Development of optimized core design and analysis methods for high power density BWRs

Abstract

Increasing the economic competitiveness of nuclear energy is vital to its future. Improving the economics of BWRs is the main goal of this work, focusing on designing cores with higher power density, to reduce the BWR capital cost. Generally, the core power density in BWRs is limited by the thermal Critical Power of its assemblies, below which heat removal can be accomplished with low fuel and cladding temperatures. The present study investigates both increases in the heat transfer area between the fuel and coolant and changes in operating parameters to achieve higher power levels while meeting the appropriate thermal as well as materials and neutronic constraints. A scoping study is conducted under the constraints of using fuel with cylindrical geometry, traditional materials and enrichments below 5% to enhance its licensability. The reactor vessel diameter is limited to the largest proposed thus far. The BWR with High power Density (BWR-HD) is found to have a power level of 5000 MWth, equivalent to 26% uprated ABWR, resulting into 20% cheaper O&M and Capital costs. This is achieved by utilizing the same number of assemblies, but with wider 16x1 6 assemblies and 50% shorter active fuel than that of the ABWR. The fuel rod diameter and pitch are reduced to just over 45% of the ABWR values. Traditional cruciform form control rods are used, which restricts the assembly span to less than 1.2 times the current GE 14 design due to limitation on shutdown margin. Thus, it is possible to increase the power density and specific power by 65%, while maintaining the nominal ABWR Minimum Critical Power Ratio (MCPR) margin. The optimum core pressure is the same as the current 7.1 MPa. The core exit quality is increased to 19% from the ABWR nominal exit quality of 15%. The pin linear heat generation rate is 20% lower, and the core pressure drop and mass of uranium are 30% lower. The BWR-HD's fuel, modelled with FRAPCON 3.4, showed similar performance to the ABWR pin design. The fuel cycle is only 12 month long, but on the per kWhr, the new design operates with 14% lower fuel cycle front-end costs and similar total fuel cycle cost to the 18 month ABWR fuel cycle. The plant systems outside the vessel are assumed to be the same as the ABWR-1I design, utilizing a combination of active and passive safety systems. Safety analyses applied a void reactivity coefficient calculated by SIMULATE-3 for an equilibrium cycle core that showed a 15% less negative coefficient for the BWR-HD compared to the ABWR. The feedwater temperature was kept the same for the BWR-HD and ABWR which resulted in 4 °K cooler core inlet temperature for the BWR-HD given that its feedwater makes up a larger fraction of total core flow. The stability analysis using the STAB and S3K codes showed satisfactory results for the hot channel, coupled regional out-of-phase and coupled core-wide in-phase modes. A RELAP5 model of the ABWR system was constructed and applied to six transients for the BWR-HD and ABWR. The AMCPRs during all the transients were found to be equal or less for the new design and the core remained covered for both. The lower void coefficient along with smaller core volume proved to be advantages for the simulated transients. Helical Cruciform Fuel (HCF) rods were proposed in prior MIT studies to enhance the fuel surface to volume ratio. In this work, higher fidelity models (e.g. CFD instead of subchannel methods for the hydraulic behaviour) are used to investigate the resolution needed for accurate assessment of the HCF design. For neutronics, conserving the fuel area of cylindrical rods results in a different reactivity level with a lower void coefficient for the HCF design. In single-phase flow, for which experimental results existed, the friction factor is found to be sensitive to HCF geometry and cannot be calculated using current empirical models. A new approach for analysis of flow crisis conditions for HCF rods in the context of Departure from Nucleate Boiling (DNB) and dryout using the two phase interface tracking method was proposed and initial results are presented. It is shown that the twist of the HCF rods promotes detachment of a vapour bubble along the elbows which indicates no possibility for an early DNB for the HCF rods and in fact a potential for a higher DNB heat flux. Under annular flow conditions, it was found that the twist suppressed the liquid film thickness on the HCF rods, at the locations of the highest heat flux, which increases the possibility of reaching early dryout. It was also shown that modeling the 3D heat and stress distribution in the HCF rods is necessary for accurate steady state and transient analyses. The safety analysis of the 20% uprated HCF design in the context of a BWR/4 RPV showed satisfactory AMCHFR performance only if CR is estimated by the EPRI- 1 correlation.