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Finalization of the conceptual design of the auxiliary circuits for the European test blanket systems
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Finalization of the conceptual design of the auxiliary circuits for the European test blanket systems A. Aiello a,∗ , B.E. Ghidersa b , M. Utili a , L. Vala c , T. Ilkei d , G. Di Gironimo e , R. Mozzillo e , A. Tarallo e , I. Ricapito f , P. Calderoni f a
ENEA UTIS – C.R. Brasimone, Bacino del Brasimone, I-40032 Camugnano, BO, Italy Karlsruher Institut für Technologie (KIT) – Institut für Neutronenphysik und Reaktortechnik (INR), D-76021 Karlsruhe, Germany c Sustainable Energy (SUSEN), Technological Experimental Circuits, Centrum vyzkumu Rez s.r.o. (CV Rez), Hlavni c.p. 130, CZ-250 68 Husinec-Rez, Czech Republic d Institute for Particle and Nuclear Physics, Wigner Research Centre for Physics, Hungarian Academy of Sciences, Budapest H-1525, Hungary e CREATE/University of Naples Federico II, Department of Industrial Engineering, P.le Tecchio 80, 80125 Naples, Italy f TBM&MD Project, Fusion for Energy, EU Commission, Carrer J. Pla, 2, Building B3, 08019 Barcelona, Spain b
a r t i c l e
i n f o
Article history: Received 4 October 2014 Received in revised form 2 April 2015 Accepted 7 April 2015 Available online xxx Keywords: Breeding blanket Integration in ITER Tritium extraction and management
a b s t r a c t In view of the ITER conceptual design review, the design of the ancillary systems of the European test blanket systems presented in [1] has been updated and made consistent with the ITER requirements for the present design phase. Europe is developing two concepts of TBM, the helium cooled lithium lead (HCLL) and the helium cooled pebble bed (HCPB) one, having in common the cooling media, pressurized helium at 8 MPa [2]. TBS, namely helium cooling system (HCS), coolant purification system (CPS), lead lithium loop and tritium extraction/removal system (TES–TRS) have the purpose to cool down the TBM and to remove tritium to be driven to TEP from breeder and coolant. These systems are placed in port cell 16 (PC#16), chemical and volume control system (CVCS) area and tritium building. Starting from the pre-conceptual design developed in the past, more mature technical interfaces with the ITER facility have been consolidated and iterative design activities were performed to comply with design requirements/specifications requested by IO to conclude the conceptual design phase. In this paper the present status of design of the TBS is presented together with the preliminary integration in ITER areas. © 2015 Elsevier B.V. All rights reserved.
1. Introduction Fig. 1 presents the adopted breakdown [3]. The subsystems of the EU TBSs (HCPB and HCLL concepts integrated in equatorial port #16) can be divided in three parts: specific SubSystems (SSs) for the HCPB, specific SSs for the HCLL TBS and common SSs [1,2]. The “HCPB specific SSs” are the HCPB helium coolant system, the HCPB tritium extraction system, the HCPB coolant purification systems and the HCPB data acquisition and control system (DACS). The “HCLL specific SSs” analogous systems are the HCLL HCS, the HCLL CPS and the HCLL DACS. To this list few HCLL specific SSs are added, namely the Pb–Li Loop and the Tritium Removal Systems, considering that the tritium extraction system is based
∗ Corresponding author. Tel.: +39 0534 801380; fax: +39 0534 801225. E-mail address: [email protected] (A. Aiello).
on the circulation of lead lithium in a specific component named Tritium Extraction Unit.
2. Subsystems design description 2.1. HCS design According to the current PBS, the HCS is the TBS subsystem that transports the heat deposited or generated inside the TBM from the blanket to the component cooling water system (CCWS) of ITER, at the same time, maintaining the coolant at pressure levels and temperatures that ensure the proper operation of the TBM [4]. In the case of the two EU-TBMs, helium has been selected as coolant. With around 1 MW of power to be transferred from the blanket to CCWS-1 cooling system, the HCS needs about 1.3 kg/s of helium at 8 MPa. In addition to that, the mechanical performances of the TBM structural material (EUROFER-97) as well as the breeding process determine a certain operating temperature window for
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Fig. 1. Schematic view of HCLL and HCPB TBS.
the helium. For the EU-TBMs, this temperature window is defined between 573 K (TBM inlet) and 773 K (TBM outlet). For the HCS, the reference structural material is austenitic stainless steel AISI 316L. The PFD of HCLL/HCPB HCS is shown in Fig. 2. The loop has the shape of an “eight” with the TBM installed on the high temperature side and the helium circulator on the low temperature branch. A cooler (HX-1001), located before the helium-circulator, reduces the helium temperature to a level that ensures the proper operation of the circulator (50 ◦ C). At the same time, the cooler acts as heat sink for the whole HCLL TBS.
In order to increase the reliability and availability of the loop, the current design foresees two identical helium-circulators (PB-10012) operating in parallel. Each of the two circulators is designed to provide the requested flow rate for cooling the TBM independently. In addition to this, in order to reduce the risk of fouling and erosion inside the circulator, the design foresees the installation of two dust filters directly at the inlet of the circulators. The current design of the TBM requires around 1.3 kg/s for the cooling of the FW while for the cooling of the internals (stiffening grid and breeder units) only a fraction of this flow (∼60%) is
Fig. 2. HCS process flow diagram.
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Fig. 3. CPS process flow diagram.
required. This requirement is mainly linked to the temperature levels required for an optimal breeding process at the level of the breeder units. For this purpose, a temperature-controlled valve adjusts the bypass flow from the TBM, to ensure that the TBM internal components are adequately cooled. A pressure control system (PCS) integrated into HCS is foreseen to maintain the helium pressure at the TBM inlet independently on the temperature variations of the coolant induced by the pulsed plasma operation. PCS essentially consists of a high and a low pressure tank connected through a helium compressor (PC-1002). During maintenance periods the PCS tanks will be used also as storage. A total of 31 kg of helium can be stored. An additional storage tank (TA-1004) is foreseen for pressure discharge in case of PCS failure. Redundant isolation valves on the TBM inlet and outlet pipes provide the isolation of the HCS (CVCS area located components) from the TBM and the other components placed in PC#16 and thus limiting the inventory of pressurized or radioactive fluid that can participate in accident evolution in the TBM and toward the ITER VV.
an oxygen donor (CuO/Cu2 O). The high temperature reaction converts rapidly and quantitatively Q2 to Q2 O; extraction of Q2 O and CO2 by a PTSA (pressure temperature swing adsorption); adsorption of residual impurities by implementing gettering technologies. The PFD of the system is in Fig. 3 while in Table 1 a summary of the selected technologies and systems design is reported. The CPS is designed to be operated at high pressure treating around 0.3% of the HCS nominal flow rate. The PTSA can be regenerated to recover Q2 O flowing pure helium. The mass flow rate of the regeneration flow is 10% of the loading flow. Basic parameters for the design, e.g. nature of impurities and their concentrations, are derived from fission gas cooled reactors, as the basic technologies for purification, as better explained in [3,4].
Table 1 Main components of CPS. Design and operative parameters Name
2.2. CPS design The coolant purification system, which is mainly devoted to remove tritium and hydrogen permeated from the TBM and to control the chemistry of the primary coolant, can be considered a subsystem of the HCS and is fully integrated with it in the CVCS area [5,6]. The reference solution for the coolant purification is a three-stage process constituted by the following steps: oxidation of Q2 (Q = H, D or T) and CO to Q2 O and CO2 using a metal oxide with
Function Helium flow-rate Working pressure Working temperature
Oxidizing PTSA (cycle 24 h) bed Q2 O adsorption Q2 oxidation 75 N m3 /h 75 N m3 /h adsorption, 2 N m3 /h regen 8.2 MPa 8.2 MPa ◦
250 C
RT in adsorption 300 ◦ C in desorption
Heated getter Reducing bed Final impurity Q2 recovery removal 2 N m3 /h 75 N m3 /h
8.2 MPa ◦
400 C
0.11 MPa 400 ◦ C
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2.3. TES design
1. tritium extraction from lead lithium; 2. tritium concentration in the stripping gas.
The main purposes of the HCPB-TES are [7]: - to extract the bred tritium from the ceramic breeder and from the neutron multiplier, by means of a purge gas; - to extract the different compounds of tritium from the purge gas; - to direct the extracted tritium to the tritium processing system in the tritium plant, providing an accurate tritium accountancy; - to control the chemical composition and physical properties of the purge gas; - to remove the impurities from the purge gas. The PFD is in [7]. The main components of the system are listed in the following: • • • • • • •
Q2 O adsorption column Q2 getter beds Heat exchanger Filters Reducing bed Compressors Heater
The TBM purge gas, flowing through the pebble bed inside the TBM, can carry out solid radioactive particles, which have to be removed by means of steel sintered filters. Then, an adsorption column traps the tritiated water extracted by the purge gas in the TBM. The temperature of the purge at TBM outlet is approximately 500 ◦ C. In order to reduce the tritium permeation through the pipes and to make effective the adsorption process, the gas stream is cooled down at room temperature by means of a gas/water heat exchanger placed in port cell. The adsorption column is filled with a zeolite type A. The regeneration of the column implies a stop of the main circuit to allow the extraction process. The process requires a temperature of the regeneration flow around 300 ◦ C. To allow the extraction of the tritiated water, a flow of He, driven by a compressor, is heated up and directed to a reducing bed having the same filler foreseen in CPS. Then, the tritiated gas is sent to the tritium plant. This operation is supposed to be carried out during the short-term maintenance The dried purge gas mixture, leaving from the Q2 O adsorption column, contains mainly Q2 in the He carrier gas. Q2 is extracted at room temperature from the purge gas by means of Q2 getter beds. The proposed purifier is composed of two beds, one working in adsorption phase and the other in regeneration phase. The purge gas returns in the TBM by means of a compressor, after being heated. After the compressor, a by-pass line is present; in case of too high temperature inside the getter bed, in adsorption phase, this line allows to operate a partial recirculation of gas from the exit to the inlet of the getter, achieving a dilution of the Q2 concentration. This by-pass works in combination with the cooler located at the inlet of the getters. When a Q2 getter bed is saturated, the purge gas is deviated to the other one. The saturated Q2 getter bed is regenerated using a flow of He heated up to approximately 300 ◦ C. The tritiated gas, leaving from the Q2 getter bed, reduces its temperature at room value and is finally sent to the tritium plant. 2.4. Tritium extraction from Pb–16Li Tritium recovery from Pb-16Li is a two steps process. It consists of [8]:
The first step is performed by the tritium extraction unit (TEU), while the second one by the tritium removal system. 2.4.1. TEU design Different technologies that in principle can be adopted for tritium extraction from the lead lithium loop were analyzed in the past. The selection exercise done recently identified the technology based on gas liquid contactors (GLC) – packed column as the most suitable for this specific application. The correct sizing of the TEU based on GLC technology is rather complex because of the specificity of the solute (hydrogen isotopes) and of the liquid phase (liquid lead alloy). However, the preliminary design has been carried out successfully. It has allowed to select a packing material characterized by a high specific surface (around 1000 m2 /m3 ) and to dimension a relatively compact column that should assure tritium extraction efficiency of around 44%, a value compatible with the assumed global target in terms of tritium migration performance in HCLL-TBS allowed to select from a preliminary analysis two types of packings were selected: MALLAPACK 750Y and MELLAPACK 752Y. On the basis of simulation of the packings, the minimum diameter of the column, which generates the maximum suggested pressure drop in the module of packings, was determined. Moreover, on the basis of the preliminary analysis carried out the minimum height of the column was fixed, taking into account a maximum stripping gas flow rate of about 250 N L/h. The total height of TEU is given by the HETP and by the space requested by gas injector, liquid distributor and instrumentations 2.4.2. TRS design The main purposes of the TRS are: - to extract the tritium from the stripping gas coming from TEU; - to direct the extracted tritium to the tritium processing system in the tritium plant, providing an accurate tritium accountancy; - to control the chemical composition and physical properties of the stripping gas, and in particular the H2 content added to this gas; - to remove the solid particles from the stripping gas. The purge gas, coming from the Li–Pb system, can carry out solid radioactive particles that have to be removed by means of filters. The temperature of the purge gas coming from the TEU is approximately 450 ◦ C. The correct operation of the Q2 getter beds requires that the purge gas is at a maximum temperature of 35 ◦ C, corresponding to the room temperature. This means that it should be sufficient to avoid thermal insulation on the pipe going from port cell to tritium building to decrease the gas temperature. The purge gas contains tritiated hydrogen that can be extracted by means of Q2 getter beds functionally similar to the ones presented in CPS. The proposed purifier is composed of two beds operated in parallel, one working in adsorption phase and one in regeneration phase. The purge gas returns into Pb–Li system by means of a small Hecompressor. The correct temperature of the purge gas is ensured by means heating cables. When a Q2 getter bed is saturated, the purge gas is deviated on the other one. The saturated Q2 getter bed is regenerated using a flow of He driven by means of a compressor and heated up at a relatively high temperature (>200 ◦ C).
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The tritiated gas, leaving from the Q2 getter bed, reduces its temperature at the room temperature value by means of heat exchange between the room atmosphere and the external surface of the not insulated pipes. Finally, the tritiated gas coming from the regeneration line is sent to the tritium plant.
2.5. Pb–Li loop design The Pb–Li Loop is designed for HCLL TBM with three major functions: to ensure proper circulation of liquid metal breeder through TBM, to extract tritium from the irradiated melt into the purge gas and to remove corrosion products. The Pb–16Li loop is a closed loop with forced circulation of the Pb–16Li alloy (Fig. 4). The main components of the loop are tritium extraction unit, cooler, air-cooled cold trap and radiation shielded storage tank with circulation pump. These components are interconnected with pipes equipped with valves. The system is indeed divided in subsections with closing on/off valves and regulation valves. During the normal operation of the loop, the Pb–16Li alloy returns from the TBM module at the temperature of 320 ◦ C and with a mass flow rate in the range of 0.2–1.0 kg/s. The Pb–16Li flow passes through two isolation valves is heated to 450 ◦ C and enters to the TEU. Behind the TEU, the Pb–16Li flow is cooled down to 300 ◦ C and divided into two branches. A portion of the Pb–16Li flow enters the cold trap for alloy purification. The other portion of the flow is sent to the storage tank. Two regulation valves allow the exact adjustment of the Pb–16Li mass flow to be purified in the cold trap or even its complete by-pass. Then the Pb–16Li from the storage tank, where it is maintained at 300 ◦ C, is pumped with a mechanical circulation pump and sent again to the TBM module (via Pipe Forest). Like the loop’s inlet, its outlet is also equipped with two isolation valves as required by IO. If needed, the system allows the by-pass of the TEU with an extra line which is maintained closed during normal operation of the loop. The Pb–16Li loop will operate in the following three basic modes:
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(a) Nominal: all Pb–16Li arriving from TBM is processed in the TEU and is then sent to the tank, partially through the cold trap for purification. (b) TEU by-pass: this mode can be used if it is needed to by-pass TEU. This mode can be also used for the Pb–16Li alloy purification campaign, for example during night shift or after long outage of the system (c) Cold trap by-pass: the CT can be by-passed in case of its unavailability. Theoretically, this mode also allows replacement of the cold trap directly in the AEU. Indeed, it is also possible to combine modes (b) and (c) and bypass both the TEU and CT. 3. Integration in ITER areas The engineering design has focused on ancillary systems of HCLL and HCPB TBMs (i.e. TBM1 and TBM2). More precisely, the activities concerned: • integration of TES and TRS subsystems in the ITER buildings, taking into account the safety requirements (e.g. fire hazard, tritium aspects, radiation protection, etc.) and the space constraints as well as the TES maintenance/access scheme; • integration of HCS and CPS subsystems in CVCS area, taking into account the safety requirements and the space constraints, as well as the maintenance/access scheme; • preliminary design of the steel frames supporting all equipment in CVCS area; • integration of PbLi subsystem in PC#16, taking into account the safety requirements (gravitational draining of HCLL TBM, radiation protection, tritium aspect, etc.) and the space constraints. Since those subsystems spread among different physical sites inside ITER plant for more convenience, the description is grouped by area, rather than by process loop: Port cell #16 (11-L1-C16), area evidenced in Fig. 5
Fig. 4. Lead lithium loop PFD.
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Fig. 5. Port cell #16 (11-L1-C16).
Fig. 8. CVCS area – main equipment.
At the current stage, HCPB and HCLL HCS contain 14 DN100 servo-actuated valves, which are heavy and quite bulky. For that reason, a further steel platform has been designed at about 3000 mm from the floor of CVCS area, which holds all the valves and allows their maintenance. That choice guarantees more space at floor level for heavy equipments and maintenance walkways. The platform has been provided with two service stairs. The appraisal weight that the platform shall bear is about 1500 kg/m2 . The pillars that support the platform have been also modeled in order to verify the actual maintainability of the equipments at the floor level. However, it should be noticed that an adequate number of steel plates embedded into the reinforced concrete floor of CVCS area (so-called embedded plates) shall be provided to support the pillars of that steel structure. In Fig. 9 the general layout of different components on CVCS area together with the maintenance corridors is reported. Fig. 6. CVCS area east 02E (11-L3-02E).
3.2. Integration in port cell #16 CVCS area East 02E (11-L3-02E), Fig. 6 Tritium process room (14-L2-24), Fig. 7. 3.1. Integration in CVCS area The overall area reserved for HCS, PCS and CPS subsystems in CVCS area is about 471 m2 . To gain space for CPS and PCS equipments, CVCS area has been ideally divided in two sub-areas: the one reserved for DN100 piping (HCS “main cycle”) and the other reserved for DN25 and DN40 piping (i.e. CPS and PCS, respectively), as shown in Fig. 8.
Fig. 7. Tritium process room (14-L2-24) – space reservations and interfaces.
As aforementioned, port cell #16 will contain TBS1 and TBS2 components by EU. Fig. 10 highlights the space initially reserved for the different subsystems. TES, TRS, Pb–Li loop and HCS system were integrated in PC#16 taking into account, and satisfying as much as possible, the following requirements: • Draining of the Pb–Li loop • Space constrain due to HCS expansions tank
Fig. 9. Final integration in CVCS area of different subsystems.
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Fig. 10. Side view of port cell#16 space reservation.
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Fig. 13. Integration of TRS (front) and TRS (back) in tritium process room.
3.3. Integration in tritium building • • • • •
Removal of heating power in the PC#16 Shielding of relevant Pb–Li equipment Thermo-mechanical design of HCS pipes Human accessibility Technology-remote maintenance
The result of this job is in Fig. 11, in which the different components assembled on the auxiliary equipment unit are integrated. One of the most challenging activities was the integration of lead lithium loop. The key issue was the gravity draining. In Fig. 12 the layout of the lead lithium loop, including TRS connections and TEU as it appears on the AEU, is reported. This system is close to the bio shield trying to obtain the maximum slope favoring the gravity draining. Also with the effort spent in this activity, a full passive draining is not possible and will have to be addressed and solved in the design phase.
Tritium process room is intended to accommodate several tritium recovery subsystems that serve each TBM. The space reserved by IO for each subsystem and the related gas interfaces defined, and proper glove-boxes shall be provided to house some components according to their “Tritium Classification”. The maintenance of equipment and in-line instruments of TES and TRS in the tritium process room is quite straightforward at the presented conceptual design stage. The accessibility of every component has been checked in virtual environment [9] by means of digital human models [10]. Fig. 13 shows the overall layout of both TES and TRS subsystem inside the tritium process room during a human maintenance operation. 4. Conclusion The conceptual design and the preliminary integration in ITER of the HCLL and HCPB-TBS ancillary systems, summarized in this paper, can be considered as close to its conclusion. Some open issues are still present but they will be solved when the interfaces with ITER will be definitively frozen and through a further step in the design development (preliminary design) and supporting R&D activities. Some selected technologies, like the reducing beds for Q2 O reduction or the getter beds need to be experimentally qualified in TBM relevant conditions even if preliminary analyses and engineering judgment shared with the manufacturers, allow to consider them as suitable for the specific application to test blanket systems. Acknowledgments
Fig. 11. Assembly of components on frame in AEU.
The work leading to this publication has been funded by Fusion for Energy under the task order F4E-OMF-331-02-01-01. The views and opinions expressed herein do not necessarily reflect those of F4E nor those of the ITER organization. References
Fig. 12. Assembly of lead lithium loop on AEU.
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Fusion Engineering and Design journal homepage: www.elsevier.com/locate/fusengdes
Finalization of the conceptual design of the auxiliary circuits for the European test blanket systems A. Aiello a,∗ , B.E. Ghidersa b , M. Utili a , L. Vala c , T. Ilkei d , G. Di Gironimo e , R. Mozzillo e , A. Tarallo e , I. Ricapito f , P. Calderoni f a
ENEA UTIS – C.R. Brasimone, Bacino del Brasimone, I-40032 Camugnano, BO, Italy Karlsruher Institut für Technologie (KIT) – Institut für Neutronenphysik und Reaktortechnik (INR), D-76021 Karlsruhe, Germany c Sustainable Energy (SUSEN), Technological Experimental Circuits, Centrum vyzkumu Rez s.r.o. (CV Rez), Hlavni c.p. 130, CZ-250 68 Husinec-Rez, Czech Republic d Institute for Particle and Nuclear Physics, Wigner Research Centre for Physics, Hungarian Academy of Sciences, Budapest H-1525, Hungary e CREATE/University of Naples Federico II, Department of Industrial Engineering, P.le Tecchio 80, 80125 Naples, Italy f TBM&MD Project, Fusion for Energy, EU Commission, Carrer J. Pla, 2, Building B3, 08019 Barcelona, Spain b
a r t i c l e
i n f o
Article history: Received 4 October 2014 Received in revised form 2 April 2015 Accepted 7 April 2015 Available online xxx Keywords: Breeding blanket Integration in ITER Tritium extraction and management
a b s t r a c t In view of the ITER conceptual design review, the design of the ancillary systems of the European test blanket systems presented in [1] has been updated and made consistent with the ITER requirements for the present design phase. Europe is developing two concepts of TBM, the helium cooled lithium lead (HCLL) and the helium cooled pebble bed (HCPB) one, having in common the cooling media, pressurized helium at 8 MPa [2]. TBS, namely helium cooling system (HCS), coolant purification system (CPS), lead lithium loop and tritium extraction/removal system (TES–TRS) have the purpose to cool down the TBM and to remove tritium to be driven to TEP from breeder and coolant. These systems are placed in port cell 16 (PC#16), chemical and volume control system (CVCS) area and tritium building. Starting from the pre-conceptual design developed in the past, more mature technical interfaces with the ITER facility have been consolidated and iterative design activities were performed to comply with design requirements/specifications requested by IO to conclude the conceptual design phase. In this paper the present status of design of the TBS is presented together with the preliminary integration in ITER areas. © 2015 Elsevier B.V. All rights reserved.
1. Introduction Fig. 1 presents the adopted breakdown [3]. The subsystems of the EU TBSs (HCPB and HCLL concepts integrated in equatorial port #16) can be divided in three parts: specific SubSystems (SSs) for the HCPB, specific SSs for the HCLL TBS and common SSs [1,2]. The “HCPB specific SSs” are the HCPB helium coolant system, the HCPB tritium extraction system, the HCPB coolant purification systems and the HCPB data acquisition and control system (DACS). The “HCLL specific SSs” analogous systems are the HCLL HCS, the HCLL CPS and the HCLL DACS. To this list few HCLL specific SSs are added, namely the Pb–Li Loop and the Tritium Removal Systems, considering that the tritium extraction system is based
∗ Corresponding author. Tel.: +39 0534 801380; fax: +39 0534 801225. E-mail address: [email protected] (A. Aiello).
on the circulation of lead lithium in a specific component named Tritium Extraction Unit.
2. Subsystems design description 2.1. HCS design According to the current PBS, the HCS is the TBS subsystem that transports the heat deposited or generated inside the TBM from the blanket to the component cooling water system (CCWS) of ITER, at the same time, maintaining the coolant at pressure levels and temperatures that ensure the proper operation of the TBM [4]. In the case of the two EU-TBMs, helium has been selected as coolant. With around 1 MW of power to be transferred from the blanket to CCWS-1 cooling system, the HCS needs about 1.3 kg/s of helium at 8 MPa. In addition to that, the mechanical performances of the TBM structural material (EUROFER-97) as well as the breeding process determine a certain operating temperature window for
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Fig. 1. Schematic view of HCLL and HCPB TBS.
the helium. For the EU-TBMs, this temperature window is defined between 573 K (TBM inlet) and 773 K (TBM outlet). For the HCS, the reference structural material is austenitic stainless steel AISI 316L. The PFD of HCLL/HCPB HCS is shown in Fig. 2. The loop has the shape of an “eight” with the TBM installed on the high temperature side and the helium circulator on the low temperature branch. A cooler (HX-1001), located before the helium-circulator, reduces the helium temperature to a level that ensures the proper operation of the circulator (50 ◦ C). At the same time, the cooler acts as heat sink for the whole HCLL TBS.
In order to increase the reliability and availability of the loop, the current design foresees two identical helium-circulators (PB-10012) operating in parallel. Each of the two circulators is designed to provide the requested flow rate for cooling the TBM independently. In addition to this, in order to reduce the risk of fouling and erosion inside the circulator, the design foresees the installation of two dust filters directly at the inlet of the circulators. The current design of the TBM requires around 1.3 kg/s for the cooling of the FW while for the cooling of the internals (stiffening grid and breeder units) only a fraction of this flow (∼60%) is
Fig. 2. HCS process flow diagram.
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Fig. 3. CPS process flow diagram.
required. This requirement is mainly linked to the temperature levels required for an optimal breeding process at the level of the breeder units. For this purpose, a temperature-controlled valve adjusts the bypass flow from the TBM, to ensure that the TBM internal components are adequately cooled. A pressure control system (PCS) integrated into HCS is foreseen to maintain the helium pressure at the TBM inlet independently on the temperature variations of the coolant induced by the pulsed plasma operation. PCS essentially consists of a high and a low pressure tank connected through a helium compressor (PC-1002). During maintenance periods the PCS tanks will be used also as storage. A total of 31 kg of helium can be stored. An additional storage tank (TA-1004) is foreseen for pressure discharge in case of PCS failure. Redundant isolation valves on the TBM inlet and outlet pipes provide the isolation of the HCS (CVCS area located components) from the TBM and the other components placed in PC#16 and thus limiting the inventory of pressurized or radioactive fluid that can participate in accident evolution in the TBM and toward the ITER VV.
an oxygen donor (CuO/Cu2 O). The high temperature reaction converts rapidly and quantitatively Q2 to Q2 O; extraction of Q2 O and CO2 by a PTSA (pressure temperature swing adsorption); adsorption of residual impurities by implementing gettering technologies. The PFD of the system is in Fig. 3 while in Table 1 a summary of the selected technologies and systems design is reported. The CPS is designed to be operated at high pressure treating around 0.3% of the HCS nominal flow rate. The PTSA can be regenerated to recover Q2 O flowing pure helium. The mass flow rate of the regeneration flow is 10% of the loading flow. Basic parameters for the design, e.g. nature of impurities and their concentrations, are derived from fission gas cooled reactors, as the basic technologies for purification, as better explained in [3,4].
Table 1 Main components of CPS. Design and operative parameters Name
2.2. CPS design The coolant purification system, which is mainly devoted to remove tritium and hydrogen permeated from the TBM and to control the chemistry of the primary coolant, can be considered a subsystem of the HCS and is fully integrated with it in the CVCS area [5,6]. The reference solution for the coolant purification is a three-stage process constituted by the following steps: oxidation of Q2 (Q = H, D or T) and CO to Q2 O and CO2 using a metal oxide with
Function Helium flow-rate Working pressure Working temperature
Oxidizing PTSA (cycle 24 h) bed Q2 O adsorption Q2 oxidation 75 N m3 /h 75 N m3 /h adsorption, 2 N m3 /h regen 8.2 MPa 8.2 MPa ◦
250 C
RT in adsorption 300 ◦ C in desorption
Heated getter Reducing bed Final impurity Q2 recovery removal 2 N m3 /h 75 N m3 /h
8.2 MPa ◦
400 C
0.11 MPa 400 ◦ C
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2.3. TES design
1. tritium extraction from lead lithium; 2. tritium concentration in the stripping gas.
The main purposes of the HCPB-TES are [7]: - to extract the bred tritium from the ceramic breeder and from the neutron multiplier, by means of a purge gas; - to extract the different compounds of tritium from the purge gas; - to direct the extracted tritium to the tritium processing system in the tritium plant, providing an accurate tritium accountancy; - to control the chemical composition and physical properties of the purge gas; - to remove the impurities from the purge gas. The PFD is in [7]. The main components of the system are listed in the following: • • • • • • •
Q2 O adsorption column Q2 getter beds Heat exchanger Filters Reducing bed Compressors Heater
The TBM purge gas, flowing through the pebble bed inside the TBM, can carry out solid radioactive particles, which have to be removed by means of steel sintered filters. Then, an adsorption column traps the tritiated water extracted by the purge gas in the TBM. The temperature of the purge at TBM outlet is approximately 500 ◦ C. In order to reduce the tritium permeation through the pipes and to make effective the adsorption process, the gas stream is cooled down at room temperature by means of a gas/water heat exchanger placed in port cell. The adsorption column is filled with a zeolite type A. The regeneration of the column implies a stop of the main circuit to allow the extraction process. The process requires a temperature of the regeneration flow around 300 ◦ C. To allow the extraction of the tritiated water, a flow of He, driven by a compressor, is heated up and directed to a reducing bed having the same filler foreseen in CPS. Then, the tritiated gas is sent to the tritium plant. This operation is supposed to be carried out during the short-term maintenance The dried purge gas mixture, leaving from the Q2 O adsorption column, contains mainly Q2 in the He carrier gas. Q2 is extracted at room temperature from the purge gas by means of Q2 getter beds. The proposed purifier is composed of two beds, one working in adsorption phase and the other in regeneration phase. The purge gas returns in the TBM by means of a compressor, after being heated. After the compressor, a by-pass line is present; in case of too high temperature inside the getter bed, in adsorption phase, this line allows to operate a partial recirculation of gas from the exit to the inlet of the getter, achieving a dilution of the Q2 concentration. This by-pass works in combination with the cooler located at the inlet of the getters. When a Q2 getter bed is saturated, the purge gas is deviated to the other one. The saturated Q2 getter bed is regenerated using a flow of He heated up to approximately 300 ◦ C. The tritiated gas, leaving from the Q2 getter bed, reduces its temperature at room value and is finally sent to the tritium plant. 2.4. Tritium extraction from Pb–16Li Tritium recovery from Pb-16Li is a two steps process. It consists of [8]:
The first step is performed by the tritium extraction unit (TEU), while the second one by the tritium removal system. 2.4.1. TEU design Different technologies that in principle can be adopted for tritium extraction from the lead lithium loop were analyzed in the past. The selection exercise done recently identified the technology based on gas liquid contactors (GLC) – packed column as the most suitable for this specific application. The correct sizing of the TEU based on GLC technology is rather complex because of the specificity of the solute (hydrogen isotopes) and of the liquid phase (liquid lead alloy). However, the preliminary design has been carried out successfully. It has allowed to select a packing material characterized by a high specific surface (around 1000 m2 /m3 ) and to dimension a relatively compact column that should assure tritium extraction efficiency of around 44%, a value compatible with the assumed global target in terms of tritium migration performance in HCLL-TBS allowed to select from a preliminary analysis two types of packings were selected: MALLAPACK 750Y and MELLAPACK 752Y. On the basis of simulation of the packings, the minimum diameter of the column, which generates the maximum suggested pressure drop in the module of packings, was determined. Moreover, on the basis of the preliminary analysis carried out the minimum height of the column was fixed, taking into account a maximum stripping gas flow rate of about 250 N L/h. The total height of TEU is given by the HETP and by the space requested by gas injector, liquid distributor and instrumentations 2.4.2. TRS design The main purposes of the TRS are: - to extract the tritium from the stripping gas coming from TEU; - to direct the extracted tritium to the tritium processing system in the tritium plant, providing an accurate tritium accountancy; - to control the chemical composition and physical properties of the stripping gas, and in particular the H2 content added to this gas; - to remove the solid particles from the stripping gas. The purge gas, coming from the Li–Pb system, can carry out solid radioactive particles that have to be removed by means of filters. The temperature of the purge gas coming from the TEU is approximately 450 ◦ C. The correct operation of the Q2 getter beds requires that the purge gas is at a maximum temperature of 35 ◦ C, corresponding to the room temperature. This means that it should be sufficient to avoid thermal insulation on the pipe going from port cell to tritium building to decrease the gas temperature. The purge gas contains tritiated hydrogen that can be extracted by means of Q2 getter beds functionally similar to the ones presented in CPS. The proposed purifier is composed of two beds operated in parallel, one working in adsorption phase and one in regeneration phase. The purge gas returns into Pb–Li system by means of a small Hecompressor. The correct temperature of the purge gas is ensured by means heating cables. When a Q2 getter bed is saturated, the purge gas is deviated on the other one. The saturated Q2 getter bed is regenerated using a flow of He driven by means of a compressor and heated up at a relatively high temperature (>200 ◦ C).
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The tritiated gas, leaving from the Q2 getter bed, reduces its temperature at the room temperature value by means of heat exchange between the room atmosphere and the external surface of the not insulated pipes. Finally, the tritiated gas coming from the regeneration line is sent to the tritium plant.
2.5. Pb–Li loop design The Pb–Li Loop is designed for HCLL TBM with three major functions: to ensure proper circulation of liquid metal breeder through TBM, to extract tritium from the irradiated melt into the purge gas and to remove corrosion products. The Pb–16Li loop is a closed loop with forced circulation of the Pb–16Li alloy (Fig. 4). The main components of the loop are tritium extraction unit, cooler, air-cooled cold trap and radiation shielded storage tank with circulation pump. These components are interconnected with pipes equipped with valves. The system is indeed divided in subsections with closing on/off valves and regulation valves. During the normal operation of the loop, the Pb–16Li alloy returns from the TBM module at the temperature of 320 ◦ C and with a mass flow rate in the range of 0.2–1.0 kg/s. The Pb–16Li flow passes through two isolation valves is heated to 450 ◦ C and enters to the TEU. Behind the TEU, the Pb–16Li flow is cooled down to 300 ◦ C and divided into two branches. A portion of the Pb–16Li flow enters the cold trap for alloy purification. The other portion of the flow is sent to the storage tank. Two regulation valves allow the exact adjustment of the Pb–16Li mass flow to be purified in the cold trap or even its complete by-pass. Then the Pb–16Li from the storage tank, where it is maintained at 300 ◦ C, is pumped with a mechanical circulation pump and sent again to the TBM module (via Pipe Forest). Like the loop’s inlet, its outlet is also equipped with two isolation valves as required by IO. If needed, the system allows the by-pass of the TEU with an extra line which is maintained closed during normal operation of the loop. The Pb–16Li loop will operate in the following three basic modes:
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(a) Nominal: all Pb–16Li arriving from TBM is processed in the TEU and is then sent to the tank, partially through the cold trap for purification. (b) TEU by-pass: this mode can be used if it is needed to by-pass TEU. This mode can be also used for the Pb–16Li alloy purification campaign, for example during night shift or after long outage of the system (c) Cold trap by-pass: the CT can be by-passed in case of its unavailability. Theoretically, this mode also allows replacement of the cold trap directly in the AEU. Indeed, it is also possible to combine modes (b) and (c) and bypass both the TEU and CT. 3. Integration in ITER areas The engineering design has focused on ancillary systems of HCLL and HCPB TBMs (i.e. TBM1 and TBM2). More precisely, the activities concerned: • integration of TES and TRS subsystems in the ITER buildings, taking into account the safety requirements (e.g. fire hazard, tritium aspects, radiation protection, etc.) and the space constraints as well as the TES maintenance/access scheme; • integration of HCS and CPS subsystems in CVCS area, taking into account the safety requirements and the space constraints, as well as the maintenance/access scheme; • preliminary design of the steel frames supporting all equipment in CVCS area; • integration of PbLi subsystem in PC#16, taking into account the safety requirements (gravitational draining of HCLL TBM, radiation protection, tritium aspect, etc.) and the space constraints. Since those subsystems spread among different physical sites inside ITER plant for more convenience, the description is grouped by area, rather than by process loop: Port cell #16 (11-L1-C16), area evidenced in Fig. 5
Fig. 4. Lead lithium loop PFD.
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Fig. 5. Port cell #16 (11-L1-C16).
Fig. 8. CVCS area – main equipment.
At the current stage, HCPB and HCLL HCS contain 14 DN100 servo-actuated valves, which are heavy and quite bulky. For that reason, a further steel platform has been designed at about 3000 mm from the floor of CVCS area, which holds all the valves and allows their maintenance. That choice guarantees more space at floor level for heavy equipments and maintenance walkways. The platform has been provided with two service stairs. The appraisal weight that the platform shall bear is about 1500 kg/m2 . The pillars that support the platform have been also modeled in order to verify the actual maintainability of the equipments at the floor level. However, it should be noticed that an adequate number of steel plates embedded into the reinforced concrete floor of CVCS area (so-called embedded plates) shall be provided to support the pillars of that steel structure. In Fig. 9 the general layout of different components on CVCS area together with the maintenance corridors is reported. Fig. 6. CVCS area east 02E (11-L3-02E).
3.2. Integration in port cell #16 CVCS area East 02E (11-L3-02E), Fig. 6 Tritium process room (14-L2-24), Fig. 7. 3.1. Integration in CVCS area The overall area reserved for HCS, PCS and CPS subsystems in CVCS area is about 471 m2 . To gain space for CPS and PCS equipments, CVCS area has been ideally divided in two sub-areas: the one reserved for DN100 piping (HCS “main cycle”) and the other reserved for DN25 and DN40 piping (i.e. CPS and PCS, respectively), as shown in Fig. 8.
Fig. 7. Tritium process room (14-L2-24) – space reservations and interfaces.
As aforementioned, port cell #16 will contain TBS1 and TBS2 components by EU. Fig. 10 highlights the space initially reserved for the different subsystems. TES, TRS, Pb–Li loop and HCS system were integrated in PC#16 taking into account, and satisfying as much as possible, the following requirements: • Draining of the Pb–Li loop • Space constrain due to HCS expansions tank
Fig. 9. Final integration in CVCS area of different subsystems.
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Fig. 10. Side view of port cell#16 space reservation.
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Fig. 13. Integration of TRS (front) and TRS (back) in tritium process room.
3.3. Integration in tritium building • • • • •
Removal of heating power in the PC#16 Shielding of relevant Pb–Li equipment Thermo-mechanical design of HCS pipes Human accessibility Technology-remote maintenance
The result of this job is in Fig. 11, in which the different components assembled on the auxiliary equipment unit are integrated. One of the most challenging activities was the integration of lead lithium loop. The key issue was the gravity draining. In Fig. 12 the layout of the lead lithium loop, including TRS connections and TEU as it appears on the AEU, is reported. This system is close to the bio shield trying to obtain the maximum slope favoring the gravity draining. Also with the effort spent in this activity, a full passive draining is not possible and will have to be addressed and solved in the design phase.
Tritium process room is intended to accommodate several tritium recovery subsystems that serve each TBM. The space reserved by IO for each subsystem and the related gas interfaces defined, and proper glove-boxes shall be provided to house some components according to their “Tritium Classification”. The maintenance of equipment and in-line instruments of TES and TRS in the tritium process room is quite straightforward at the presented conceptual design stage. The accessibility of every component has been checked in virtual environment [9] by means of digital human models [10]. Fig. 13 shows the overall layout of both TES and TRS subsystem inside the tritium process room during a human maintenance operation. 4. Conclusion The conceptual design and the preliminary integration in ITER of the HCLL and HCPB-TBS ancillary systems, summarized in this paper, can be considered as close to its conclusion. Some open issues are still present but they will be solved when the interfaces with ITER will be definitively frozen and through a further step in the design development (preliminary design) and supporting R&D activities. Some selected technologies, like the reducing beds for Q2 O reduction or the getter beds need to be experimentally qualified in TBM relevant conditions even if preliminary analyses and engineering judgment shared with the manufacturers, allow to consider them as suitable for the specific application to test blanket systems. Acknowledgments
Fig. 11. Assembly of components on frame in AEU.
The work leading to this publication has been funded by Fusion for Energy under the task order F4E-OMF-331-02-01-01. The views and opinions expressed herein do not necessarily reflect those of F4E nor those of the ITER organization. References
Fig. 12. Assembly of lead lithium loop on AEU.
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