HyPEP FY-07 Report: System Integration Model Development

The Very High Temperature Gas-Cooled Reactor (VHTR) coupled to the High Temperature Steam Electrolysis (HTSE) process is one of two reference integrated systems being investigated by the U.S. Department of Energy and Idaho National Laboratory for the production of hydrogen. In this concept the VHTR outlet temperature of 900 °C provides thermal energy and high efficiency electricity for the electrolysis of steam in the HTSE process. In the second reference system the Sulfur Iodine (SI) process is coupled to the VHTR to produce hydrogen thermochemically. In the HyPEP project we are investigating and characterizing these two reference systems with respect to production, operability, and safety performance criteria. Under production, plant configuration and working fluids are being studied for their effect on efficiency. Under operability, control strategies are being developed with the goal of maintaining equipment within operating limits while meeting changes in demand. Safety studies are to investigate plant response for equipment failures. Specific objectives in FY07 were (1) to develop HyPEP Beta and verification and validation (V&V) plan, (2) to perform steady state system integration, (3) to perform parametric studies with various working fluids and power conversion unit (PCU) configurations, (4) the study of design options such as pressure, temperature, etc. (5) to develop a control strategy and (6) to perform transient analyses for plant upsets, control strategy, etc for hydrogen plant with PCU. This report describes the progress made in FY07 in each of the above areas. (1) The HyPEP code numeric scheme and Graphic User Interface have been tested and refined since the release of the alpha version a year ago. (2) The optimal size and design condition for the intermediate heat exchanger, one of the most important components for integration of the VHTR and HTSE plants, was estimated. (3) Efficiency calculations were performed for a variety of working fluids for this reference design. (4) Efficiency improvements over the reference VHTR/HTSE plant were investigated for an alternative design that directly couples a High Temperature Steam Rankin Cycle (HTRC) to the HTSE process. Integration of the VHTR with SI process plants was begun. (5) Plant control studies showed that inventory control in the VHTR plant and flow control in the HTSE plant is effective in maintaining hot-side temperatures near constant during load change. (6) Dynamic calculations showed that thermal transients arising in the chemical plant are strongly damped at the reactor resulting in a stable combined plant.

The very high temperature gas-cooled reactor (VHTR) is envisioned as a single- or dual-purpose reactor for electricity and hydrogen generation. The concept has average coolant temperatures above 1173 K (900°C) and operational fuel temperatures above 1523 K (1250°C). The concept provides the potential for increased energy conversion efficiency and for high-temperature process heat application in addition to power generation. While all the high-temperature gas-cooled reactor concepts have sufficiently high temperatures to support process heat applications, such as hydrogen production, tar sands, oil shale, desalination, or cogenerative processes, the VHTR’s higher temperatures can be detrimental to safety if a loss-of-coolant accident occurs and causes the mechanical strength degradation of the supporting graphite in the lower plenum. Following the loss of coolant through the break and coolant depressurization, air will enter the core through the break by molecular diffusion or density-gradient–driven stratified flow phenomena and ultimately by natural convection, leading to oxidation of the in-core graphite structure and fuel. The oxidation will accelerate heatup of the reactor core and the release of toxic gases (CO and CO2) and fission products. Thus, without any effective countermeasures, a pipe break may lead to significant fuel damage and fission product release. Therefore, there was a need to develop a computer code that can be used for VHTR air ingress-related graphite oxidation analyses. Prior to the start of the Republic of Korea/United States International Nuclear Energy Research Initiative collaboration, no computer codes were available that had been sufficiently developed and validated to reliably simulate an air ingress phenomenon in the VHTR. Therefore, we have worked for the past 3 yr on developing and validating advanced computational methods for simulating air ingress in the VHTR. The Idaho National Laboratory is developing a system integration model of VHTR and hydrogen production plant. GAMMA code is being considered to be an integrated computer tool to analyze the thermal hydraulics of the coupled plant. Computer models for a high-temperature steam electrolysis (HTSE) process were developed and were implemented in an overall system process optimization code, HYSYS. The HTSE model will be implemented into GAMMA code as the integrated computer tool.This paper describes the governing equations and numerical methods used in GAMMA code and presents a portion of verification of the GAMMA code along with turbomachinery models and HTSE models that will be linked to GAMMA code.

Technology readiness levels (TRLs) of electrolysis systems have dramatically increased in recent years as the interest in clean hydrogen production and decarbonization of transportation, industrial and other sectors increases across the globe. This is especially true of high temperature steam electrolysis (HTSE) / solid oxide electrolysis cell (SOEC) systems which show promise of much higher system efficiencies than other more developed electrolysis technologies. This possibility of higher efficiencies of HTSE / SOEC systems has been previously assumed to be theoretically possible but in recent years it has become less theoretical and more realistic as an increasing amount of suppliers complete lab and pilot tests showing very promising results. Research in the areas of manufacturing techniques, material selection, electrode and electrolyte compositions, and balance of plant size and integration continues at a fast pace as an increasing number of suppliers both internationally and domestically become involved. The advantages of HTSE become more pronounced when HTSE is coupled with nuclear power plants (NPPs). This is because thermal energy produced by the nuclear reactor can be used in a series of heat transfer loops and heat exchangers to vaporize HTSE feedwater, which drastically improves the economics of the process. Idaho National Laboratory (INL) has been very involved in the research and modeling of HTSE systems for a number of years, in collaboration with other national laboratories, academia, and industry stakeholders both on the hydrogen production as well as the hydrogen demand side. The modeling completed over the years on a large variety of projects has led to a wealth of knowledge at INL including in the area of the technoeconomic assessment (TEA) of HTSE systems. TEAs include process modeling of the HTSE systems to calculate system energy requirements and equipment sizing, followed by estimation of capital and operating costs to enable calculation of the levelized cost of hydrogen (LCOH). The TEA work performed has produced incremental improvements and tuning of the methods, assumptions, models, and results of the analyses as well as providing some opportunities for validating these results. The purpose of this document is to record the current baseline HTSE analyses led by INL to show the current status of assumptions and costs of these systems. Given the rapid development of this technology, the variety of suppliers entering the space, and the increasing attention government and industry are giving to such systems, this document may be updated on a periodic basis with updated analysis and assumptions. This document compiles various analyses results and approaches completed over a period of years into a single document to be used as a baseline going forward. It represents what the INL HTSE analysis group assumes to be the internal best estimate of the current operation, costs, and landscape of the HTSE industry state of the art capability for current SOEC technology in an Nth-of-a-Kind (NOAK) plant, which in this study is defined as existence of the manufacturing capacity to support previous deployment of N = 100 count of 25 MWe modular HTSE blocks (with modular equipment component cost reductions specified as following a 95% learning curve). That said, Tthis is a public document and as such so no proprietary data was used or included in this report. There may be HTSE suppliers that have performance specifications, and cost estimates, and test data that differ from the analysisose presented in this document. This document is meant to be a best conservative estimate of the technology and not an absolute reference.

Two-dimensional simulation and critical efficiency analysis of high-temperature steam electrolysis system for hydrogen production

The tritium concentration in the hydrogen product in Japan's future very high temperature gas-cooled reactor (VHTR) system coupled with a thermochemical water-splitting iodine-sulfur (IS) process (VHTRIS system), named GTHTR300C, was estimated by numerical analysis. The tritium concentration in the hydrogen product significantly depended on undetermined parameters, i.e., the permeabilities of a SO3 decomposer and a H2SO4vaporizer made of SiC. Thus, the estimated tritium concentration in the hydrogen product for the conservative analytical condition ranged from 3.4 × 10−3 Bq/cm3 at STP (38 Bq/g-H2) to 0.18 Bq/cm3 at STP (2,000 Bq/g-H2). By considering the tritium retained by core graphite and the reduction in permeation rate by an oxide film on the heat transfer tube of the IHX and the HI decomposer, the tritium concentration in the hydrogen product decreased to the range from 3.3 × 10−5 Bq/cm3 at STP (0.36 Bq/g-H2) to 5.6 × 10−3 Bq/cm3 at STP (63 Bq/g-H2), which were smaller than those for the conservative analytical condition by factors of about 3.2 × 10−2 and 9.6 × 10−3, respectively. The effectof the helium flow rate in the helium purification system on the tritium concentration in the hydrogen product was also evaluated.

In Korea, the Very High Temperature Gas-Cooled Reactor (VHTR) PMR200 is being developed in the Nuclear Hydrogen Development and Demonstration project. Its core consists of hexagonal prism-shaped graphite blocks for the fuel and reflector, and each hexagonal fuel block contains 108 cylindrical coolant holes and 210 fuel compacts. Because of these holes and fuels, the heat transfer in lateral directions in the fuel blocks becomes very complicated. Especially in accident situations when forced convection is lost, the majority of the afterheat flows in the radial direction by conduction across the large number of coolant holes. Moreover, radiation heat transfer is supposed to be added to the radial heat transfer modes owing to the high temperature of the VHTR core. Because of these complexities in radial heat transfer, reliable modeling for effective thermal conductivity (ETC) is required in order to analyze the reactor core thermal behavior using lumped-parameter codes, which are often used to evaluate the integrity of nuclear fuel embedded in the graphite block. In this study, the ETC model adopted in the GAMMA+ code was introduced, and the adequacy of the model was assessed by the commercial computational fluid dynamics (CFD) code CFX-13. The results of the CFD analysis were consistent with the ETC model in general even if a slight disagreement was shown for the case of high temperature. From these analyses, it could be concluded that the ETC model adopted in the GAMMA+ code is an adequate model for the analysis of the PMR200 reactor core. Moreover, it was found that the effect of fuel gap can cause an overprediction of the ETC if the fuel compact thermal conductivity is larger than the applicable range of the model.

The Department of Energy envisions the next generation very high temperature gas-cooled reactor (VHTR) as a single-purpose or dual-purpose facility that produces hydrogen and electricity. The Ministry of Science and Technology (MOST) of the Republic of Korea also selected VHTR for the Nuclear Hydrogen Development and Demonstration (NHDD) Project. The report will address the evaluation of hydrogen and electricity production cycle efficiencies for such systems as the VHTR and NHDD, and the optimization of system configurations. Optimization of such complex systems as VHTR and NHDD will require a large number of calculations involving a large number of operating parameter variations and many different system configurations. The research will produce (a) the HyPEP which is specifically designed to be an easy-to-use and fast running tool for the hydrogen and electricity production evaluation with flexible system layout, (b) thermal hydraulic calculations using reference design, (c) verification and validation of numerical tools used in this study, (d) transient analyses during start-up operation and off-normal operation. This project will also produce preliminary cost estimates of the major components.

Thermo-economic analysis and optimization of the very high temperature gas-cooled reactor-based nuclear hydrogen production system using copper-chlorine cycle

Scaling and design analyses of a scaled-down, high-temperature test facility for experimental investigation of the initial stages of a VHTR air-ingress accident

Experimental studies on the thermal and hydraulic performance of the fuel stack of the VHTR: Part II. HENDEL multi-channel test rig with twelve fuel rods

This work is concerning a methodology of Ni-base superalloy development for a very high temperature gas-cooled reactor(VHTR) using design of experiments(DOE) and thermodynamic calculations. Total 32 sets of the Ni-base superalloys with various chemical compositions were formulated based on a fractional factorial design of DOE, and the thermodynamic stability of topologically close-packed(TCP) phases of those alloys was calculated by using the THERMO-CALC software. From the statistical evaluation of the effect of the chemical composition on the formation of TCP phase up to a temperature of 950 oC, which should be suppressed for prolonged service life when it used as the structural components of VHTR, 16 sets were selected for further calculation of the mechanical properties. Considering the yield and ultimate tensile strengths of the selected alloys estimated by using the JMATPRO software, the optimized chemical composition of the alloys for VHTR application, especially intermediate heat exchanger, was proposed for a succeeding experimental study.

Air-ingress events caused by large pipe breaks are important accidents considered in the design of Very High Temperature Gas-Cooled Reactors (VHTRs). A main safety concern for this type of event is the possibility of core collapse following the failure of the graphite support column, which can be oxidized by ingressed air. In this study, the main target is to predict the strength of the oxidized graphite support column. Through compression tests for fresh and oxidized graphite columns, the compressive strength of IG-110 was obtained. The buckling strength of the IG-110 column is expressed using the following empirical straight-line formula: σ cr,buckling = 91.34—1.01 (L/r). Graphite oxidation in Zone 1 is volume reaction and that in Zone 3 is surface reaction. We notice that the ultimate strength of the graphite column oxidized in Zones 1 and 3 only depends on the slenderness ratio and bulk density. Its strength degradation oxidized in Zone 1 is expressed in the following nondimensional form: σ/σ0 = exp(—kd), k = 0.114. We found that the strength degradation of a graphite column, oxidized in Zone 3, follows the above buckling empirical formula as the slenderness of the column changes.

ABSTRACTA 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.

Hydrogen is a commercially important element. Basically, there are several methods of hydrogen production that have been commercially used, such as Steam Methane Reforming (SMR), High Temperature Steam Electrolysis (HTSE), and thermochemical cycles, like Sulphur-Iodine (SI). Among these methods, SMR is the most widely used for large-scale hydrogen production, with conversion efficiency between 74–85% and it has commercially used in some fertilizer industries in Indonesia. Steam reforming is a method to convert alkane (natural gas) compounds to hydrogen and carbon dioxide (synthetic gas) by adding moisture at high pressure and temperature (35-40 bar; 800-900°C). These hydrogen production technologies can be coupled with different nuclear reactors based on the heat required in the process. The High Temperature Gas-cooled Reactor (HTGR) using helium as a coolant, has a high outlet temperature (900°C), so it can potentially be used to supply for process heat for hydrogen production, coal liquefaction/gasification or for other industrial processes requiring high temperature heat. Hydrogen production cost from SMR method is influenced by a range of technical and economic factors. The fuel component of natural gas needed in the SMR method can be replaced by nuclear heat from a nuclear power plant (NPP) operating in cogeneration mode (i.e. simultaneous producing electric power and heat), hence contributing to the reduction of carbon dioxide in the process.In the SMR method, fuel costs are the largest cost component, accounting for between 45% and 75% of production costs. Therefore, there is opportune to assess the economics of hydrogen production by using nuclear heat. The economic evaluation is done by using IAEA HEEP-4 Software.The results comprise cost break up for 2 cases, coupling SMR process for hydrogen production with: (1) 2 HTGRs of 170 MWth/unit; and (2) 1 HTGR of 600 MWth/unit. The cost of hydrogen production is highly depend on the scale of the NPP as energy source and results indicated that hydrogen production cost of the 1 HTGR Unit600 MWth (Case 2) has a lower value (1.72 US$/kgH2), than the cost obtained when 2 HTGR units of 170 MWth each (case 1) are considered (2.72 US$/kgH2). For comparison, the hydrogen production cost by using SMR with carbon capture and storage (CCS) with natural gas as fuel is 2.27 US$/kgH2.

High-temperature electrolysis for large-scale hydrogen production from nuclear energy – Experimental investigations