reactor. It flows out to the outer radius of the core and in between the upper
inner dished heads, feeding salt into the nipples emerging from the upper head.
Fuel passes up through the three 7/8-in. holes of each fuel cell and down
through the center 1 1/2 in. hole through the inner pipe nipple into the
collecting plenum. From there it flows through the slip joint into the inner
concentric fuel line to the pump suction at the center of the fuel heat
exchanger.
The blanket salt flows into a distributor at the top of the
reactor, and, emerging through holes in the bottom of this header, it flows
behind the graphite reflector to the bottom of the reactor. There it flows up
through the balls in the blanket annulus and out of the suction line near the
top of the reactor.
Some of the blanket salt fills the interstices between the
fuel nipples and the fuel cells. Circulation of the blanket salt is governed by
thermal convection. Heat generation and temperature calculations are in
progress to determine whether this flow is adequate.
The center location for a fuel cell is left vacant. This is
for a control rod. In Fig. 9.6 this control rod is, represented as a hollow
graphite cylinder 5 in. in outside diameter, 4 in. in inside diameter, and
equipped with a gas inlet at the top. By controlling the gas pressure, blanket
salt can be positioned at any height within this cylinder, and this blanket
volume controls the reactivity of the core. Calculations indicate a change of
1.8% in reactivity between the full and empty condition of this cylinder.
It may be that, instead of a hollow cylinder, a graphite rod
5 in. or less in diameter will be used to displace blanket salt from this
position in the core. Effective control can be obtained by driving this rod in
a more conventional way. In the event of failure of the drive, the rod would be
lifted out of the core by the more-dense blanket, thereby reducing the
reactivity.
The reactor has been optimized as far as nuclear performance
is concerned. There is no very sensitive parameter, and rather large changes in
all dimensions can be tolerated without changing the characteristics
materially. Table 9.1 gives the calculated performance of this reactor. This
core volume is 503 ft3, with a fuel volume in the core of 83 ft3. This gives an
average power density in the core of 39 kW/liter.
For comparison, the performance of a reactor having a power
density of 78 kW/liter is given in Table 9.1. This
reactor has half the volume in the core and would give somewhat better
performance. At present we do not know just what the limit is on graphite
radiation tolerance. The smaller reactor, whatever the graphite limit, would be
expected to have approximately half the core life of the larger one, which is
used as the reference design.
Some general comments can be made about the reactor as it is
currently conceived. As we stated above, the nuclear performance is so
insensitive to parameters that the final reactor design is likely to be close
to the present concept. We would prefer to have the core removable in modules
rather than having to remove it in one piece. This is particularly desirable if
we have to maintain the lower power density and if it becomes desirable to make
reactor modules larger than the 556-MWt size with which we are concerned at
present. We do not yet have what we consider an acceptable way of making these
core sub-modules, but work is continuing to try to develop one.
The thickness of the heads has not received rigorous
attention. At present the top or load-bearing head is 1 in. thick. This is
thicker than the load seems to require but is used to give an adequate
thickness for tapping for the nipples. The analysis of all stresses in these
heads is being made but has not yet been completed. The same is true for the
pressure drops.
The top of the reactor as shown has a welded joint which can
be ground off for removal and re-welded when a new core has been installed.
Probably this access joint will be moved up outside at least one layer of
shielding in the final core design. In this case some of the shielding blocks
would be supported by the top of the reactor vessel. The closure point for the
reactor would, by this means, be more accessible.
Fuel Heat Exchanger
The heat transfer work which had been done for the Breeder
Reactor study was reevaluated. This was made necessary by the results obtained
from the MSRE. It was found that the salt thermal conductivity was less by
about a factor of 3 than the value used in the original heat transfer
calculations. This difference resulted in degradation of the overall heat
transfer coefficient, necessitating an increase in heat transfer surface of the
heat exchanger of approximately 20%. A new heat exchanger design with a larger
number of tubes and a slight change in the baffle arrangement was developed.
The parameters of this new heat exchanger are given in Table 9.2.
While the new heat exchanger has a higher fuel holdup by
reason of the additional tubes, a more favorable arrangement of the header and
other reductions in parasitic volumes compensated for this larger number of
tubes, so that the net fuel inventory in the heat exchanger-pump complex did
not change significantly from that required in the first heat exchanger used in
the reactor study.
A significant change in the heat exchanger design concerns
the method of flanging the heat exchanger into the coolant circuit piping. The
coolant flows up around the heat exchanger and is discharged symmetrically
across the outer bank of fuel tubes. In this arrangement the toroidal coolant
header is replaced by a jacket around the tubes. Figure 9.7 shows the
arrangement of this new heat exchanger.
After traversing the outside of the fuel tubes in a
countercurrent flow pattern, the coolant salt leaves the heat exchanger through
a central discharge pipe which connects to the center of the concentric
coolant-salt line through a slip joint. The entire heat exchanger can be
removed from the circuit by opening the large flange, cutting the large fuel
pipe communicating with the reactor, and disengaging the center fuel pipe by
slipping it out of the slip joint provided for this purpose. The drain and
overflow lines and auxiliary pump lines must also be cut to remove the
exchanger.
Removing and replacing a primary heat exchanger is a major
repair. However, with the design as shown, the difficulties appear to be less
formidable than if both coolant lines had to be cut and welded to perform the
task. Adequate remote cutting, aligning, welding, and inspecting equipment and
methods must be demonstrated for this application.
Because of the expansion of the fuel tubes, the toroidal
header at the bottom of the exchanger will move relative to the vessel
enclosing the exchanger. For this reason and also to permit removal of the
exchanger, a drain line cannot be connected to this header. Instead, a dip line
for draining fuel extends into this header from the top of the exchanger. This
line connects through a freeze valve to the fuel drain tanks for the reactor.
When the drain valve is thawed and the drain tank is vented, the fuel salt in
the heat exchanger flows through this line into the drain tank. The gas
pressure in the pump bowl is sufficient to effect a
complete drain of the fuel salt from the system.
In case of a pump stoppage with the attendant necessity to
drain the reactor, the following sequence takes place. Upon pump stoppage the
reactor automatically drains into the pump sump tank and through the 5-in.
overflow line; the salt goes to the drain tank. A gas flow into the reactor
inlet plenum is furnished by the gas separator lines from the pump sump cover
gas. This automatic drainage takes place in the order of a few seconds.
However, the concentric lines to the reactor and the head space above the fuel
tubes in the heat exchanger remain full of salt and will overheat if not
cooled.
When the pump stops, the pressure in the lower header of the
heat exchanger drops to the static pressure of the salt, about 14 psi. If now
the gas valves in the line are opened, the stored gas will flow into the bottom
of the heat exchanger, displacing the fuel into the pump sump from which it
overflows into the drain tank. By proper sizing of this tank, enough fuel can
be displaced from the heat exchanger to bring the level at equilibrium below
the top tube sheet of the exchanger. The lines and volumes above the tube
sheets will be empty of salt, and no overheating will result.
We have calculated the cooling required for fuel in the
tubes of the heat exchanger under the stagnant conditions. Because of the
geometry of the coolant salt system, there is convective flow of coolant salt
even when no coolant pump is running. This convective flow of coolant is
adequate to remove afterheat from the stagnant fuel in the tubes.
To provide cooling but to avoid overcooling requires some
modification of the steam circuit of a module. We have not studied the
modifications in sufficient detail to justify a discussion at this time.
The large sump tank on top of the heat exchanger is not
intended to hold the drained fuel from the reactor. Because of the
undesirability of installing the afterheat cooling system in the reactor cell
and also in order to be able to drain the lines to the reactor, an overflow
pipe was installed from the sump tank to a separate dump tank. This tank is
equipped with a cooling system adequate for afterheat removal.
The sump tank on top of the heat exchanger appears to be
larger than necessary inasmuch as excess fuel flows through the 5-in. drain
line to the drain tank. The size of the tank is dictated by the fact that it
must hold the reactor volume (83 ft3) upon starting the reactor. Fuel cannot be
forced by gas pressure out of the drain tank fast enough to keep the fuel pump
primed on startup. The fuel must be displaced into the sump tank and held there
by gas overpressure in the drain tank until the reactor is filled by the action
of the pump.
Not shown in the drawing of the heat exchanger is the gas
separator and associated apparatus for handling the sparge gas for the fuel
system. The plans for handling this gas are being worked out, and drawings of
the equipment are not yet ready. The criteria and flowsheet are discussed in
Sect. 4.
Blanket Heat Exchanger
The blanket heat exchanger is shown in Fig. 9.8. This heat
exchanger is similar to the fuel heat exchanger but considerably smaller and
less complicated. There is no need for the gas sparge system, and there is no
afterheat problem that has to be provided for here. In addition, the coolant
flow is less complicated since counterflow is unnecessary. The temperature
difference is modest between blanket salt and coolant, and the total rise in
temperature is only 11°F as the coolant passes through. Table 9.3 gives the
characteristics of the blanket exchanger.
9.5 REACTOR PHYSICS
In addition to optimization studies described above, work on
MSBR reactor physics included (1) a series of cell calculations performed to
examine the sensitivity of the MSBR cross sections and reactivity to various
changes in cell structure and composition, and (2) several two-dimensional
calculations of the entire reactor. All of the calculations were based upon the
most accurate description of the system that was available as of January 1,
1967. The graphite-moderated portion of the core was 10 ft in length and 8 ft
in diameter, contained ~0.2 mole % 233U, 27 mole % 232Th, and had a fuel volume
fraction of 16.48% and a fertile volume fraction of 5.85%. The reactor had a
1.75-ft-thick radial blanket consisting of 60% fertile salt and 40% graphite,
surrounded by a graphite reflector 6 in. thick. The top axial blanket was 1.5
ft thick and contained 60% fertile salt and 40% graphite. The bottom axial
blanket was 1 ft thick and contained 3.18% Hastelloy N, 16.48% fuel salt, and
80.34% fertile salt. A number of structural details below the lower blanket
were included in the two-dimensional calculations.
Figure 9.9 shows the geometry of a cell in the
graphite-moderated core. Graphite dowels of appropriate size are located at the
six corners of the cell to yield the desired fertile salt volume fraction. The
cell calculations were performed with the code TONG and involved varying (1)
cell diameter, (2) fuel distribution (i.e., fuel separation distance, s), (3)
233U concentration, (4) 232Th concentration, (5) fuel volume fraction, and (6)
fertile volume fraction. Each of these parameters was varied separately while
holding the others constant. Table 9.4 and Fig. 9.10 show the effect on
reactivity of varying the parameters. The variations are shown relative to a
reference cell which had a diameter (flat to flat) of 3.156 in. and a fuel
separation distance, s, of 1/8 in.
The results of these calculations (compare cases 1 and 3)
indicate that there may be a reactivity advantage (attributable to increased self-shielding
of the 232Th resonances) to using a cell somewhat larger than the 3.156-in.
reference cell. If the conversion ratio is not adversely affected, use of a
5-in. cell may, for example, permit reduction of the 233U inventory. Pending
further study, case 3 (which differs from case 1 only in cell size) is
considered to represent the current cell dimensions used in the design.
Table 9.5 and Fig. 9.11 show information about the flux
distribution for case 3. Table 9.5 shows the ratio of the average flux in the
fuel to the cell average flux, the ratio of the average flux in the graphite to
the cell average flux, and the ratio of the average flux in the fertile salt to
the cell average flux for the epithermal and fast flux ranges. Figure 9.11
shows the thermal flux distribution in the cell. The results in Fig. 9.11 are
based upon an annular approximation to the cell of Fig. 9.9.
The two-dimensional calculations used the 5-in.-diam cell
composition and cross sections for the core, and they were performed with the
diffusion theory code EXTERMINATOR-2. Nine energy groups were used and are
shown in Table 9.6. Figure 9.12 shows the radial flux distribution in the core
midplane for neutron energy groups 1 and 6 separately, and Fig. 9.13 shows the
total flux distribution. The radial peak-to-average flux ratio in the
graphite-moderated part of the core is 1.58. Figure 9.14 shows the axial flux
distribution for groups 1 and 6 at a radial distance 18 in. from the axis of
the core, and Fig. 9.15 shows the total flux distribution. The axial
peak-to-average flux ratio in the graphite-moderated core region is 1.51. Thus
the total peak-to-average flux ratio is 2.39, the peak occurring at the
geometric center of the graphite-moderated core.
The central cell of the reactor is intended for control
purposes and consists of a graphite tube 5 in. in outside diameter and 4 in. in
inside diameter. It is envisioned that control will be achieved by regulating
the height of the fertile salt in the tube. If the completely empty tube is
filled with fertile salt, the change in reactivity is δk/k = -0.018%. If
the empty tube is filled with graphite, the reactivity change is δk/k =
+0.0012%. Thus there appears to be a substantial amount of reactivity control
available by varying the height of the fertile column in the tube.
9.6 MSBR GAS HANDLING SYSTEM
The gas handling system for the MSBR serves several
functions in the operation of the plant. These include: supplying helium for
purging and pressurization of the gas spaces; rapidly removing 135Xe from the
salt; transporting, removing, and storing the radioactive fission product
gases; and processing the helium for recycle into the gas supply or disposal to
the atmosphere. A scheme for accomplishing these functions is described below.
Xenon Removal
Preliminary studies of the migration of 135Xe to the
graphite in molten-salt breeder reactors indicated that it would
be possible to reduce the 135Xe poison fraction to an
acceptable value of ½% if a gas stripping system could be devised which would
process the entire reactor fuel-salt inventory in about 30 sec. Since the
reactor system salt circuit time is about 9 sec, it is required that the entire
inventory be processed every 3 to 4 passes around the circuit.
The required xenon processing time could be extended by
processing the fuel for removal of the precursor, 135I. However, the advantages
of 135I processing are limited by the fact that 20% of the total 135Xe produced
in the fissioning of 233U appears directly, and very high processing rates
would be required to obtain even modest gains. For example, if the entire fuel
inventory were processed for 135I removal once every hour, the xenon removal
process rate would only be extended to about 80 sec, and a very high 135I
processing rate would increase the xenon processing time to only about 110 sec.
Therefore, processing for iodine is not, at this time, being considered as a
method of removing 135Xe.
The method proposed for removal of 135Xe involves stripping
of xenon-enriched helium bubbles from the fuel stream by means of a gas
separator located at the heat exchanger outlet. The bubbles will be generated
by injecting helium into the salt at the fuel pump suction, and transfer of
xenon from the salt to the gas will be effected during
passage through the heat exchanger.
Mechanical Design
The flowsheet for the MSBR off-gas system is given in Fig.
9.16. Helium is injected into the suction of the fuel salt pump and is removed
by centrifugal separation at the heat exchanger outlet. The liquid-gas mixture
from the separator is then fed into a cyclone separator where the entrained
liquid is removed and returned to the pump bowl. The gas from the pump shaft
purge and the instrument lines is combined with that from the cyclone separator
and fed into the 48hr xenon holdup system. A small portion of the flow from
this system is fed into the long-term xenon holdup and then through the
noble-gas separator to a recycle system for supplying clean helium to the pump
shaft purge and the instrument gas lines. The remainder of the gas from the
48-hr xenon holdup system is fed into the gas injector system at the fuel pump
suction. It is the salt-powered gas injector that serves as the prime mover for
the high-gas-flow recycle system. Some of the design
criteria of the critical components are described below.
Gas Injector System
1. The gas addition rate shall be sufficient to produce
about 1% void volume in the salt at the pump suction.
2. The location and manner of gas injection shall provide a
balanced distribution of bubbles in the liquid entering the pump impeller. This
consideration affects the bubble distribution in the heat exchanger and the
bubble size, as well as the pump dynamic balance.
3. There shall be operator control over the gas addition
rate into the gas injector.
4. The supply for the gas injector shall be taken from the
outlet line from the 48-hr xenon holdup helium recirculation system. There
shall be a backflow preventer arrangement at this gas supply point to prevent
salt from getting back into the charcoal beds as a result of a sudden pressure
transient in either the salt or gas system.
5. The method of injecting bubbles into the pump suction
shall be a fuel-salt-powered jet pump taking its salt supply from the heat
exchanger discharge.
The suction pressure for the salt-powered jet pump shall be less
than 10 psia at a flow rate of 6.5 scfm of helium.
Bubble Separator System
1. The bubble separator shall be installed within the outer
annulus of the fuel-salt line from the heat exchanger to the reactor.
2. The separator, including the entrance region, shall be
kept as short as is reasonably possible, and the separator shall be as close to
the heat exchanger as good design permits. The purpose of this restriction is
to permit removal of the separator along with the heat exchanger and at the
same time permit locating the heat exchanger close to the reactor.
3. The design of the system shall include assurance that the
separator will not admit gas into the salt line to the reactor except when the
fuel pump stops. Check valves or liquid submersion of the discharge will not be
used to prevent backflow, since the reactor drain scheme will use the separator
outlet as a gas source.
4. The bubble fraction of the salt as it enters the reactor
shall be less than 0.1% during steady-state operation.
5. The fuel line outside the gas separator shall be free of
protrusions all the way to the heat exchanger outlet. Equipment for cutting and
welding the 24-in.-diam fuel line will occupy this space during some
maintenance operations.
6. The gas outlet from the bubble separator and the gas line
to the pump bowl shall stay within the salt line if possible. This will reduce
the number of penetrations through the pipe wall.
7. A modified gas cyclone separator shall be an integral
part of the bubble separator discharge stream. The liquid would be discharged
to the pump bowl, and the gaseous discharge would go to the xenon holdup
system.
Volume Holdup System
The first stage of the high-flow 48-hr xenon holdup is a gas
volume holdup whose several functions are listed below.
1. The first stage shall be a cooled volume for the decay of
the very short-lived gaseous fission products. A reentrant tube system similar
to the one in the fuel drain tank of the MSRE will be investigated for
providing the cooling.
2. There shall be a provision for a final demisting of the
gas as it comes from the cyclone separator.
3. Since there will be a total of more than a kilogram of
fission products produced each day in the reactor complex, and since a sizable
fraction is involved in the short-lived gaseous products, a method of
collecting, cooling, and conveying to a disposal area must be included. The
collecting device should pass only gas which has resided in the volume holdup
for at least the specified minimum transit time.
4. The volume holdup system shall be sized to reduce
significantly the heat load and particulate loading rate from short-half-life
fission products in the first stage of the charcoal bed, which is immediately
downstream.
Noncritical Components
Many of the remaining components in the off-gas handling
system are reasonably well understood, and, while they must be designed and
ultimately tested, it is believed that they will offer no critical problems.
Some of these are listed below:
1. High-gas-flow charcoal bed design.
2. Biological charcoal bed design (low flow).
3. Noble-gas separator and disposal system. This includes
85Kr and tritium removal from the helium which is to be returned to the recycle
system.
4. Helium compressor for recycle of clean helium.
5. Gas sampling system for purity control and for
surveillance of the chemical condition of the salt.
6. Instrumentation and controls for operating the gas
system.
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