Page 1 Petten 27 – Feb. - 2013 ALFRED and ELFR Secondary System and Plant Layout

Page 1Petten 27 – Feb. - 2013

ALFRED and ELFR Secondary System and

Plant Layout


• Secondary system optimized for demonstrating that ALFRED reactor would be able to efficiently produce electric power

• Important considerations and constraints:– Lead temperature never drops to alarming values– ST 182 bar; 450ºC superheated steam– Pipes dimensioning: feed water, main steam and pipes through the

containment– Operational Modes:

• Normal Mode Efficient electric production• Partial load Mode Partial thermal load operation• By-pass Mode Direct heat transfer through the condenser• Auxiliary heating Mode Lead heating from the secondary system

1. Scope

ALFRED Secondary System


• Secondary system main parameters:– Steam Generators:

• Outlet pressure: 182 bar (180 bar at inlet of the HP turbine valve)• Inlet pressure: 188 bar• Outlet temperature: 450ºC• Inlet temperature: 335ºC• Steam flow: 192.7 Kg/s. Thermal power 300 MWth

– Heat sink:• Mechanical draft cooling tower• Nominal: 18ºC; 60% relative humidity• Extreme summertime (EUR): 37ºC; 60% relative humidity• Extreme wintertime (EUR): -25ºC; 100% relative humidity

– Steam turbine group inlet control: throttle control valve– Steam turbine mechanical losses: 0.25%– Deaerator elevation: 22.86 m

2. Main input data



• Two turbines HP and LP with three extractions each• Heater fed with main steam (Feedwater Temp. Control Heater - FWTCH)• Three low pressure (LP) preheaters and three high pressure (HP) preheaters • Single train for the HP and LP preheaters • Moisture separator (MS) is included • HPT exhaust pressure of 12 bar

3. Secondary system options



Steam Cycle Efficiency: 44,68%

Net Cycle Efficiency: 41,50%

Generator Output: 133 MWe



4. Secondary system layout



4. Secondary system feasibility study: Normal Mode

• Turbine configuration:– HP Turbine and a LP Turbine, with no intermediate stage (typical nuclear

configuration)– HP Turbine: 180 bar to 12 bar range, with three extraction lines– Turbine power range for medium turbines (less than 200 MW)– Axial exhaust turbine is chosen for ALFRED



4. Secondary system feasibility study: Normal Mode STEAM MASTER 21.0

177 02-15-2012 12:38:14 C:\Documents and Settings\gpp\Mis documentos\GPP_C\LEADER\Informes\informe f inal 2012\CÁLCULOS\15_02_12\nominal y carga parcial\2REC_180_II_100%.stm

5,5 6 6,5 7 7,5 8 8,5

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

3100

3200

3300

3400

ENTROPY kJ/kg-K

EN

THA

LPY

kJ/

kg

180 bar

138,7 bar

175,9 bar

94,3 bar

54,23 bar

28,69 bar

12,44 bar 4,913 bar

1,569 bar

0,374 bar 0,054 bar

Exhaust (LPT0)

0,95

0,9

0,85

0,8

200 C

300 C

400 C

8D188 p335 T

1541,1 h192,7 M

188,5 p299,2 T1330,7 h192,7 M

(0)182 p450 T3098 h20,17 M

139,5 p425,2 T3095 h20,17 M

13,33 M

300,7 T1342,8 h33,49 M

p [bar] T [C] h [kJ/kg] M [kg/s]

p [bar] T [C] M [kg/s] h [kJ/kg]

FWH type: Flash Back with Drain Cooler Total heat transfer = 40545 kWHeat transfer(s) in Condensing section = 31254 kW Drain cooler = 7178 kW Shell pressure = 139,5 bar Saturation temperature = 336,4 CNumber of passes = 2 Surface area = 1697,9 m^2Tubes: OD = 19,05 mm Length = 16,3 m Number = 1740FW vel. = 2,002 m/s DP = 0,539 bar

139,5 p336,4 T

HPT LPT1

M ois tureSeparator

RH1 RH2

0

12

34 5

67

8


182 p450 T

3098 h33,49 M

94,3 p353,4 T

2955,8 h16,68 M

54,23 p283,8 T

2851,8 h22,63 M

28,69 p231,4 T

2747,4 h9,482 M

12,44 p189,6 T

2627,7 h7,358 M

4,913 p252,4 T

2966,4 h6,151 M

1,569 p137,8 T

2747,6 h5,784 M

0,374 p74,28 T

2525,2 h4,012 M

Total exhaust0,054 p34,39 T

2304,8 h77,87 M89,31 %

180 p448,3 T3095 h159,2 M

175,

9 p

12,44 p189,6 T

2627,7 h101,4 M

11,96 p357,4 T3170 h93,82 M

FWH4 (DA) shell189,1 T803,8 h8,034 M

12,32 p189,1 T2784,7 h93,33 M

(2)51,83 p280,7 T10,57 M

FWH6 shell266,2 T10,57 M

12,14 p268 T2975,6 h93,33 M

(0)180,1 p449 T

13,33 M

FWH8 shell357,1 T13,33 M

11,96 p357,6 T3170 h93,33 M

Expansion powerMechanical lossGenerator lossGenerator power

136203340,61839,6134023

kWkWkWkW

STEAM MASTER 21.0 Empresarios Agrupados, A.I.E.177 02-15-2012 12:38:14 C:\Documents and Settings\gpp\Mis documentos\GPP_C\LEADER\Informes\informe final 2012\CÁLCULOS\15_02_12\nominal y carga parcial\2REC_180_II_100%.stm



4. Secondary system feasibility study: Partial Load Mode

35

36

37

38

39

40

41

42

43

44

45

46

100% 75% 50% 25%

%

0

20

40

60

80

100

120

140

160

MWe

Cycle Efficiency (%) Generator output (MWe)

• Throttle control valve System is able to lower the load without lowering too much the pressure of the temperature

• Performance decreases as the load decreases• FWTC Heater Valve maintain the feed water temperature (335ºC)



• Only liquid water is not feasible• System with only steam is proposed:

– Lead temperature: 380ºC – 400ºC– Steam temperature: 400ºC – 450ºC– Optimum SG inlet pressure? 30 bar

4. Secondary system feasibility study: Auxiliary Heating Mode

0

10

20

30

40

50

60

25 35 45 55 65 75 85 95

SG inlet pressure (bar)

kW

405

410

415

420

425

430

435

440

445ºC

Circulating power Auxiliar heater intlet temperature

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

25 35 45 55 65 75 85 95

SG inlet pressure (bar)

Ste

am

sid

e m

ass

flo

w (

kg/s

)0

5

10

15

20

25

Le

ad

sid

e m

ass

flo

w (

kg/s

)

Steam side mass flow Lead side mass flow



• Deaerator (operating at atmospheric pressure) fed with main steam• FWTC Heater maintains 335ºC• High FWTC Heater DDA attemperation with condensate water

4. Secondary system feasibility study: By-Pass Mode



4. Secondary system feasibility study: Heat Sink Analysis

20,91 T4046 M


0,054 p34,39 T2303,1 h78,08 M89,24 %

STexh 78 MMisc. 0,088 M

0,353 p

15,96 p34,6 T

78,08 M

20,92 T4046 M

30,9 T

18 T60% RH4982 M13,43 T w et bulb

24,1 T w et bulb100% RH5038 M

Condenser heat rejectionCondensate pump powerCW circulation pump powerCooling tower fanCW blowdownCW makeup

168592187,81190,11193,113,9569,73

kJ/skWkWkWkg/skg/s


32,47 T4046 M


0,101 p45,98 T2389 h79,68 M91,84 %

STexh 79,59 MMisc. 0,088 M

0,4 p

15,98 p46,19 T79,68 M

32,49 T4046 M

42,85 T

37 T60% RH4712 M29,91 T w et bulb

36,33 T w et bulb100% RH4783 M

Condenser heat rejectionCondensate pump powerCW circulation pump powerCooling tower fanCW blowdownCW makeup

175010188,31187,61141,117,7788,85

kJ/skWkWkWkg/skg/s


Environmental conditions Nominal Extreme summer Extreme winter

Steam Cycle Efficiency (%)

44.68 42.57 > 44.68

Transferred Heat (MW) 168 175 < 168

Condenser Pressure (bar) 0.054 0.101 < 0.054

Nominal

Extreme summer

Extreme winter

- Mechanical draft cooling tower- Nominal: 18ºC; 60% relative humidity- Extreme summertime (EUR): 37ºC; 60% relative humidity- Extreme wintertime (EUR): -25ºC; 100% relative humidity



5. Main steam and feed water pipes dimensioning

• High temperature material: SA-335 Gr91• Design temperature: 450ºC• Design pressure: 20 MPa



• Good performance of the proposed secondary system is demonstrated

• Requirements are complied:– High steam cycle efficiency: 44.68% reactor economic viability– Good behavior at partial loads– Minimum FW temperature at SG inlet is well controlled (335ºC)– By-pass operation mode is feasible– Auxiliary heating system is proposed: heating lead from secondary system– Performance at extreme summer and wintertime

• SG operational parameters are defined• Pipes dimensioning (SA-335 Gr91) and preliminary track through the

containment is proposed

6. Conclusions



Plant surface: 276x270 m2

ALFRED Plant Layout


ALFRED Reactor Building

Supported over seismic isolators


ELSY PLANT AREA TENTATIVE PARAMETERS

Power About 600 MWe

Thermal efficiency About 40 %

Primary coolant Pure lead

Primary system Pool type, compact

Primary coolant circulation (at power) Forced

Primary coolant circulation for DHR Natural circulation + Pony motors

Core inlet temperature ~ 400°C

Core outlet temperature ~ 480°C

Fuel MOX with assessment also of behaviour of nitrides and dispersed minor actinides

Fuel handling Search for innovative solutions

Main vessel Austenitic ss, hanging, short-height

Safety Vessel Anchored to the reactor pit

Steam Generators Integrated in the main vessel

Secondary cycle Water-supercritical steam

Primary Pumps Mechanical, in the hot collector

Internals As much as possible removable, (objective: all removable)

Hot collector Small-volume above the core

Cold collector Annular, outside the core, free level higher than free level of hot collector

DHR coolers Immersed in the cold collector

Seismic design 2D isolators supporting the main vessel

ELFR Secondary System


The data for the supercritical cycle were:• Steam generator inlet temperature: 335ºC• Steam generator outlet temperature: 450ºC• Steam generator outlet pressure: 24,3 Mpa• Steam Generator pressure for supercritical cycle: 26 MPa

EfficiencySteam Generator Inlet

TemperatureMass Flow

Superheater Steam Cycle 36,25% 260 ºC 1009 kg/s

Supercritical Steam Cycle 43,24% 335 ºC 961,3 kg/s

He-Brayton Cycle 30,67% 308,6 ºC 2665 kg/s

CO2 Supercritical Cycle 41,69% 259,8 ºC 6022 kg/s

ELFR Secondary System


Access Control

Visitor Building

Administration Building

Cooling Towers

Pump House

Water Storage Tanks

Service Water Building & Water TreatmentEffluent Collection Pond

Make-Up Pumps House

Dematerialized Tank

N2 Plant & Warehouse

Diesel Tank

Warehouse

Switch Yard

Cold Machine Shop

Turbine Building

Auxiliary Boiler Reactor Building

Condensate Storage Tanks

Diesel Generators

Transformers

Service Building & Operation Support Center

Fire Brigade & Fire Water Storage Tank

Independent Spent Fuel Storage

Fuel Building

Plant surface: 360 x 450 m²

ELFR Plant Layout. Option 1


Cooling Tower

Pump House

Service Water Building & Water Treatment

Effluent Collection Pond

Make-Up Pumps House

Dematerialized Tank

Condensate Storage Tanks

N2 Plant & Warehouse

Transformers

Diesel Tank

Warehouse

Diesel Generators

Switch Yard

Cold Machine Shop

Turbine Building

Service Building & Operation Support Center

Fire Brigade & Fire Water Storage Tank

Reactor Building

Independent Spent Fuel Storage

Fuel Building

Administration Building

Visitor Building

Access Control

ELFR Plant Layout. Option 2


3

1-2

3

ELFR Reactor Building