Fuel Sphere Manufacture - Atoms for Peace and · PDF fileFuel Sphere Design Overview ......
Transcript of Fuel Sphere Manufacture - Atoms for Peace and · PDF fileFuel Sphere Design Overview ......
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Fuel Sphere Manufacture
Presented by: David Boyes – STL Nuclear
IAEA 2015
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Contents
• Fuel Sphere Design Overview
• Matrix Graphite Powder (MGP) Manufacture
• Coated Particle Over-coating (OCP)
• Fuel Sphere Manufacture (FS)
• Mould Manufacture
• Complex Processes
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Fuel Sphere Design Overview
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Fuel Sphere Design Overview (Cont.)
• The Kernel contains the heat-generating fuel material and provides chemical hold-up of fission products
• The Buffer Layer provides void volume for gaseous fission products and accommodates Kernel swelling
• The Inner Pyrolytic Carbon Layer provides a gastight diffusion barrier for metallic fission products and reduces tensile stresses on the Silicon Carbide Layer
• The Silicon Carbide Layer is the main diffusion barrier to metallic fission products and the primary pressure-retaining layer
• The Outer Pyrolytic Carbon Layer provides a barrier to gaseous fission products, a diffusion barrier to metallic fission products and reduces tensile stresses on the Silicone Carbide Layer
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Fuel Sphere Design Overview (Cont.)
• The Graphite Matrix:
- consists of carbonized organic binder and nuclear-grade graphite material which acts as a fission neutron moderator
- provides the contact with the Coated Particles as a heat transfer medium and acts as a buffer to prevent exposure and damage of Coated Particles
- should exhibit high density, high thermal conductivity, high mechanical strength, low thermal expansion, low anisotropy, low Young’s modulus, good corrosion resistance and good dimensional stability under neutron irradiation
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MGP Manufacture - Process Flow
Kneading
Drying (1000C)
Hammer Milling
Pre-Crushing
Graphite Powder Natural (64 %)
Graphite Powder Electro (16 %)
Phenolic Resin (20 %)
Methanol
Homogenization Dissolving
Homogenization
To Fuel Sphere Manufacture
Fine Milling To Coated Particle Over-coating
Swarf from Fuel Sphere Manufacture
(~11%)
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TO FUEL SPHERES
MANUFACTURE
DISSOLVER MIXER
STORAGE
FINE MILLING
MILLING
RECYCLED GRAPHITE (SWARF)
METHANOL RECOVERY
DRYING OVEN
Coarse Milling
KNEADER
SOLVENT (METHANOL) & PHENOL BINDER
ELECTROLYTIC GRAPHITE NATURAL GRAPHITE
OVERCOAT MATRIX POWDER
MIXER
MIXER
MATRIX GRAPHITE POWDER
Matrix Graphite Powder
Manufacture
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TO FUEL SPHERES
MANUFACTURE
DISSOLVER MIXER
STORAGE
FINE MILLING
MILLING
RECYCLED GRAPHITE (SWARF)
METHANOL RECOVERY
DRYING OVEN
Coarse Milling
KNEADER
SOLVENT (METHANOL) & PHENOL BINDER
ELECTROLYTIC GRAPHITE NATURAL GRAPHITE
OVERCOAT MATRIX POWDER
MIXER
MIXER
MATRIX GRAPHITE POWDER
Matrix Graphite Powder
Manufacture
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OCP Manufacture - Process Flow
Over-coating (200µm)
Drying (800C)
Sorting
Sieving
Portioning
To Fuel Sphere Manufacture
Methanol
Removal of Over-coat Layer
Combining and Portioning
Fine Milled MGP from Matrix
Graphite Powder Manufacture
Scrap
Scrap
Coated Particles
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OVERCOATING
OVERCOAT GRAPHITE & SOLVENT (METHANOL)
COATED PARTICLES
METHANOL REMOVAL
DRYING
SIEVING &SORTING
REJECT
COMBINING & PORTIONING
Coated Particle Over-coating
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OVERCOATING
OVERCOAT GRAPHITE & SOLVENT (METHANOL)
COATED PARTICLES
METHANOL REMOVAL
DRYING
SIEVING &SORTING
REJECT
COMBINING & PORTIONING
Coated Particle Over-coating
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FS Manufacture – Process Flow
Final Pressing (3 t/cm2)
Machining
Annealing (19500C in vacuum)
Carbonizing (8000C) Argon
Core Pressing
MGP from Matrix Graphite
Powder Manufacture
OCPs from Over-Coated Particle Manufacture
Core and Final Moulds from Mould Manufacture
Storage
Swarf to MGP Manufacture
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OVERCOATED PARTICLES
CORE MOULD
PRE MIXER
MATRIX GRAPHITE POWDER
PRESSED FUEL
SPHERE CORE
CORE PRESS
SPLITTER
INMOULD MIXER
SCREW FEEDER
ROBOT
Fuel Sphere Manufacture (Sheet 1)
PRESSED FUEL
SPHERE
X-RAY INSPECTION
QA
MATRIX GRAPHITE POWDER FINAL PRESS
MATRIX GRAPHITE POWDER
SHELL FORMING
FINAL MOULD
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CARBONISING CHARGE CARRIER
SWARF TO MGP MANUFACTURE
BUFFER STORAGE
PRESSEDFUEL
SPHERES
BUFFER STORAGE
VACUUM LIFTING INTO TRAYS
MACHINING
CARBONISING FURNACE
ANNEALING FURNACE
QA
REJECTS
DIMENSION INSPECTION VISUAL INSPECTION
MASS CONTROL X-RAY
COOLING TOWER
Fuel Sphere Manufacture (Sheet 2)
FINAL FUEL
SPHERES TO
STORAGE
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CARBONISING CHARGE CARRIER
SWARF TO MGP MANUFACTURE
BUFFER STORAGE
PRESSEDFUEL
SPHERES
BUFFER STORAGE
VACUUM LIFTING INTO TRAYS
MACHINING
CARBONISING FURNACE
ANNEALING FURNACE
QA
REJECTS
DIMENSION INSPECTION VISUAL INSPECTION
MASS CONTROL X-RAY
COOLING TOWER
Fuel Sphere Manufacture (Sheet 2)
FINAL FUEL
SPHERES TO
STORAGE
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Complex Processes are:
• To produce a particle size and distribution with hammer milling for reaching optimum density with the Graphite Matrix
• Mould tooling design
• Assembly of a fuel sphere
• Over-coating of coated particles
• Sorting of coated particles
• Understanding the splitting and portioning of Over-coated Particles to obtaining the correct fissile material loading per fuel sphere
Complex Processes