Achievement of Reactor-Outlet Coolant Temperature of 950°C in HTTR

A High Temperature Gas-cooled Reactor (HTGR) is particularly attractive due to its capability of producing high-temperature helium gas and to its inherent safety characteristics. The High Temperature Engineering Test Reactor (HTTR), which is the first HTGR in Japan, achieved its rated thermal power of 30 MW and reactor-outlet coolant temperature of 950°C on 19 April 2004. During the high-temperature test operation which is the final phase of the rise-to-power tests, reactor characteristics and reactor performance were confirmed, and reactor operations were monitored to demonstrate the safety and stability of operation. The reactor-outlet coolant temperature of 950°C makes it possible to extend high-temperature gas-cooled reactor use beyond the field of electric power. Also, highly effective power generation with a high-temperature gas turbine becomes possible, as does hydrogen production from water. The achievement of 950°C will be a major contribution to the actualization of producing hydrogen from water using the high-temperature gas-cooled reactors. This report describes the results of the high-temperature test operation of the HTTR.     

Thermal and hydraulic tests of test sections in the helium engineering demonstration loop

The helium engineering demonstration loop (HENDEL) has been constructed and operated to test the large-scale components of the high temperature engineering test reactor (HTTR) under simulated reactor operating conditions. The fuel stack test section (T₁) of HENDEL simulates the fuel stack of the HTTR core and is used to investigate thermal and hydraulic performance. Hot tests with 1000°C helium gas have been conducted using simulated fuel rods having uniform, exponential and cosine axial heat flux distributions. The test results agreed with previously proposed correlations, although the simulated fuel rods had various heat flux distributions and high heat flux rates.

The in-core structure test section (T₂) also was installed in the HENDEL to verify the performance of the core bottom structure of the HTTR. The tests show that good performance was obtained. Examination of the thermal mixing characteristics indicated that mixing started at the location where the hot helium gas flowed into the hot plenum and that complete mixing was achieved during the downward flow in the outlet hot gas duct. The seal performance testing indicated no change of the leakage flow rate after 4000 hours of operation. The temperature of the metal portion of the structure was below 500°C and uniform around circumferential cross-sections due to the good performance of the thermal insulation blocks.     

Development of control technology for HTTR hydrogen production system with mock-up test facility: System controllability test for loss of chemical reaction

The Japan Atomic Energy Agency has been planning the demonstration test of hydrogen production with the High Temperature Engineering Test Reactor (HTTR). In a HTTR hydrogen production system (HTTR-H2), it is required to control a primary helium temperature within an allowable value at a reactor inlet to prevent a reactor scram. A cooling system for a secondary helium with a steam generator (SG) and a radiator is installed at the downstream of a chemical rector in a secondary helium loop in order to mitigate the thermal disturbance caused by the hydrogen production system. Prior to HTTR-H2, the simulation test with a mock-up test facility has been carried out to establish the controllability on the helium temperature using the cooling system against the loss of chemical reaction. It was confirmed that the fluctuations of the helium temperature at chemical reactor outlet, more than 200 K, at the loss of chemical reaction could be successfully mitigated within the target of ±10 K at SG outlet. A dynamic simulation code of the cooling system for HTTR-H2 was verified with the obtained test data.     

Numerical investigations of thermal mixing performance of a hot gas mixing structure in high-temperature gas-cooled reactor

A numerical simulation study was performed to clarify the thermal mixing characteristics of coolant in the core bottom structure of the high-temperature gas-cooled reactor(HTR). The flow field and temperature field in the hot gas chamber and the hot gas duct of the HTR were obtained based on the commercial computational fluid dynamics(CFD) program. The numerical simulation results showed that the helium flow with different temperatures in the hot gas mixing chamber and the hot gas duct mixed intensively, and the mixing rate of the temperature in the outlet of the hot gas duct reached 98 %. The results indicated many large-scale swirling flow structures and strong turbulence in the hot gas mixing chamber and the entrance of the hot gas duct, which were responsible for the excellent thermal mixing of the hot gas chamber and the hot gas duct. The calculated results showed that the temperature mixing rate of the hot gas chamber decreased only marginally with increasing Reynolds number.     

Research and development on nuclear hydrogen production using HTGR at JAERI

JAERI has been conducting R&D on HTGR and on hydrogen production using HTGR. The reactor technology has been developed using HTTR installed at Oarai site of JAERI. HTTR reached its full power operation of 30MW in 2001 and demonstrated reactor outlet helium temperature of 950°C in April 2004. As for the hydrogen production technology, the thermo-chemical IS process is under study. The process control method for continuous hydrogen production has been examined using a bench-scale apparatus. Also, studies are underway on process improvement and on materials of construction to be used in the corrosive environment. As for the system integration of HTGR and the hydrogen production plant, R&D is underway aiming to develop technologies for safe and economical connection. It covers safety technology against explosion, safety technology against radioactive materials release, control technology to prevent the thermal disturbance from hydrogen production plant to reactor, etc.     

Present status of energy in Japan and HTTR project

An amount of primary energy supply in Japan is increasing year by year. Much energy such as oil, coal and natural gas is imported so that the self-sufficiency ratio in Japan is only 20% even if including nuclear energy. An amount of energy consumption is also increasing especially in commercial and resident sector and transport sector. As a result, a large amount of greenhouse gas was emitted into the environment. Nuclear energy plays the important role in energy supply in Japan.Japan Atomic Energy Research Institute (JAERI) has been carried out research and development of a hydrogen production system using a high temperature gas cooled reactor (HTGR). The HTTR project aims at the establishment of the HTGR hydrogen production system. Reactor technology of the HTGR, hydrogen production technology with thermochemical water splitting process and system integration technology between the HTGR and a hydrogen production plant are developed in the HTTR project.     

辐照条件下高温锂热管不凝性气体产生特性研究

在新型热管冷却反应堆中,高温金属热管会受到持续的中子辐照。锂在热中子区的中子反应微观截面很大,会产生一定量的氦气,氦气作为不凝性气体将影响高温热管的正常运行。本文分析了堆内中子辐照条件对高温锂金属热管中不凝性气体产生特性的影响。首先对稳态标准算例进行了产氦量分析,并转换得到了不凝性气体体积份额。此外,得到了不凝性气体产量随热管充液量、金属锂富集度、中子通量密度、热管工作温度等因素的变化关系。不凝性气体产量随热管充液量、锂富集度的增大而增加。控制转鼓位于不同角度时,中子通量密度改变有限,对产氦量影响不大,由于高温锂热管工作温度很高,高温下中子反应微观截面差距很小,因此热管工作温度对产氦量影响也有限。本研究可为热管冷却反应堆内高温锂热管中锂富集度设计提供借鉴。     

Post-test analysis of helium circulator trip without scram at 3 MW power level on the HTR-10

Safety demonstration tests were conducted on the 10 MW High Temperature Gas-cooled Reactor-Test Module (HTR-10) to verify the inherent safety characteristics of modular High Temperature Gas-cooled Reactors (HTGRs) as well as to obtain the transient data of reactor core and primary cooling system for validation of HTGR safety analysis models and codes. As one of these safety demonstration tests, a simulated anticipated transient without scram (ATWS) test called loss of forced cooling by tripping the helium circulator without reactor scram was carried out at 3 MW power level on October 15, 2003. This paper simulates and analyzes the power transient and the thermal response of the reactor during the test by using the THERMIX code. The analytical results are compared with the test data for validation of the code.Owing to the negative temperature coefficient of reactivity, the reactor undergoes a self-shut down after the stop of the helium circulator; the subsequent phenomena such as the recriticality and power oscillations are also studied. During the test a natural circulation loop of helium is established in the core and the other coolant channels and its consequent thermal response such as the temperature redistribution is investigated. In addition, temperatures of the measuring points in the reactor internals are calculated and compared with the measured values. Satisfactory agreements obtained from the comparison demonstrate the basic applicability and reasonability of the THERMIX code for simulating and analyzing the helium circulator trip ATWS test. With respect to the safety features of the HTR-10, it is of most importance that the maximum fuel center temperature during the test is always lower than 1600 °C which is the limited value for the HTGR.     

Direct implementation of an axial-flow helium gas turbine tool in a system analysis tool for HTGRs

This study concerns the development of dynamic models for a high-temperature gas-cooled reactor (HTGR) through direct implementation of a gas turbine analysis code with a transient analysis code. We have developed a streamline curvature analysis code based on the Newton-Raphson numerical application (SANA) to analyze the off-design performance of helium gas turbines under conditions of normal operation. The SANA code performs a detailed two-dimensional analysis by means of throughflow calculation with allowances for losses in axial-flow multistage compressors and turbines. To evaluate the performance in the steady-state and load transient of HTGRs, we developed GAMMA-T by implementing SANA in the transient system code, GAMMA, which is a multidimensional, multicomponent analysis tool for HTGRs. The reactor, heat exchangers, and connecting pipes were designed with a one-dimensional thermal-hydraulic model that uses the GAMMA code. We assessed GAMMA-T by comparing its results with the steady-state results of the GTHTR300 of JAEA. We concluded that the results are in good agreement, including the results of the vessel cooling bypass flow and the turbine cooling flow.     

A pilot test plan of the thermochemical water-splitting iodine–sulfur process

Research and development (R&D) of hydrogen production systems using high-temperature gas-cooled reactors (HTGR) are being conducted by the Japan Atomic Research Institute (JAERI). To develop the systems, superior hydrogen production methods are essential. The thermochemical hydrogen production cycle, the IS (iodine–sulfur) process, is a prospective candidate, in which heat supplied by HTGR can be consumed for the thermal driving load. With this attractive feature, JAERI will conduct pilot-scale tests, aiming to establish technical bases for practical plant designs using HTGR. The hydrogen will be produced at a maximum rate of 30 m³/h, continuously using high-temperature helium gas supplied by a helium gas loop, with an electric heater of about 400 kW. The plant will employ an advanced hydroiodic acid-processing device for efficient hydrogen production, and the usefulness of the device was confirmed from mass and heat balance analysis. Through design works and the hydrogen production tests, valuable data for construction and operation will be acquired to evaluate detailed process performance for practical systems. After completing the pilot-scale tests, JAERI will move onto the next R&D step, which will be demonstrations of the IS process to which heat is supplied from a high-temperature engineering test reactor (HTTR).     

Inspection techniques for primary pressurized water cooler tubes in the high temperature engineering test reactor

A primary pressurized water cooler (PPWC) with 136 inverse-U-tubes is installed in the primary cooling system of the high temperature engineering test reactor (HTTR). The HTTR is the first high temperature gas-cooled reactor in Japan with an outlet gas temperature of 950 °C and thermal power of 30 MW. The heat transfer tubes form the reactor pressure boundary of the primary coolant. Inspection techniques for the tubes should be established to carry out the in-service inspection efficiently. An automatic inspection system for the tubes uses probes for eddy current testing and ultrasonic testing. Defect detecting characteristics of the inspection probes and the application of the automatic inspection system to nondestructive test of the tubes were examined by a mockup test utilizing artificially degraded tubes. The automatic inspection system could smoothly insert and withdraw the probe at its moving velocity in the fixed positions of the defected tube. Nondestructive test of the tubes using the automatic inspection system was conducted during reactor shutdown period of the HTTR after test operation of about 55% of the full power. Through the nondestructive test, it was concluded that there was no defect on the outer surface of the heat transfer tubes of the PPWC inspected.     

Numerical simulation of three-dimensional thermal-hydraulic behavior for HTTR (High Temperature Engineering Test Reactor)

Safety demonstration tests using the HTTR (High Temperature Engineering Test Reactor) are now in progress in order to verify the inherent safety features and to improve safety designing and analysis technologies for future HTGR (high temperature gas-cooled reactor). Coolant flow reduction test is one of the safety demonstration tests for the purpose of demonstration of inherent HTGR safety features in the case that coolant flow is reduced by tripping of helium gas circulators. If reactor core element temperature and core internal structure temperature during abnormal events are estimated by numerical simulation with high-accuracy, developed numerical simulation method can be applied to future HTGR designing efficiently. In the present research, three-dimensional in- and ex-vessel thermal-hydraulic calculations for the HTTR are performed with a commercially available thermal-hydraulic analysis code “STAR-CD^®” with finite volume method. The calculations are performed for normal operation and coolant flow reduction tests of the HTTR. Then calculated temperatures are compared with measured ones obtained in normal operation and coolant flow reduction test. As the result, calculated temperatures are good agreement with measured ones in normal operation and coolant flow reduction test.     

Investigation of absorption characteristics for thermal-load fluctuation using HTTR

A commercial very high-temperature gas-cooled reactor (VHTR) hydrogen cogeneration system named gas turbine high temperature reactor 300-cogeneration (GTHTR300C) is designed and developed in Japan Atomic Energy Agency (JAEA). Moreover, it has been planned that hydrogen production system and gas turbine system is connect to high-temperature engineering test reactor (HTTR). The reactor system is required to continue a stable and safety operation as well as a stable power supply in the case that thermal-load is fluctuated by the occurrence of abnormal event in the heat utilization system like as the hydrogen production facility. Then, it is necessary to confirm that the thermal-load fluctuation could be absorbed by the reactor system so as to continue the stable and safety operation. The thermal-load fluctuation absorption tests using the HTTR were planned to clarify the absorption characteristics of the HTGR system. However, it is difficult to clarify the phenomenon due to many kinds of fluctuation in nuclear thermal power in the reactor core. Moreover, the actual data regarding how the delay of the temperature response is effective for the reactor system had been gained quantitatively.

The thermal-load fluctuation absorption tests without nuclear heating were planned and conducted in JAEA to clarify the absorption characteristic of thermal-load fluctuation mainly by the reactor and by the intermediate heat exchanger (IHX). The absorption characteristics of thermal-load fluctuation can be revealed with sufficient temperature fluctuation. So the tests were conducted with the primary coolant temperature 120 °C which is the start-up temperature of the HTTR. As a result it was revealed that the reactor has the larger absorption capacity of thermal-load fluctuation than the expected one and that the IHX can be contributed to the absorption of the thermal-load fluctuation generated in the heat utilization system in the reactor system. It was confirmed from their results that the reactor and the IHX has effective absorption capacity of the thermal-load fluctuation generated in the heat utilization system. Moreover, the calculation with the safety evaluation code based on RELAP5/MOD3 was performed. It was confirmed that the calculated temperature for the reactor is almost same to the measured one with the new analysis model. On the other hand, it was confirmed that the calculated temperature for the IHX decreased faster than the measured one due to smaller absorption capacity in the calculation model than that in actual one. It can be considered that the calculation for the IHX produces the conservative result. It was summarized that the safety evaluation code can represent the thermal-load fluctuation absorption behavior conservatively.     

Indirect air cooling techniques for control rod drives in the high temperature engineering test reactor

The high temperature engineering test reactor (HTTR) is the first high-temperature gas-cooled reactor in Japan with reactor outlet gas temperature of 950 °C and thermal power of 30 MW. Sixteen pairs of control rods are employed for controlling the reactivity change of the HTTR. Each standpipe for a pair of the control rods, which is placed on the top head dome of the reactor pressure vessel, contains one control rod drive mechanism. The control rod drive mechanism may malfunction because of reduction of the electrical insulation of the electromagnetic clutch when the temperature exceeds 180 °C. Because 31 standpipes stand close together in the standpipe room, 16 standpipes for the control rods, which are located at the center, should be cooled effectively. Therefore, the control rod drives are cooled indirectly by forced air circulation through a pair of ring-ducts with proper air outlet nozzles and inlets. Based on analytical results, a pair of the ring-ducts was installed as one of structures in the standpipe room. Evaluation results through the rise-to-power test of the HTTR showed that temperatures of the electromagnetic clutch and the ambient helium gas inside the control rod standpipe should be below the limits of 180 and 75 °C, respectively, at full power operation and at the scram from the operation.     

Integrity assessment of the high temperature engineering test reactor (HTTR) control rod at very high temperatures

The high temperature engineering test reactor (HTTR) is the first high temperature gas-cooled reactor (HTGR) in Japan with a reactor outlet coolant temperature of 950°C at high temperature test operation. The HTTR contains 16 pairs of control rods for which Alloy 800H is chosen of the metallic parts. Because the maximum temperature of the control rods reaches about 900°C at reactor scrams, structural design guideline and design material data on Alloy 800H are needed for the high temperature design. The design guideline for the HTTR control rod is based on ASME Code Case N-47-21. Design material data is also determined and shown in this paper. Under the guideline, temperature and stress analysis was conducted, and it is confirmed that the target life of the control rods of 5 years can be achieved.     

Thermal performance test of the hot gas ducts of HENDEL

A hot gas duct provided with internal thermal insulation is to be used for high-temperature gas-cooled reactors (HTGR). This type of hot gas duct has not been used so far in industrial facilities, and only a couple of tests on such a large-scale model of a hot gas duct have been conducted. The present report deals with the results of the thermal performance of the single tube type hot gas ducts which are installed as parts of a helium engineering demonstration loop (HENDEL).Uniform temperature and heat flux distribution at the surface of the duct were observed, the experimental correlations being obtained for the effective thermal conductivity of the internal thermal insulation layer. The measured temperature distribution of the pressure tube was in good agreement with the calculation by a TRUMP heat transfer computer code. The temperature distribution of the inner tube of the co-axial hot gas duct was evaluated and no hot spot was detected.These results would be very valuable for the design and development of HTGR.     

Safety design

JAERI established the safety design philosophy of the HTTR based on that of current reactors such as LWR in Japan, considering inherent safety features of the HTTR. The strategy of defense in depth was implemented so that the safety engineering functions such as control of reactivity, removal of residual heat and confinement of fission products shall be well performed to ensure safety. However, unlike the LWR, the inherent design features of the high-temperature gas-cooled reactor (HTGR) enables the HTTR meet stringent regulatory criteria without much dependence on active safety systems. On the other hand, the safety in an accident typical to the HTGR such as the depressurization accident initiated by a primary pipe rupture shall be ensured. The safety design philosophy of the HTTR considers these unique features appropriately and is expected to be the basis for future Japanese HTGRs.This paper describes the safety design philosophy and safety evaluation procedure of the HTTR especially focusing on unique considerations to the HTTR. Also, experiences obtained from an HTTR safety review and R&D needs for establishing the safety philosophy for the future HTGRs are reported.     

Off-design performance research of an axial helium compressor for HTGR-10 power conversion unit

Helium compressor is a determining part of the power conversion unit (PCU) which is used in high-temperature gas cooled reactor (HTGR). A direct Helium Brayton cycle is applied to the PCU system for the power conversion. In order to optimize the compressor design, a performance test about helium compressor is given out to verify the CFD results. Also because of the strong relevancy between helium compressor and the other parts of the PCU system, it is quite important for designers to evaluate the performance of a helium compressor in different operational states. Tests have been carried out in different operating conditions and the compressor performance characteristics were obtained. Numerical simulation could help to further the understanding the details of compressor's flow channel and blades. Meanwhile, an economic method with air as the working fluid to perform the aerodynamic design and optimization of helium compressor is obtained. The experimental results showed that as long as the air flow conditions are correctly selected, the aerodynamic design of air compressor will be a valuable reference for the design of helium compressor.     

The design of 2300 MW(e) twin high temperature gas-cooled reactors for the philadelphia electric company

The basic design features of a 2300 MW(e) twin high temperature gas-cooled reactor (HTGR) power plant are described. The reactor core consists of vertical columns of hexagonal graphite fuel-moderator elements and graphite reflector blocks which are grouped into a cylindrical array and supported by a graphite core support structure. Reactivity control is accomplished by means of 146 control rods. The distribution of helium coolant flow through the core is controlled by variable orifice valves. Each of the six primary coolant loops is equipped with a helium circulator. The main steam/water section of each steam generator consists of a single helical tube bundle arranged in an annulus around the center duct. A core auxiliary cooling system is provided to furnish an independent means of removing reactor afterheat. The inherent safety characteristics and the design safety features of the large HTGR are discussed. Station arrangement, steam cycle and twin turbine generators, plant performance and control, containment and fuel handling, and environmental controls, are described.     

我国高温气冷堆的发展

模块化高温气冷堆具有的固有安全特性、建造周期短和相处容量小等优势正好符合电力系统非管制化（Ｄｅｒｅｇｕｌａｔｉｏｎ）发展趋势对于发电厂的要求，清华大学核能设计研究院正在建造一座１０ＭＷ高温气冷实验堆。本文着重分析了高温气冷堆的安全特性和提高发电效率的氦循环方式。