1 research test reactors may 21, 2015. 2 b&w cost analysis cost analysis in 2012 for projected...

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Babcock & Wilcox Cost & Yield ReviewNAS

Research Test Reactors

May 21 , 2015

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B&W Cost Analysis Cost Analysis in 2012 for Projected Costs in 2019

Purpose:

Utilize the current LEU information and process knowledge to develop a steady-state cost for HEU & LEU fuel

Goal:

To develop a process which is cost neutral from HEU to LEU Maintain HEU Manufacturing capability until LEU manufacturing is

demonstrated for all 5 reactors. 2010 DOE funded independent study estimated an increase of 37%

GSA020.001.020.001

Cost based on a Set of AssumptionsLEU Steady-State utilizing what we defined as a “Base-line Process”Compared LEU to HEU in 2019 $$

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Fabrication Processes

Fuel Powder Process

Compact Process

Plate Process

Element Process

Coupon/ Ingot Process

Foil Process

Plate Process

Element Process

Processing Unchanged

HEU Process

LEU Process

B&W fabricates Powder for ATR, MURR, and MIT

Y-12 fabricates Powder for HFIR

and NIST

Y-12 fabricates Coupons/Ingot

The conversion from HEU to a LEU

transitions from a cermet to a metal plate fabrication

process

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Current HEU Processes

Fuel Powder Fabrication

Issue Material

Weight Charges

Arc Melt

Crush

Blend

Weight

Inspect

Processes eliminated

Processes eliminated

TBD

TBD

TBD

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“U-Moly Base-line Process”

Foil Processing

Receipt Inspect Coupon

Can Coupon

Hot Roll Coupon Into Foil

Cold Roll Foil

Size Foil

U-Mo PlateU-Mo HIP

Can AssemblyU-Mo FoilU-Mo Coupon

Can Assembly0.015” Thick With ~ 0.001” Thick Zr Layer on Both Sides

304 SSAl 6061

Mild Steel

U-Mo Coupon:19.75% U-235~6” x 6” x 0.125”

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Assumptions

What’s not Included

•Coupon Costs (GFM – Y-12)•Burnable absorbers cost•Manufacturing of burnable absorbers (ATR, HFIR)•Shipping Costs•Waste Costs•Costs associated with transition from HEU to LEU

Low Impact•Estimate is at full LEU production, no HEU fabrication•Steady State Production Rate ~8000 plates per year•Facility will include storage for 3 years worth of coupons/Ingots (backlog inventory)•HEU and LEU Equivalent Operations•New Rates for 2019

High Impact•U-Mo Coupons•LEU Process Yields•~ 1000 kgs of Zr coded scrap generated per year•Uranium recovery could be performed at NOG-L in existing facility

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Yields

HEU Process Yields

• Compacts ~ 99%• Plates ~ 93%

Projected LEU Process Yields

• Foils ~ 88%• Plates ~ 90%

Yields have not been demonstrated

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Created Cost Estimating Tool

Process flow Diagram WBS Time Standards Equipment List Rates (variable based on many factors) Cost per Assembly Assemblies per year Annual Operating Cost

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Total Manufacturing Hours/Plate

ATR HFIR MIT MURR NIST

HEU2012 Estimate

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2012 U-Moly Cost Summary

Contract % increase in Cost of HEU Assembly

ATR 17%

HFIR 115% *

MIT 13%

MURR 49%

NIST 60%

* Due to the complex geometry of the HFIR fuel and the lack of manufacturing development, it is estimated that HFIR foil manufacturing will take 2X longer

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Program R&D Projects

National Labs (LANL & PNNL)

• Casting Optimization• Optimize HIP Process operations (HIP Can)• Develop an alternate process for Zr Application• Foil Rolling and Anneal Studies• Demonstration of Complex Shape Fabrication (HFIR)• Coupon/Ingot Size Optimization

Y-12

• Casting Optimization• Demonstrate LEU Manufacturing Cycle

B&W

• Demonstrate complex fuel process• Develop a Foil Process with less Scrap• Demonstrate LEU Manufacturing Cycle• HIP Processing Parameters

44%

31%

25%

Total Mfg HoursPlate Manufacture

Assm/Structure Mfg

Foil Manfacture

9%

4%8%

13%

66%

Plate Mfg Hours

HIP Can FabricationHIP DecanningUTThickness MachiningOther

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Program LEU Manufacturing Cycle

LEU

Metal Alloying

Coupon

Foil

Plate

Element

RecoveryRecovery

Reduce to LEU Metal

HEU Metal

DU or NU Metal

Mo

Yellow – Y-12Blue – B&WClear – Unknown

ZR

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B&W Current Manufacturing Development Efforts

Foil Processing

Receipt Inspect Coupon

Can Coupon

Hot Roll Coupon Into Foil

Cold Roll Foil

Size Foil

Development Focus

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Foil Standard Process Flow Development Efforts

Homogenize Coupon or

Ingot

Pack & Weld (Coupons or

Ingots)

Hot Roll with Zirconium

Decan and Clean Cold Roll Vacuum

Anneal Sizing

Hot Roll without

Zirconium

Decan and Clean Sizing Cold Roll Pack & Weld

Hot Roll with Zirconium

Decan and CleanCold RollSizing Vacuum

Anneal

Coupon Process

Ingot Process

Additional Process Steps

Alternate process being developed to minimize Zr Coded Scrap

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B&W Cost Analysis 2014 Update

2014 Cost Analysis Update Reviewed 2012 analysis to update assumptions Determined change to 2012 estimate Update was Changed to Hours Based

• New Conversion dates beyond 2030• Rates too hard to predict• Compared reduction in hours from 2014 to 2012

Same assemblies / year No Yield Changes Compared Mfg & Total Hours

• Mfg hours = Shop & QC

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Assumptions for 2014 Update

What’s not Included

•Coupon Costs (GFM – Y-12)•Burnable absorbers cost•Manufacturing of burnable absorbers (ATR, HFIR)•Shipping Costs•Waste Costs•Costs associated with transition from HEU to LEU

Low Impact•Estimate is at full LEU production, no HEU fabrication•Steady State Production Rate ~8000 plates per year•Facility will include storage for 3 years worth of coupons/ingots (backlog inventory)•HEU and LEU Equivalent Operations•New Rates for 2019

High Impact•U-Mo Coupons•LEU Process Yields•~ 1000 kgs of Zr coded scrap generated per year•Uranium recovery (could be performed at NOG-L in existing facility)

Coupon size change - increased foil fabrication

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2014 Assumption ChangesFoil Processing

Receipt Inspect Coupon

Can Coupon

Hot Roll Coupon Into Foil

Cold Roll Foil

Size Foil

• Optimized Pre-formed Hip Can (Not yet Demonstrated) Capacity change Eliminated Internal HIP Can Fabrication Eliminated Plate Thickness machining & UT for Support Thickness Machining

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Total Manufacturing Hours/Plate

ATR HFIR MIT MURR NIST

HEU2012 Estimate2014 Estimate

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2014 U-Moly Cost Summary

Contract % Reduction from 2012 Estimate

ATR 15%

HFIR 16%

MIT 16%

MURR 14%

NIST 25%

Overall Reduction 17%

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Conclusions

Still in Development Dedicated Team working on U-Moly Program Concerted effort between all Organizations

Y-12, PNNL, LANL, INL & B&W

Our Focus is two-fold Manufacturing capability Cost Consciousness (Cost neutral between HEU and LEU)