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Progress on Design and R&D of CN Solid Breeder TBM

Progress on Design and R&D of Progress on Design and R&D of CN Solid Breeder TBMCN Solid Breeder TBM

1. Introduction2. Progress on Updated Design3. Progress on Relevant R&D4. Test and Delivery Plan 5. Summary

K.M. Feng, G.S. Zhang, T.Y. Luo, Z. Zhao, Y.J. Chen, X.F. Ye, G. Hu, P.H. Wang. T. Yuan, Y.J. Feng, B. Xiang, L. Zhang, Q.J. Wang, Q.X. Cao, F.Wang, Z.X. Li, and Chinese HCSB TBM team

Southwestern Institute of Physics, P.R. China

FTP/3-5Ra

OUTLINEOUTLINE

23rd IAEA Fusion Energy Conference11 – 16 October 2010, Daejeon, Republic of Korea

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1. Introduction1. Introduction� ITER is an unique opportunity to test tritium breeding blanket mock-ups in an integrated tokamak operating conditions;� Helium-cooled solid breeder (HCSB) test blanket module will be the primary option of the Chinese ITER TBM program;� China has the position of Port Master (PM) in port number 2 and is leading the HCSB concept as the TBM Leader (TL). HCSB TBM will be tested at different phases of ITER operation; � In order to reduce the effects of magnetic field ripple, the design was updated with reduced RAFM mass;

� Related R&D on key components, materials, fabrication and mock-up test have being implemented.

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2. Description of HCSB TBM Design

- TBM structure: Sub-module arrangement- Structure material: RAFM (CLF-1);- Tritium breeder: Li4SiO4 pebble bed, 80%Li-6 ;- Neutron multiplier: Be pebbles bed;- Coolant and purge gas: Helium gas - Coolant pressure: 8MPa- Coolant temperature: 300 OC(inlet) -500 OC (outlet)- Tritium production ratio (TPR): 0.0505g/d

3-D View of CN HCSB TBM

Cross-section of SB

Assembly scheme of Sub-Modules

Main characteristics:

�A series of the Chinese HCSB TBM design have been carried-out since 2004 within the space limitation and technical requirements specified by ITER.

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Updated Design of HCSB TBM for Reduction RAFM Mass

HCSB TBM Module TBM Sub-module arrangement Cross-section of SM

- The RAFM mass is reduced to 58% (from 1.6t to 726kg).

- TPR is increased to 46% (from 0.051g/d to 0.0798g/d).

316SS

Outlet

Outlet

Objectives of updated design:- to simplify Sub-module structure;- to reduce RAFM mass;- to improve TPR performance;

- Reduce radial dimension of the First Wall and sub-modules :- Radial dimension of FW is reduced to 35cm;- Radial dimension of sub-modules is reduced to 32cm;

- Arrangement of pebble beds in sub-module is changed;- Using 316 SS instead of RAFM as structural materials for the back-plate and support plate.

Exploded view of sub-module

� Main modification:

� An optimized all RAFM design with reduced mass of 1.3t is on going.

316SS

316SS

• Results shown:

5500kg Ingot

plates and bars

3. Progress on R&D:3. Progress on R&D: (1) (1) Structural Materials-CLFConsumable electrode furnace

� Two RAFM alloys are being developed in China; CLF and CLAM�A 500kg of CLF-1 steel was recently produced by vacuum induction melting and electro-slag remelting method. � The optimization of the melting technique for the larger ingots to ton- level is underway.

Tensile strength of CLF-1 DBTT of CLF-1

Remelting facility

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(2) Ceramic Breeder Pebbles(2) Ceramic Breeder Pebbles

Relative density 94% TDLi4SiO4 phase content �90%Closed porosity 0.72%

Open porosity 5.2 %Average crush load 7.0 NSpecific surface area 1.092 m2/g

Li2TiO3 Pebbles (D=1mm)@CAEPLi4SiO4 Pebbles (D=1mm) by extrusion–sintering method @CIAE

� Two kinds of ceramic breeders (Li4SiO4, Li2TiO3) for TBM are being developed at different institutions in China;� Lithium orthosilicate (Li4SiO4 ) pebbles will be the primary option in the CN HCSB TBM.

Li4SiO4 Pebbles (D=1mm) by metl spraying method @SWIP Li4SiO4 Pebbles (D=1mm)

by freeze-sintering method @CAEP

� Ceramic breeder (Li4SiO4) pebbles fabricated by melt spraying method have good sphericity, and high density.

� Ceramic breeder (Li4SiO4) pebbles prepared by Freeze-sintering process have good mechanical properties (the average crush load is 50N) ;

� Li2TiO3 Pebbles have good surface feature by using sol-gel method.

XRD pattern of Li4SiO4 pebbles

Main properties (Li4SiO4) by melt spraying method

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(3) Fabrication of Be PebblesChineseVHP-Be Be BeO% Al C Fe Mg Si Other metallic

elements1# ≥99% 0.750 0.006 0.060 0.050 0.003 0.009 <0.04

� Be metal of high performance was developed in China ;� Be pebbles have been produced by Rotating Electrode Process (REP) method in China. Related performance tests are on going.� A new project to develop higher quality Be pebbles in China is being implemented for the ITER project.

Main chemical composition of Chinese Be 1#

Be Pebbles (D=1mm)

Micrographs of Be Pebbles (D=1mm) REP Facility Be electrode by VHP-Be

Be (wt%) 98.3BeO (wt%) 1.67Al (ppm) 235Si (ppm) 18Mn (ppm) 58Mg (ppm) ≤10Co (ppm) ≤10 Sample of Be Pebbles(D=1mm)

Chemical Composition of Be pebble

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(4) Construction of Helium Coolant Test Loop(4) Construction of Helium Coolant Test Loop

Flow diagram of He Loop Layout of He Loop

� The construction of a small He Test Loop to validate circulator technology will be completed soon. - The He test loop has two impellers. It uses aerostatic bearings to avoid oil lubricating.

Flow diagram of small He loop

Parameters Maximum flow rate /kg-1s

Inlet pressure /MPa

Maximum pressure head /MPa He inlet/outlet temperature /℃

Circulator ~0.35 8 0.4 ~50/65

� A prototyped Helium Test Loop to validate TBM components and design is also to be built in SWIP. The circulator will use magnetic bearings. The flow rate will up to 1.3kg/s.

3-D view of circulator Impeller of circulator

Cross-section view

Main parameters of circulator design

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(5) Fabrication Process of U(5) Fabrication Process of U--Shape FWShape FW

OR

� Fabrication of the U-Shaped first wall is ongoing; � Two kinds of fabrication method will be considered;� A small-sized mock-up (1:3) of FW and sub-modules

using the RAFM steel (CLF-1) will be completed .

Split Mill Weld

Laser solid forming

Bend Split Mill Weld

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4. TBS R&D and Delivery Plan4. TBS R&D and Delivery Plan1. CN HCSB TBS qualification activities

– Helium experimental loop (1:3) construction (2010.01-2011.06)– Preliminary design of CN TBM(2010.01-2012.6)

� Conceptual design of TBM� Preliminary design of CN TBM� Final design of CN TBM

– CN TBM testing and update design (2011.06-2013.12)– Prototype helium loop design & construction (2012.01-2014.06)– Large scale TBM mock-up tests (2014.06-2015.12)

2. CN HCSB TBS delivery activities.– Main components fabrication (2015.01-2016.06)

� Final CN TBS design in ITER.� Main components fabrication.� TBS function tests (domestic).

– CN TBS delivery (2016.12-2017.06)– CN TBS acceptance tests in ITER site (2017.06-2017.12)– EM TBM delivery (2018.01-2018.06)– EM-TBM System acceptance tests(2018.06-2019.06)

3. EM-TBM will be installed in ITER port after the first plasma shutdown (2019)

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5. Summary5. Summary� HCSB TBM with the Solid Breeder/Helium coolant/ RAFM material is the primary option of the Chinese TBM program.� Updated design, current progress on R&D, test and delivery plan up to the installation in ITER (2019) are presented.� Relevant R&D on key techniques for the HCSB TBM concept are supported by the Chinese ITER- DA domestic agency (2009-2012) , including:

– TBM optimization design and validation of technology;– Fabrication of Li4SiO4 pebbles and Be pebbles to kg level;– Fabrication of structure material RAFM to ton level;– Construction of High Heat Flux Test Facility (Power:400kW);– Construction of small-scale and prototyped Helium Test Loop.

� Testing HCSB TBM on ITER will be implemented with the cooperation of domestic and international institutions and industries.

H. Tanigawa, T. Hirose, A Yoshikawa, Y. Seki, K. Yokoyama, K. Ezato, D. Tsuru, H. Nishi, S. Suzuki, M. Enoeda

Blanket Technology Group, Japan Atomic Energy Agency

Mock-up Fabrication and Component Tests for Water Cooled Ceramic Breeder Test Blanket Module

FTP/3-5Rb

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OUTLINE1. Introduce to WCCB TBM proposed by Japan;2. Components of WCCB TBM and mock-ups fabrication;3. Recent results of fabrication technology and function tests:

- First Wall (FW) reported in FEC 2008- Side Wall (SW)- Assembly of FW and SW- Pebble bed container and Breeder pebble bed

4. Summary

WCCB TBM demonstrates functions required for DEMO blanket in ITER condition

Power generator

ITER Cross Section

Demonstration of tritium production and electric power extraction

Japan has a position to- act as a Port Master and a TBM Leader to test the WCCB TBM,- participate as a Partner in HCPB/HCCB and LiPb-based TBMs.

TCWS Vault

V.V.

Water loop

Tritium building

Purge gas loop TES

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WCCB TBMproposed by Japan

Plasma side

RAFM(F82H)

Pebble bed(Be)

Pebble bed(Li2TiO3)

Armor (Be)

Components and fabricated mock-upsFirst wall Side wall Pebble bed container

Back wallArmor

to be fabricated

High heat flux test

U-shaped FW

FW/SB assembly SWs Pebble container

1.5 m

1.5 m 1 m

Li2TiO3pebble

Be pebble

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• The first wall and the Side Wall have been assembled into an open box with five faces.• The achieved technologies can be applied to the fabrication and the assembly of the TBM ‘s components in the next stage.

WCCB TBM Assembly process

Fabricated WCCB TBM Mock-ups

Real scale side wall was fabricated by drilling and plugging

φ10 mm×1450 mmL cooling channels were formed within 0.5 mm accuracy at the end of the drilled holes. Maximum length of 1700 mm is available.

• Fabrication procedure• F82H plate of 30mmT

• Drill 7 branch channels of φ10• Drill 2 manifolds of φ23• Weld plugs to branch channels• Cut SW to 1450 mm to fit FW

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plugs

φ23 manifolds

φ10 branch channels

50 mm pitch400

1550

30 mm thick F82H plate

1285

• These fabrication procedures and tests confirmed these fabrication technologies are applicable to the TBM

Fabricated Side Wall with real scale

Side Wall dimension

Water flow test validated the heat removal capability of the Side Wall mock-up is sufficient for the TBM conditions

• Based on results of the flow test, maximum temperature of F82H in the side wall was calculated under the TBM conditions.• It shows that the present design and the fabrication process for the coolant path are acceptable for the heat removal requirements.

Result of flow distribution measurementReal scale side wall mockup 5/9

Inlet Outlet

manifold manifoldparallel branch channels

•1 2 3 4 5 6 70.06

0.08

0.1

0.12

0.14

0.16

0.18

0.2

1 2 3 4 5 6 7Channel ID

Flow

rate (

kg/s)

MeasurementCalculation (Linear)

Observed flow rate distribution was within 15% of average flow rate

Minimum required flow rate

Real scale FW mockup and Side Walls were successfully assembled by EB welding to form a blanket box structure

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• Fabrication procedure• Weld FW to jig• Trim FW and SWs to minimize gap• Weld backing metals to FW• EBW with single path in a normal position• Remove jig• Post weld heat treatment at 720oC.

FW/SW welding

FWFW

SWSW

FWFW

SWSW

FWFW

SWSW

Backing metal

SWFW

jig

SW

U-sh a p e d FW

Full scale FW/SW assembly

Full scale mock-up of the FW and Side Wall with the cooling channel were prepared and assembled by EBW.

FW and SW welding

The plate with thin tube welding technique was established for fabrication of membrane structure of pebble bed container

Breeder pebble bed

11211 15

28

1.5

1.51.5

38

1 m

OD11, 1t

Fiber laser welding was employedto minimize heat affected zone.

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•The leak test using helium gas of 0.5 MPa confirmed a gas tightness of the container.

Plate with Tube Welding

Cross-section of pebble bed container

pebble bed container

Side wall

WCCB TBM Module

•The hardness testing was conducted on the partial test piece that was fabricated with same process.

•The test showed that the heat-affected zone in the cooling tube was very limited.

Li2TiO3 Pebble Packing Test

X-ray CT image of cross section of Pebble bed Pressure drop in breeder pebble bed

• φ1 Li2TiO3 pebble packing test• X-ray CT• He purge gas flow test

0

10

20

30

0 20 40 60He flow rate (L/min)

Pres

sure

drop i

n peb

ble be

d (kP

a) pebble bedempty box

•P.F. 67%

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• Li2TiO3 pebbles were packed into the container and acceptable packing state is confirmed;•The designed value of packing factor 67 % was confirmed by the packing test.; By the X-ray CT measurement, no deflection of the packing was confirmed.

Summary�Japan is the lead party of the WCCB TBM, which is the primary option of the Japanese TBM.

� The full-scale side wall mock-up was successfully fabricated, and the water flow test shown that the required water flow was obtained.

� The full scale First wall and Side wall assembly mock-up was successfully fabricated.

� The full-scale pebble bed container mock-up was successfully fabricated, and the packing test using Li2TiO3 pebbles confirmed that designed packing state can be obtained.

� The fabrication technology development is proceeding to R&D phase of the large scale mock-up fabrication and demonstration tests toward ITER TBM testing.

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Thank you for your attention!