ORNL-TM-3579.txt

 

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ORNL-TM-3579

Contract No, W-TLO5-eng-26

CHEMICAL TECHNOLOGY DIVISION

DESIGN AND COST STUDY OF A

o - FLUORINATION--REDUCTIVE EXTRACTION--METAL

TRANSFER PROCESSING FLANT FOR THE MSER

W. L. Carter
-:E; L. Nicholson

 MAY 1972

-

OAK RIDGE NATIONAL LABORATORY -
Oak Ridge, Tennessee 37830
.. operated by :
UNION CARBIDE GORPORATION
- for the
U S. ATOMIC ENERGY COMMISSION

 

 
 

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4

~ Abstract . . . .

~ CONTENTS

. . * * * ’ *

Summeary. . o . ..

’ + * + . *

Scope of the Design Study.

The Mblten Salt.Breeder Reactor.

Reactor Plant . . . . . . .

Fuel Salt . .

* . . .

Equilibrium Comp051tlon of the MSBR

Behavior of Fission Products and Fuel Salt

in Proce351ng. e o o o o & a

The Fluorlnatlon--Reductive Extraction--Metal Transfer.

Fluorination. . . .

*

iii

*

Components

- - - - .

* * ’ & * . .

* . & LE . e . * LN

Protactinium Extraction and Isolation . .
Protactinium Isolation System. . .
Rare Earth Extraction and Metal Transfer.
Mbtal Transfer to LiCl . .
Rare Earth Stripping . . . . .
Chemical Reactions in Reductlve Extractlon

Transfer . . . . .
Fuel Reconstitution . . .

. - o

e + ¢

. 4

Metal Reduction and Bismuth Removal.
Filtration and Valence Adjustment. .
G&S Recy01e ¢ & -8 4 6 s & & 4 ¢ 4 d .

Halogen Removal. . .

Noble Metal and Noble Gas Removal

Waste Accumulatlon. e e
Fluorlde Salt Waste.

- & .

Waste From Gas Recycle

- Process Losses. .

'KOH Scrubber Waste .

Hydrogen Discard . . -

" Design and Cost Estimate . .

Capltal Cost of the Plant. -

Process P1p1ng. e o e e 4
Process Instrumentation .

e 6 e e

Fluoride Salt Waste. .

-

&
.
»

*

Cell Electrical Connections

Thermal Insulation. . . .

Radiation Monitoring. . .
Sampling Stations.. . . .

Fluorine Plant. .

System. .
i e e s ]
L
oie-e o s
o s & o @
¢ . ..
?' * !. e - *
« o 0 e s .
..‘ .' e .0 .0 .
e . * .9 ¢ +
[ ] ”O & & ¢ e
* * » . ¢ .
* * '. * [ ] *

- - - -

s s = - - - . .

- - - - - »

. ® - .

*

- - - o & 's .

*

- - - -

e s ® e . .

- - - - - ‘

- - L] - > -

*

- -

.'.".q.‘l

*
&
and

.
* - *» -

o 2 *

Process
o« o o

fibtal

-
- L] - - -
¥
- - - - - - - - -
L > - - .. - - - -

.« = - - - »

- - - - . [} » . - -

2 e & s =
e e e e w

. - - -» - - - L] -

. - - - - - - - -

 

 
 

 

iv

Indirectocosts, e e e e e e e e

Construction Overhead, ', . . . . .

Engineering -and Inspection Charge,
' Taxes &nd Insurance. s s o0 e o e

"'Contingency. e e e e e e s e e e e
Interest During Construction —

mel GyCle cos‘b‘ 0 e . L] . * * . * . * & ' *

Capital Cost Versus Plant Size ...'. . .
Cost Estimate for & 3, 33-Day Fuel Cycle
Process Piping . . ., .., ;

Process Instrumentation, , ., . .
Cell Electrical Connections. “« o o
Thermal Insulation , . . + .+ « « »
Radiation Monltorlng € o 4 o6 o e
Sampling Stations, . ., . . ... .
Fluorine Flant . . . ¢« « « ¢« + o &
"Indirect Costs v 4 o o ¢ ¢ o o o &

Needed Development, Uhcertainties and Alternatives

Materials of Construction . . . . . .
Continuous Fluorination . . . . . . .
Bismuth Removal from Salt . ., . . . .
Instrumentation for Process Control ,
Noble and Seminoble Metal Behavior. .
Operational and Safety Considerations

* & & & & @

| Acknowledgment e o o s o o .'...'.-... . a
References-. ¢ ¢ 5. o 8 o 5 s & s e s s e s e
| Appendixes e
for the MSBR Processing Plant , , .

Once-Through Process Cycle ., ., .

- Gas Recycle Systéem . . . . ..
Fuel Cycle Cost Comparison . ., . .

 Appendix B: Useful Data for the MSBR and

’ - - T - - .- ..

L » - . - -

- - - .- . l.,

Time,

* & & & 8 s & o

- L] . i - L]

e * o & & & & 8 & & »®

.Appendix A: Economic Comparison of Process

" & & @

Processing Plant.

. - - - - [ ]

s & % 8 & o
. * s - o.
e.% » . .o .

e e s & & s

- . - - - - - - - .
- . @ - - - - - & -
- . - - . = - - - -

e & & & & & = &
& ® & & & & =& & & ‘@

s & 8 & s & =
e & e s e & e
e e e e ..o .
s s s s s e &

+ * . * * e

Gas Systems

- - - .

ooa_c'

Appendix C: Steady State Concentrations in the Metal

Tr&nsfersystem.r..-.,.._.......'.....-..'

‘Appendix D: Flowsheet of the Fluorination--Reductive
Extraction--Met&l Transfer Process [ 1000- MW(e) MSBR]. . .

« ® 8 & & = &% & s = - e 8 e & s »

e 8 8 8 8 e. &

* & s = & &

- - - L

‘s 8 e & & ®

- - - - - - - - * . &

* a & 's & & &
s & ® & & & =

¢ & 8 = 8 & & & e .®

. & & a & - @

L

v .
 

o -

4

C

- DESIGN AND COST STUDY OF A
FLUORINATION--REDUCTIVE EXTRACTION—-METAL
TRANSFER PROCESSING PLANT FOR THE MSER

W, L. Carter = E L. Nicholson
ABSTRACT

A preliminary design study and cost estimate were made

- for an integrated processing plant to continuously treat

irradisted LiF-BeF,-ThF,-UF, fuel salt from a 1000-Mi(e).

-single-fluid, molten-salt breeder reactor, The salt is
. treated by the fluorination--reductive extraction--metal

transfer process to recover and recycle uranium and carrier
salt, to isolate R33pg for decay, and to concentrate fis-
sion products in waste media. For a plant that processes
the active inventory (1683 fts) of reactor fuel on a 10-day
cycle the direct costs were estimated to be $21 million and
indirect costs were $15 million for a total investment of
$36 million, Allowances for site, site preparation, and
buildings plus facilities shared with the reactor are not
included since these costs are included in the overall cost
of the power station, The net fuel cycle cost for process-
ing on a 10-day cycle at 80% plant factor was estimated to

‘be 1,1 mills/kWhr; this includes credit for a 3. 3%/yr yield

of bred fuel, The capital investment wés not strongly in-
fluenced by processing rate, A plant to process the 1000-
MW(e) reactor on a 3. 3 day cycle was estimated to cost $L8
mllllon.

A 0.9-gpm stream of fuel salt flows directly from the

- reactor to the processing plant, and, after about 30 min-

utes holdup for’ ‘decay of short-lived fission products, the

~salt flows to a fluorinator where approximately 95%.of the
~ uranium is removed, The salt is then contacted with bis-
. -muth containing metallic lithium reductant to extract *>°Pa
~ end the remaining uranium, which are hydrofluorlnated from

the bismuth into a captive salt phase and held for **®Ps

decay. - The U- and Pa-free salt is treated in & second ex-

tractor with additionel Bi-Ii solution to remove most of

_the rare earth fission products which are isolated via the

~ metal transfer operation in Bi-Ii alloys and held for decay
"~ Finally, the rare earths are hydrofluorlnated into a waste -
- salt for disposal,, : \ . :

Fuel salt is reconstltued by redu01ng recycle UF from

fhé fluorinator directly into the purified LiF-BeF -ThF4

carrier, Gaseous reaction products (HF and excess Hé) from
UF reduction are treated to remove volatile fission products
and recycled. A portion of the HF is electrolyzed to provide

- F, for fluorlnatlon.

 
 

 

. Reductive extraction and metsl trensfer operations are
carried out at about 6L0°C; fluorlnatlon and hydrofluorina-
tion can be conducted at 550 600°C, ~ Molybdenum is the
assumed construction material for vessels that conteined.
molten bismuth and bismuth-salt mixtures; Hastelloy N was
used for vessels oontalning only molten fluoride salt

o Keywords: Fluoride'Salt-Processing, MSBR, Reductive
Extraction Process, Metal Transfer Process, Fluorination, .
Fuel Cycle Cost, Capital Cost, Fused Fluoride Salts, . Chem-
»1cal Processing, Fission Product Heat Generstion, Process
D981gn, Blsmuth Mblybdenum, Protactinium

 

SUMMARY

An essential objective of the design &nd devélopmental'sffort on &
molten salt'breeder resctorr(MSBR) is & satisfactory and economic reproc-
essing method for the irradiated ffiel | As procossihg development'advancés .
in the laboratony and on an englneerlng scele, it is informative to relate
the oonoeptual process to the operation of the reactor and to the cost of
producing power, We have made & preliminary de51gn and oost estimate for
& processing plant that uses the fluorlnation—-reductlve extraction—-metal
transfer process to determine capital 1nvestment and fuel cycle costs,
Our study was for an integrated processing facility for treating irradi-
' ated LiF-BeF,-ThF,-UF, fuel from a single-fluid, 1000-Mi(e) MSER on a
'10-day cycle., The estimated capital and fuel cycle costs are:

 

Cagitai Costs | | o o 10° $
Direct costs | o | o 20,568 . -
~ Indirect costs ... 15,046
Total plant inveStment o o ‘35,61h
Fuel Cycle Costs (80% plant faotor) S  ,'m111s/kwhr |
Fixed charges 0,696
Reactor inventory (flss11e; - o - 0.328
Reactor inventory (nonflss11e) | 7 . 0,061
Processing plant 1nventory (fissile) = 0,029
Processing plant inventory (nonfissile) - 0,012 ‘
. Operating charges : , ... . 0,079 .
Production Credit (3.27%/yr fuel yield) . -0.089

Net Fuel Cycle Cost ‘ | L6

o

a)

4
The costs are for installed process equipment, piping, instrumentation,
.thermal,insfilation, electrical supply, sempling stations, and various |
auxiliary equipment including pumps, electricel heaters, refrigeration
system, and process'gas:supply and purification‘Systems. The estimate |
does not include site, site preparation, and building costs er the cost

of facilities and equipment Shared'with the_reector plantj these costs

are included in the overall cost of the power station, - Installed spare
equipment and redundant cooling circuits for fail-safe design are also

not included Molybdenum was the aSSumed éonstrucfiiOn naterial for all
equipment that contained blsmuth or blsmuth-salt maxtures, Hastelloy N

was used for vessels that contalned only molten salt

.‘Irrad;ated fuel ;s removed contlnuously from the reactor'and held
~ about 30 minutes for decay of short-lived fission products (see Fig. 1).
- Most of tne-nraniumisithen removed_fi& fluorinafiion.end is qnickly're- |
cycled by reduction with hydrogen into-previously processed salt that is
returning to'the'reactor. Tne salt is then contaeted'in an extractien
column with bismuth contalnlng about 0,2 at.% lithium metal and 0,25 at,®
thorium metal reductants to extract protactinlum, zirconium, and the
remaining uranium, The uranium- and protactlnlum-free salt flows to a
second extraction colum where & large portion of the rare earths, al-
kaline earths, and alkali metel fission products are extracted by further
contact wifh'Bi-Li reductant. Some thorium is also extracted, The salt
is then'recenstifuted.nith recycle and makeup nraninm, treated to remove
entrained bismnth c°rros10n products, end suspended particulates.’ The
! UB*/U4+ concentratlon ratlo is adgusted and the salt is returned to the
-\reactor. | | | | | |

The bismuth effluent'frbn the‘firS£aextrsctionveolumn'is hydroflu-'
orinated in the presence -of reclrculatlng LJ.F-Tth,-ZrF4 PaF4 salt to
oxidize 253Pa, uranium, and zirconium to soluble fluorides which dissolve
'1n the salt; unused llthlum ‘and thorium reductants also transfer to the
salt, The clean bismuth recelves makeup reductant and returns to the
process. Protactinium-233 is isolated from the rest pf the process in |
. the salt phase and held for deeay. To avoid 2 large uranium inventory,

the protactinium decay salt is fluorinated on a one-day cycle, and,

 
 

Fecvered
ECYCLED
TO PROCESS

Hy 6L5
PURIFICATION

H2

fpUGRINE M| misTicaTion I :

 

SALY UF, —emyFy |
PURIFICATION REDUCTION |

INT

FUEL SALY BISMUTH
-—— . s e

 

 

 

 

v

REACTOR I P

 

 

FLUORINATION

£

‘Fig. 1. -

by the Fluorlnatlon-—Reductive Extraction--Mbtal Transfer Process._

    

 

' —— -
E RACTION
RARE EARTHS
N.KlLI M T‘L‘r
ALKALINE
F---_-_- ---d
. - .
Ufg f
PRODUC
EXTRACTION
(Pe, U, Iv)
UFg
e e —

 

   

t33p, DECAY

 

 

 

 

 
 

—— —— —— —— -

" [T uFy Recovery
AND
WASTE RETENTION

HF

_———————b
» r |
|
i

ORNL DWG 72140

+Ct

 

 

[ ————
|
(
. |
2+
© EXTRACTION .
AC ATION
we2+ IN Bi-80 ol % bt | -

 

 

 

v

T

- wd e ——— r-ssvonmooucrs
T WASTE
———— Tt a:cwh:o

 

 

 

 

£\

EXTRACTION
(FISSION T
INTO LiC1)

 

. (€l . i
- —— o

Li METAL

o4
" EXTRACTION b
: ACCUMULATION
Red IN Bi=5 of. % Li
- ) 1
—— s o )
- q

Conceptual Flow Diagram for Processn.ng -a Single Fluid MSBR

. @

 
n

al

every 220 days, about 25 ft° of the salt is withdrawn, held for 2>Pa
decay, fluorinated, and'disCarded to purge accumulated fission products,

LiF, ThF4,'and some corrosion prcducts. The F,-UFg stream from this

fluorinator contains uranium of the highest isotcpic purity in the proc-

essing plant; therefore,“a pcrtion of this stream is withdrawn to remove:

excess uranium above that required to refuel the reactor,

Fissicn;products removed from the carrier selt in the second extrac-
tion column are transferred from—Bi4Li solution to molten lithium chloride;
however, the distribution coefficient for thorium between LiCl and Bi-Li
solution is much lower'than'that of the rare earths and uery little tho-
rium transfers, The lithium'chloride-circulates_ih a closed loop,vand'
is treated in two steps to isolate the rare earths'ahdvalkaline earths,
The'entire LiCl stream is contacted with Bi-5 at.% Li alldy to strip

trivalent rare earths into the metal; about two percent of this treated

stream is then Stripped.uith Bi-50 at,% Li alloy to remove divalent rare

earths and alkaline earths, Alkali metals (rubidium, cesium) remain in

the llthlum chloride and are removed by occa51onally dlscardlng a small

 volume of the salt. FlSSlon products bulld up in the two Bi-Li alloys

and are purged,perlodlcally by hydrofluorlnatlng relatively small volumes
of each alloy in the presence of a molten waste salt.
Large fractions‘of some classes. of fission products (noble gases,

noble and seminoble metals) are presumed to be removed from the fuel salt

'1n the reactor, and for these, the process1ng plant is not designed to

handle the MSBR'S full productlon. Noble gases are sparged from the
01rcu1at1ng fuel in the reactor wlth inert gas on a 50 sec cycle, and
noble and semlnoble metals are expected to plate out on reactor and heat
exchanger surfaces on a relatlvely short cycle. A removal cycle time of

2.l hours was used for. thls study Since this cycle is Short compared

" to 10-day proce551ng qycle tlme, only about 0.1% of ‘these metals are

removed in the process1ng plant Halogenous flSSlon products are vola-

tilized in fluorination and are. removed from the process gas by scrubblng

| w1th aqueous caustlc solutlon after uranlum has been recovered

The capltal cost for the fluorlnatlon-areductlve extractlon--metal

transfer proce331ng plant is not strongly affected by throughput The

 
 

 

 

direct,_indirect, and total plant investments were $28;5'million;.$2b.0h1
million,randt$h8.5h1 million respectively:for a plant to process a 1000-
“Mi(e) MSBR.on a 3.33-day.cyole. The scale factor for capital cost versus |
| throughput is 0,28 for a’range of processing qycle times from 3 to 37 days.

Although con51derable knowledge has been galned in recent years on
processing molten fluoride salts, the current concept still has & number
of ‘major uncertalntles and problem areas that must be resolved to prove
‘its practlcablllty ‘From a chemical standp01nt the process is funda-
mentally sound; however, engineering- problems ere difficult, A basic
-problem is & material for containing bismuth and blsmuth—salt mlxtures,
moledenum has excellent corrosion res1stanoe,.but_the technology for
: fabrioating'complex shapes and systems is undevelOPed..-Graphite isa
Vpossible z2lternate material, howerer, its use introduces design and fab- .
rication difficulties particularly in joint design and.porosity |
Fluorlnatlon of a flowing salt stresm has been demonstrated but establish-
ing and malntalning a protective layer of frozen salt on the fluorinator
walls has not been demonstrated except in a fluorination 51mu1atlon.
Complete removal of entrained bismuth from molten salt, and satisfactory
-high-temperature 1nstrumentatlon for process control are yet to be de-
veloped and demonstrated. Experimental data from the MSRE indicate that -
noble metal fission products will dep051t on reactor surfaces as we have
. assumed in this study; if this is not the case, there will be & consider-
able effect on processing plant design in fac111t1es for handllng these

addltlonal f18$1on preoducts,
SCOPE OF THE DESIGN STUDY

This design and cost study was made to estimate the cost of proc-
essing irradiated LiF-BeF -ThF4 UF, fuel'of a 1000-MW(e) molten-salt
breeder reactor, The proce531ng plant 1s an 1ntegrated facility that

shares conmon services and maintenance equlpment with the reactor and

power conversion plant, Fuel is treated contlnuously by the fluorlnatlon--f

reductive extractionfl-metal transfer process

C, )
o

<«

4

Our costs are based upon preliminary design caloulatlons of each
major item of process equipment, A sufficient study'was made of all
process operations to esteblish the geometry, heat transfer surface,
material of construction, coolant requirement, and other features that
influenced operability and cost of the'equipment . No plant layouts or

designs of'auxiliary equipment were made, Aux111ary 1tems such as pumps,

' sampllng statlons, reagent purification systems, etc., were 1dent1f1ed

by size and number in relatlvely broad categories from flowsheet require-
ments and a general knowledge of the overall plant layout. The costs of
magor equipment items were estlmated on the basis of unit cost per pound

of fabricated,material for the required shapes, fOr example, plate, tubing,

pipe, flanges; etc. The costs of conventional aux111ary equipment and

of f-the-shelf items were estimated from prev1ously developed molten salt

reactor proaect 1nformat10n.

Estimated costs for major and auxiliary equipment were the basis
for other diréct costs that could not be determined without detailed
designs and equipment layouts. Cost for piping, instrumentation, insula-
tion, etc,, were estimated'by taking various percentages of the installed_'
equipment costs, The applied factors wererobtained_from previous experi-
ence in chemical processing;plant_deSignland construction,

The study does not include allowances for site, site preparation,

buildings, and facilities shared with the reactor plant.' TheSe costs

are identified with the overall- cost of the power station and it is not

practicable to proratevthemlorer.various sections of the installation,
o Facilities‘andlequipment7for”treating the reactor off-gas are usually
- considered to be part of the reactor system and their cost was not in-

cluded, ‘Furthermore, our study was not sufficiently-detailed to determine

the'required‘duplication:of;eQUipmentVfor continuity of operations, nor .

: did we make'a thorough'safety'analysis that could resuit in additional .
'cost especially with regard to redundant and fail-safe coolant 01rcu1ts
VA more detailed study than ours mlght also show that add1t10na1 equipment
is needed to treat fuel and/or reactor coolant salt in case of accidental

_ cross contamlnatlon

 
 

For consisteocy with‘ihe cost study for-the referencc'moltén—salt .
breeder reactor,l wc‘have.based our costs on the 1970fvalue of the -
o dollar; Privétc ownerShip of the plant is assumed, Interest on borrowed
'-‘money for the three-year constructlon perlod is taken at 8% per year; no

'.escalatlon of costs durlng constructlon is taken into account Costs of."

- site, buildings, facilities and services, and reactor off-gas treatméht__

may be found in reference 1.
' THE MOLTEN SALT BREEDER REACTOR

Reactor Plant o

The processing plant of this study trects irfadiated fuel from the
'1000-Mw(e) reference molten salt breeder reactor descrlbed by Robertson.l,
The single-fluid resactor is fueled with’ 235UF4 in a carrier of molten
7LiF-BeF,-ThF, (72-16-12 mole %); about 0.3 mole % *°3UF, is required
- for criticality., The molten fuel is circulated at high éclocity in |
-cloSed loops consisting of the reactor core and primary heatvexchangcrs
(Fig. 2) wheré fission energy is transferred to & secondary coolant salt
for the production of supercritical steam at 1000°F and 3600 psia,
‘ FiSsioning'uranium in the core heats fihe salt to zbout 1300°F; this témf
perature is reduced to about 1050°F in the primany heat'exchaogers from

which the salt returns to the core to repeat the cycle, ‘A sidestream of

s&lt flows continuously through the fuel-salt drain tenk, and & very small

portion (0.87 gpm) of this stresm is routed continuously to thefprOcessing'

 plent for treatment. Processed salt is returned to the drain tank end
- then to the reactor, S |

‘A few pertinent data gbout the MSER are'given in_Table H

Fuel Salt

In a_sifigle-fluid'MSBR'the fertile material‘(thorium) is cerried in.
the fuel stream, and bred fuel is produced in the fuel salt, Most of the

‘bred fuel is burned to produce power; however, excess 256U amounting to
~ about 3,27% of the reactor 1nventory is produced each year and is recov- .

ered in the chemlcal processing plant,

€
 

( 1 w“ : | «} . o - -3

ORNL—DWG 70-11906
FLOW DIVIDER

 
 
 
 

 

1000°F 3600P
10 x 105 1b/hr

   

TO
BOTTLE
STORAGE 18

   
    
 

- CLEAN

   

700°F

 
 
 

HU50°F

  
   
    

1300°F

850°F
71 %108 b/

   
 

     

1050°F 95 x 108 Ib/hr

    
 
 

STACK

  
    

FREEZE
VALVE

CHEMICAL _E
PROCESSING I

Fig. 2. Simplified Flow Diagram of MSBR System, (1) Reactor, (2)
Primary heat exchanger, (3) Fuel-salt pump, (L) Coolant-salt pump, (5)
Steam generator, (6) Steam reheater, (7) Reheat steam preheater, (8)

- Steam turbine-generator, (9) Steam condenser, (10) Feedwater booster
pump, (11) Fuel-salt drain tank, (12) Bubble generator, (13) Gas sepa-

. rator, (1};) Entrainment separator, (15) Holdup tank, (16) L7-hr Xe
holdup charcoal bed, (17) Long-delay charcoal bed, (18) Gas cleanup and
compressor system, .

 
 

 

10

Teble 1. Selected Data for the Molten Selt Breeder Reactor”

 

Reactor Flant

Gross fission heat generation L 2250 MA(t)

Gross electrical generation = - 1035 Mi(e)
Net electrical output | - | 1000 Mw(e)
Net overall thermal efficiency W LW
Reactor vessel o 2e2,2ftIDx 20 £t high
- Construction material for reactor . : Hastelloy N - ,
.vessel and heat exchanger , - - o
Moderator = - ~Graphite (bare)
Fissile uranium inventory : o - 1346 kg
Breeding ratio | | - 1,06
Fuel yield - 3.27%/year
Doubling time, compounded contlnuously . 22 years : _ .
at 80% plant factor | | ' e
Fuel Salt - | | = S | ‘ v
Components ' - LiF-BeFé-ThF4—UF
Composition ' e ' 71.7-16.0-12,0-0,3 mole %
Liquidus temperature | ~930°F (L499° c)
Isotopic enrichment in 7Li S - 99.995%
Volume in primary systemP | 1720 £t3

Processing cycle time | - 10 days

 

%pata taken from ref, 1.

- : bThe fuel salt volume used in our study was 1683 fta . The 1720-f£9 value
resulted from later calculations in optimlzlng the - MSBR, S ' _
 

.

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LA

")

11

A thermel-neutron reactor must be processed rather rapidly for both
fission prodfict and **®Pa removal if the reactor is to maintain favorable
breeding characteristics, &nd a significant advantage of the MSBR is the
ease of withdrawing fuel for processing. The moderately high absorption
cross section and large equilibrium inventory (~102 kg) of **°Pa make
this nuclide a significant neutron poison and require that its removal
rate by processing'be sbout four (or more) times its decay rate, that is,
a cycle time of about 10-dsys.‘-In this system the processing plant is |
an integral part of the installation, and irradiated fuel can flow easily
from the primary reactor circuit to the processing plant (Fig. 1). Treated
fuel is returned in a similar manner, The processihg,cycle time is de- |
termined from an economic_balance between the cost of prccessihg and the

creditvfrcmvincreased fuel yield, The cycle time for this study (10 days)

‘might not be the optimum because it was fixed to give the MSBR favorable

nuclear performance withoutrpriof knowledge of the processing cost.

Contaminants in the reactor fuel can be gfouped into three broad

categories with respect to their influence on processing plant design:1?

| (1) volatile fission products, (2} soluble fission and corrosion products,

and (3) fission products that have an afflnlty for surfaces in the reactor

system. “The flrst group 1ncludes the noble gases which are removed from
the reactor prlmsry system on about a 50-sec cycle by sparging the circu-
lating fuel W1th an inert gas, Therefore, these gases @re ohly a2 minor
con31derat10n in the design of the proce531ng plant, Experimental evi-
dence - suggests that portlons of the noble metal fluorides mlght also be
removed by sparging, but the data are inconclusive in establlshlng the
magnltude of this effect The ‘second group of flSSlon products has the

most effect on proce351ng plant deS1gn because thelr only means of re-

-moval is by process1ng the fuel salt, These f1551on products 1nc1ude :
primarily the halogens, elkal:. metals, ‘alkaline earths, and rare earths,
protactinium (as PaFg, is also soluble and ‘a very important nuclide in

h-_proce351ng plant de31gn because of 1ts hlgh specific decey heat (50, 8
'w/g) and 1arge equlllbrlum 1nventory. ‘The third group 1nc1udes the ndble
~ and seminoble metals which appears to attach themselves to surfaces in

the reasctor circuit, These metals are called "noble".because they are

 
 

12

_'noble with respect to the materlals of oonstructlon of the reactor &and R &\-)
- are normally in the reduced state in this system. The effect1ve cycle - |
tlme for this removal 1s'not deflnltely known but. is‘belleved_to be

&bout 2, L hr, the removal time used in this study, ‘This group of fission'
'products aceounts for sbout 30% of the total f1$Slon product decay heat, -
hence noble metals could become an 1mportant factor in proce551ng plant

: _de31gn 1f their removel in the reactor is not as efflclent &s we have

' assumed, or if they build up dep051ts that occa51ona11y bresk away end
'enter the proce551ng plant, - S { ~

Ehullibrlum Comp031tlon of the MBBR

The equ111br1um comp051tlon of the 1000-MW(e) MSER has been calcu-
lated by Bell® for use in this study and the results are given in Table 2,
- The fission product values are the sum of 1nd1v1dual values for_eveny '
isotope of the particular fission product, At equilibrium, g + f heat
generation by fission products is 91,9 NMQ which is L, 08% of the total -
thermal power, '

, Protactlnlum is processed on a 10-day cycle and held for decay in B o v
~ the processing plant The **®Pa 1nventony distribution between the | -
reactor and the processing plant is 20.6 kg and 81,8 kg respectlvely. |

Most of the fission products are removed from the fuel salt by |
several mechanisms, and the processing cycle time for éach givcn'in the
~table is for the dominant removal pfocess. Howcvér,'all rcmOVolproc-'
esses were considered in computing thc equilibrium COmpoéition,.forl'
.example, ncutron absorption;'plating out on reactor surfaces, extraction',‘
in the processing plent, fueifsait discard, or &ny other &pplicsgble
. method, ‘ ' '

BEHAVIOR OF FISSION PRODUCTS AND
FUEL SLT COMPONENTS IN PROCESSING

Flssion products and fuel component behav1or in the fluorlnatlon--
reductive extractlon--metal transfer process is more ea511y explained by =~ . 77
associatlng groups of elements w1th the pr1no1pal operatlon for thelr - ) \fivzv.
AR T TR Treemem—— T T TeTE—————————

13 3
!
. .
L - o | : )
- Table 2." PEguilibrium Composition and Hest Generation for Principal Radioactive Nuclides in the 10_00-1‘!4(9) MSER

Carrier Salt: LiF-BeF,-ThF, §

79-16=12 mole ¢ o ’
Cycle Time for Sait Through i
Processing Plant: 10 days : . !
Reactor Thermal Power: 2252 MW :
Fuel Salt Volume: 1683 £1° - ~ ‘ o
Breeding Ratio: 11,0637 ‘

i

}
fisslion Products - o

 

 

 

 

Processing o ‘ ' j ;
Element . Cycle Time Grams/cnf® : Beta Watts/cr® . Gamma Watts/cn® ' B + y Watts/cm®
sg 50 see - 4.08360 x 1072% 4.30620 x 0724 0.0 |  1.50620 x 10724
" Zn 2.4 hr : 2,74881 x 10722 3,4382) x 1070 3,15231 x 1070 - 3,75347 x 107°
Ga 2L hr ' 8,58LoL x 107® b, 208¢5 x 107" _ 1,62267 x{ 1078 : 5.93163 x 107%
' Ge N 7.07118 x 10720 5,32699 x 107° 2.15637 x 107° | 7.78336 x 107°
As 2.4 hr - 5.7€132 x 107*° ' 1,402 x 107 LB x 10t 1.72803 x 107
Se 2.4 br 2.03324 x 107 : 2.3LL497 x 107 | 1.60351 x 107 2.50532 x 1072
. Br 10 days i 5.09811 x 1077 | 1.18250 x 1072 1.53979 x, 1072 1,93648 x 107>
ke 50 sec. 2. 74746 x 107° | 3.47011 x 1072 : 1.63905 x 1072 . 3.04915 x 107
b 12 days 2.17168 x 1077 1.72154 x 107" , - 5.82752 x{ 107 - 2,30530 x 107t
Sr ¢ days - 2.L14L5 x 107% €.83795 x 1072 * 7.99L46 x 1072 . ‘ 1.L8324 x 107
Y i days - 2,61858 x 10"  1,35111 x 10 7.90656 x 1072 2,14176 x 107%
zr 10 days | 6,68950 x 107® 155792 x 107 . 1,7807L %1107 1,73599 x 1073
Nb 2.4 hr _ 6,26768 x 107 6.55LLL x 1072 1 3.57730 x!m'2 : 1,01317 x 107%
Mo b 2.69109 x 107" 126209 x 102 1.14136 x| 1072 - 2,70385 x 1072
Te 2,4 hr 1.40352 x 107® . 1.88519 x 1072 . 1.40781 x|107® 3.29300 x 107®
Ru 2,5 hr . 1.6630L x 1077 ' 6.85229 x 107* 3.13669 x;ao‘* : . 9,98897 x 10°*
Rh 2.5 hr | 3,64718 x 107° 0T x 107 2.65L75 x(107* -  B.669L7 x 107*
Pd 2,5 hr 6,6323 x 167° 2,48215 x 107 1,26885 x!1q‘° o 2.60901 x 107%
Ag 2.k hr 9,603 x 1071° 2.805L0 x 107 7.14535 x'107° |  A.5199L x 167t
cd 2,44 hr 1.84528 x 167° ' 1.141829 x 107* . B.oWTE x 107 o 2,22267 x 107*
In 2,4 br 1,96374 x 107*° 8.05530 x 107* S 7.80937 ;f10'* 1.586L7 x 107°
Sn 2.5 hr 5.33362 x 107° 3.64733°x 107% : 4, L8932 xw1o‘3 L.09626 x 1072
Sb Z,4 hr 7.05005 x 107° 1,11958 x 10"t 1,82056 x;1072 - - 1,30164 x 1072
Te 2.k hr 2,99511 x 1077 6.6L000 x 1072 ' 1.L2928 x}1o'? ‘ - B.06928 x 107*
I 10 days | L.56947 x 107® | 1,02468 x 107t 6.55365 x|10°2 " 1.68024 x 107t
Xe 50 sec - 5.94758 x 107° 3.38396 x 107% | 7.76081 x 107 | 3.16156 x 1072
cs - ‘¢ days ¢,35421 x 107 1$.51023 x 1072 " 3,826k2 x 1072 | 1.33666 x 107
Ba 16 days - 1,63160 x 107° 6.77054 x 1072 1,61180 x ;10 6.93212 x 102
ia 21 days: : 3.49987 x 107% - 8.02147 x 1072 ‘ 5.67829 x|1072 : 1.36548 x 107
Ce 16 days 9.£7732 x 10°% . 2248l x 107 5,12100 x 1073 - 3.83694 x 1072
Pr 30 days 3,L7094 x 1078 2,86306 x 1072 1.27302 x 1072 . L.13608 x 1072
Nd 30 days 1.11061 x 107 - 3.32523 x 107 6.80195 x 107 1.005L2 x 107
Pm 29 days 1,19068 x 10°% . 1,94832 x 107 1,057L8 x:107° ©3,00580 x 10°~°
S 27 days 1,17938 x 107  1.57257 x 107 1,718L0 xi107® 1, 7ubh x 107%
Pu 51 days | 2,46931 x 107® ' 2,95250 x 10-° 6.97780 x 107° 9,93030 x 107°
ad 30 days 2.57869 x 107" | 7.77752.x 1077 1.18335 x,1077 9.26088 x 1077
T - 30 days 8.0L5L9 x 107° ' 5.27005 x 107° 1.39630 x 1078 6.66635 x 1078
Dy 30 days: €.32113x 107*° 1.73535 x 107*° ' 3,06505 x 1071 2,04186 x 10°*°
Ho 30 days 1.5914) x 10712 5,27681 x 1072 8.66869 x 10718 5.27682 x 10712
Er 30 days 3.18597 x 10722 0,0 0.0 ' 0.0
| | k. L9TLY x 1074 N +.36011 5.68318 x 107 1.92842

(Contimmed)

 
 

‘Table 2, (Continued)

L

 

Nutlide

‘Fuel Components

_Amount 1n Reactor

 

 

 

Grams/cn® Fuel Circuit (keg)
238Th ~1.L4572 69,450
233 py 4,3226 x 10°* 20,6"
e 37433 x 1077 0.018 .
, 232y 12,5805 x 107% 1230
23by 9.3163 x 107 Ll
238y 2,315 x 107 116
33y 2,5200 x 107 120
337y 4.7592 x 107° 0.227
=31p 36116 x 107 17,2
- aseyy 1,3338 x 107¢ 0.063
=33 py L.3420 x 1078 0,207
5.3161 x 107

23PPu

1

1

0.0025

 

*For removal on a 10-day cycle.

 

 

A e
|

 

 

 
L)

¥

15

removal, Thisrelationship_is shown in Table 3, All chemical species
in the fuel salt can be divided into twelve groups, the members of'each
group haV1ng similar behavior in the processing plant The-primary'reA

moval operatlon is the domlnant process for the group, whereas, - the

;secondany removal operatlon is a downstream operation de51gned for
_removal of a dlfferent group but also effectlve in remov1ng components

'of a preV1ously removed group.

Noble gases,.sem;noble metals, and noble metals have only a small

influence on processing plant design because of their fast removal rate
in the reactor, However, soluble daughters of these nuclides will prob-

'ably reenter the fuel salt and be removed in the proce831ng plant,

Noble gases are sorbed from the inert sparge gas and retalned for decay

on. charcoal beds in the reactor off-gas circuit that 1s removed from the

| proce881ng plant Decay times are sufficient to decontamlnate the gas

from all krypton and-xénon 1sotopes except 85kr, which has a 10, 76-yr
half life, Krypton-BS is concentrated and stored in cylinders by routing

@ sidestream of the carrier_gas'thrOUgh either a;cryogenic operation.or

the more recently developed hydrocarbon sorption process,

There are small concentrations of heavy elementsr(neptunium and
protactinium) formed byfneutrOn oaptnre and decay, These elements are
easily extracted and will be held in the R53pg decay tank, Neptunium

can be fluorinated from the. salt but not as ea51ly as uranlum, therefore,

we can expect part of the neptunlum to behave 11ke uranium and be returned

to the reconstltuted fuel

| -THE-FLtpRiNATION--REDUCTIVE |
 EXTRACTION--METAL TRANSFER PROCESS -

- A 31mplif1ed flowsheet of the fluorlnatlon--reductlve extractlon—-

metal transfer process 1s shown 1n F1g 3, The plant can be d1v1ded into
_six areas each of which is characterlzed by 1ts prlmary process operation:
| _fluorlnatlon, protactlnlum extractlon and 1solatlon, rare earth extract1on

- and metal transfer, fuel reconstltutlon, gas recycle, and waste accumu-

lation., Fuel solt flows qulckly through the plant 50 that there is

minimal holdup of salt and uranlum.

-»

 

 
 

 

Table 3. Removal Methods for Fission Products and

16

Fuel Components in Processing MSBR Fuel

4

 

dhemical Group

Noble gases

Seminoble metals®

Noble metals’

Uranium
Halogens

.Zirconium and
protactinium

"Corrosion
products

-Trivalen:g rare
. earths

Divalent rare
earths

. Alkaline earths

Alkali metals

Carrier salt

- Components

Kr snd Xe; present
in szlt as elgments

Zn, Ga, Ge, As, Se

‘Wb, Mo, Tc, Ru, Rh,

Pd, Ag, Cd, In, Snm,
Sb, Te; present in
salt in reduced

: state

- %330' ESGU 2360’—

3“0’ “"U- present
in salt as fluorides

Er and I; present in

salt as bromides and
iodides

Zr and >>Pa; present
in s3lt as fluorides

. Wi, Fe, Cr; present

in salt as fluorides

Y, la, Ce, Pr, Nd,
Pm, Gd, Tb, Dy, Ho,
Er; present in salt
as fluorides

Sm and Eu; present

in salt as fluorides

Sr and Ba; present
in salt as fluorides

Rb and Cs; ‘present
in salt as fluorides

Ii, Be, Th; present.
as fluorides

- Primary Removal Ogeraticm

Sparging with ipert gas in re-
actor fuel circuit

Plating out on eurfaces in re-

actor vessel and heat exchangers

Plating 6ut on surfaces in re-
sctor vessel and heat sxchangers

Volatilization in primary flu-
orinator; recovered and recy-

.cled to regctor

Volatilisation in primary flu-
- orinator followed by isolation ‘

in ECOH solution

Reductivp extraction with Bi-
11 alloy in Pa extraction
column followed by isolation
in Pa decgy salt

" . Reductive extraction with Bi-

Li alloy in Pe extraction
colum followed by isolation
in Pa decay salt

Reductive extraction with Bi-
Li alley in rare sarth ex-
traction colwm; metal transfer
via LiCl to isolation in Bi-S

. at,f Ii solution

Reductive ext.raction with Bi-
1i alloy in rare earth ex-
traction column; metal transfer

.via LiCl to isclation in B:l-50

at.% 11 solution

Reductive e.itraction with Bi-
11 alley in rare earth ex-
traction columm; metal transfer
via 1iCl to isolation in Bi-59
at,? 11 solution

Reductive extraction with Bi-
Ii alloy in rare earth ex-
traction column' accumlat.ion
in LiC1

Fuel salt'discard to remove
~ excess Li added in reductive.

extraction units

Secondary Removal Ojerat’ion :

Purged 1n fluorinators and

. purge colums due to sparging

action of F, and H2

Reduction by Bi-Ii alloy in
reductive extraction; SeF,
volatilized ,_.‘m fluorinator .

W5, Mo, Tc, Ru, Rh, Sb, and Te
have volatile fluorides and

‘are removed in fluorinators;

Pd, Ag, Cd, In, and Sn reduced

“py Bi-I4 alloy in reductive

extraction

Reductive extraction with Bi-Li '
. alloy in Pa extractlon column .

followed by volatilization in
secondary fluorinator

Reduction to metallic particulates
by Hy in reduction column fol-.
lowed by filtration

#

Fuel salt discard
Fuel salt discard
Fuel salt discard

Fuel salt discard

 

allm"e recent information suggesta that Zn, Ga, Ge and As may not be in reduced state in this system and
plate out on am'faces' however, in this study t.hey were treated as if they did plate out, .

h!ttritm is not a rare earth but its bebavior is analogous. )
QRNL DG TI-188% W

, g e
s T0 FURGE COLUmNE VENT TO RTAER

   
   

{10 8CFR)

Hy o FRUM HYDROF L UORINATORS
A0 PURGE Cui.UWMNG

 

    
    

CAUSTIC

scHQY EVARORATION &N T LTI ADDIT

     
 
 
   
 
   

 

   

 

 

 

 

 

 

 

   

    
 
 

 

 

 

 

 

 

   

 

 

     
 
 
     
   
   
 
 
    

 

 

 

  

   

 

 

 

 

 

 

 

o
BALY fnE STORA 153 GM MOLE/DAY)
) . . ———- ——
3ALT MAKELR XOM M8~y et ° e e BT i e -
o 168 GALITATY
84F,174.8 G MOLE/DAY) 2 BALIMINY SCCUMULATION | .
T t .
THFGUOU S GM MOLE/DAY) . s "
g - T 'l .
. : ’ ! }
: : o ene ! e mmm .4 t
- . ! CARRIER SALT DiSCAND i
. ‘ ‘ (LF- BeFy-ThF |
2 """ . 2 !
. ’ - - he!
: & . - l . (730 GAL/DAYY l : STAIFPER - 1 O g
T o] g 2 o ' ————— L mesoanmgua® L. POGMRAELOM o,
Cos i r 1oAT TR AN @ 4 GAL/ORY) —
A r - o : P
54 . " N o
3 g . ‘ na. 1 rissdh Flooucr ! e
g1 ‘ T i TRANSEEN AATHINM ADDITION R
ol fiq i ™ |‘ } ToLLL - L.-.—-_J MW“EN*\‘!' 1 :
5 , b
: g_g ' .‘ ‘ BiSWUITH P
. g cob W Ta 3 L L o S
SALT SAEANGE KND B 1 WYDHOFLUDAINAT OAS Ao ation, 1 BT DALY *: P
e 1 g ‘ i N mltn.l'r” i r 1 !
‘gfi';;‘gm § / Lo om0 i i S e 4 B W G S S e -n\-l1 \ "é':'c:: i L
: \5 .-o;-'-q“\a'lnw—h-fl' 0 e s e e it e ] e i : -
e |24 GAL /M) : Fasiy i | 3 ! o
. . e a tr e - - et 2R ' e ‘ R
FueL SALT RE FURN i . i T P M MOLE L0 . : Vo
Ti AEACTGM . }] ‘ I aEpoen ey daiomn : L
1087 GAs #WINF ' o et : : II I: g
PRODUC v
” : Y ) t [
'
" : CONDARY \
. ' ! Fl:tuollfllwon t | F' b
. i i . g} q ' (-
. P } 1313 GRLIWING . i ' v
: 1
ALY FRUM AEACTOR e [
Lif -BeFy- THE g F g 0.:.?6.“_"':_!‘}'_& e : Vo
71 7-18.0-12.0- 3 MOLE % 1§ GAL AN 3 oo
10 87 GAL/AMN} )
1
i e STONAGE AMD DECAY aianoN PROOUCT ‘ T
LiF=They 2rfy-Pary - WABTE ALY AL Ao v
(H0-260-20-02 MOLE W LiTHRR ALDITION 1344 GAL/DAYY ‘o
150115 ¥ £371L G WO EDAYY vy
" Vo
y ! 1|
1
orimaRy- STREAMS 3 5 o
o L Bafp TM LT . s ET 2O DAYSY s P
s GEMITH ! . i 230+ DAY ! |
e i | 1G) Ca ' . Pg DECAY o
e i Py g ol
P Vo
1 [
‘ ! TGTR AL /NN o
|
- - - - ———— !

i
[ : - e mmmememsasm—As wSse—mum e
e imamemem e e ‘

. - Fig.‘B.: Flow Diagram of the Fluorination--Reductive Extraction--
. Metal Transfer Process, Values apply to processing a_TOOOwMW(e) MSBR
on a 10-day cycle. o :

Li

 

 
 

 

 

g

‘ | Fluorination |
Irradiated fuel salt from the MSER enters the processing plant at
. ebout 0,87 gal/mln and is held for ‘gbout 30 minutes to allow the decay
heat generatlon rate to drop from about 5L.6 to 12,6 Ki/ft>. (See the
detalled flowsheet in Appendix D for material and energy‘balance data )
The salt then flows to a fluorlnator where gbout 95% of the uranium is
f volatlllzed at about 550°G as UF .- The fluorlnator must be protected '
from catastrophlc attack by the Fé-molten salt mixture by a 1eyer of
frozen selt on wetted surfaces of the unit, Salt leaves ‘the fluorinator
and enters e similer column, which is also protected by frozen salt,
'where hydrogen gas reacts with dlssolved fluorine and UFg to produce HF

. &nd UF, respectively, The hydrogen &lso strips HF from the selt, prevent- B

ing corrosion of downstream equlpment

The fluorinator is also the primary removal unit for the halogens,'
which are oxidized to volatile Bng and IFE} Certain noble &nd semi-
noble metals, namely, Se,'Mo, Tc, Ru, Sb, and Te, are converted to :
_volatlle fluorldes by fluorine and are removed with the uranium, ,How- -
ever, as stated above, the equlllbrlum amounts of these metals in- the |
salt are small because of the 2, 4-hr removal time in the reactor. Re51d-
ual Kr and Xe are removed by the stripping actlon of Fy in the fluorlnator

and. H2 1n the purge column,

The principal reactions are:
In the fluorinator
2 UF, + Fp » 2 UFg
72UF5+F27'*~2.UF6,
2B + 5.F, »2 BrF + 267
2 I +5F2~>21F +2e
‘MM° + 3 Fy » (NM)Fg (NM = noble metal;

 

Tne last'equation illustrates a typical noble metal reaction{ The
behav1or of 211 noble and semlnoble metals is not completely understood
7 and other oxldatlon stetes might be present ’

In the purge column'r
Py + B, > 2 HF -
2 UFg + Hy » 2 UFy, + 2 HF

 
 

 

»

@

)

]

.

19

Protactirium Extraction &nd TIsolation

The salt stream, containing about 5% of the urenium and all of the

protactlnlum, enters the bottom of .a packed extraction column and is

contacted with a countercurrent stream of bismuth containing about 0,2
at, % lithium and 0,25 at, % thorium reductants, Protactinium and ura-

nium are reduced by lithium‘and thorium and extracted into the bismuth;
fission product zirconium, the remalnlng noble and seminoble metals, and
corrosion products are also extracted Salt 1eav1ng the top of the ex-

tractlon column is essentlally free of uranium and protactlnium.,

The'reductlve_extractlon column operates at about 6L0°C with a salt/

'-metal flow ratio around 6,7/1, Extraction is essentially complete for

the affected nuclides, Thorium can be extracted into the metal as shown

in the third equation below, However, operating conditions are_fixed to

minimize the extraction of thorium, and, since thorium is a reductant

for protactinium and uranium, it is partially returned-tohthe salt phase,

- The principal reactions occurring in the protactinium extraction column

are: Co
 PaF, (selt) + L Li(Bi) - L IiF (salt) + Pa(Bi)
UF, (salt) + 4 Li(Bi) - 4 I4iF (salt) + U(Bi)
ThF, (salt) + L Li(Bi) - L LiF (salt) + Th(Bi)
 UF, (salt) + Th(Bi) - ThF, (salt) + U(Bi)
PaF, (salt) + Th(Bi) —'»ThF,,, (salt) + Pa(Bi)
ZrF, (salt) + 4 Li(Bi) - L LiF (salt) + Zr(B:L)

| Gorrespondlng reactions between Ber and L1(Bl) or Th(Bi) do not occur,

As shown in the above reactions, reductive extractlon 1ncreases the LiF

content of the carrler salt‘ The excess is removed by dlscardlng a

rsmall amount of the csrrler 1n a later operatlon.

 

, Protactlnium Isolatlon System

" The metal stream from the reductlve extractlon column enters a ,'
hydrofluorlnator where 21l nuclldes dlssolved in the blsmuth are ox1dlzed..
to fluorldes with HF gas ‘at about €L0°C in the presence of LiF-ThF,-
ZrF,-PaF, (71.00-25.97—2.8h-0,19 mole %) salt. The oxidized materials
transfer to the salt. A minuscule stream (0.6 gal/day) of Bi-Li alloy

 
 

20
from the divalent.rare earth accumulation system‘also enters|the'hydro;
“fluorinator, Fission products and 1ithium in this stream -ere &lso
converted to fluorides which transfer to the salt, A cleen bismuth
stream leaves the hydrofluorinator;. Part of it is reconstituted.with ,
lithium reductant and returned to the rére earth removal system, the
remalnder is made 1nto Bl-SO at., % Li allqy fof the divalent rare earth
accumulation system, ‘

The protactinium isoiation system consists of a 150-ft3 volume of

_: - L1F-ThF4-ZrF4-PaF szlt circulatlng in a closed 1oop con51sting of the
' hydrofluorinator, fluorlnator, purge column, and *>°Pa decay tank, ‘The

system has no direct communication with arezs of the plant handling fuel
selt, meking it an effective safeguard against the accidentai'return of
~ large quantities of **°Pa or fission products,to the reactor, At equi-
‘1ibrium sbout 81,8 kg 23%Pa, which is 80% of the plant inirentofir, is in.
the ®°%°Pg isolation system, This system is the largest source. of decay

" heat, generatlng gbout L, MW of 233pp decey hest &nd 1,7 Md of fission -

 

product decay heat,

| Steady state concentrations are estzblished for the components of
the system by regulating their removal rate, Uranlum is removed by
fluorlnatlng the salt 1mmed1ate1y upon 1eav1ng the nydrofluorlnator,
most of the UFé being sent dlrectly to the UF, reductlon unit for recom-
bination with fuel carrier salt. 'Ekcess'uranium above that'needed to '
refuel the reactor is withdrawn at this point, The entire volume of
salt is fluorinated on a one-day cycle so that the uraniumxinventony'is

egbout that from one day's decay of the 263Pa 1nventony (~2,6 kg U).

The volume of salt in the protactinium decay system slowly increases
due to the addition of fission products, 11th1um, and thorium 1n the
, hydrofluorlnator._ The volume is allowed to build up to 175 £t2; then &
25-ft> batch is withdrawn and the cycle is repeated," The ‘calculated
cycle tims'is 220 days, This perlodlc discard of salt purges f1ss1on
'products and establishes the composition of the system. Discarded salt e

- is held for %*°Pa decay, fluorinated, and sent to waste,i
 

"

o

.

"

21

Rere Earth Extraction and Metal Trensfer

Uranium- and protactinium-free salt from the protactinium ektraction

. column enters the bottom of & second extraction column and is contacted

with Bi-0,2 at. % 1i-0.25 at, % Th alloy to extract some of the rare
earths, alkaline earths, and slkali metals. Effective cycle times (see
Table. 2) range from about 16 days for barlum, strontium, and cerium to

51 days for europium;  the effective cycle tlme for 2all elements is about
25 days, Thus, extraction efficiencies range from 20 to 60% for individ-
ual elements, About 2, h'gal/day ofrthe treated salt is discarded to

 maintain a lithium balance on the system, BeF, -ThF4 makeup is added and

the salt is sent to the UF reduction unit for fuel reconstitution, _
Excess lithium enters the carrier salt in the reductive extraction oper-

ations,

"~ Metal Transfer to LiCl .

 

The bismuth stream containing-fission products flows'to.another
packed column where it is contacted with LiCl at about 640°C, Fission
products.transfer from the metal to the salt., Although some thorium is
extracted from tfie fluoride salt with the_rare earths, only a very small
amount of thorium trensfers to the chloride salt; thus, large separation
factors are achieved between thorium and rare earths, Separation factors
for Th/RE®* and Th/RE2* are as lerge as 10* and 40P respectively.*® The

LiCl salt is a captive volume of 20 f£t®; fission products build up to

,steady state concentrat1ons determlned by their decay rates and removal

rates 1n the- two rare earth strlppers. It is believed that the alkali

.metals, rubldlumland cesium; will remain in the LiCl salt, and e_15—yr

discard cycle has beeh'eSShmedeto purge'these fisSion products,

‘At steady state, the L101 salt contalns about e.31 at., g rubidium,

L. 36 at, & ce51um, 0,29 at % dlvalent rare earths and alkaline earths,
- and O 00C1 at, % trlvalent rare earths. The heat generation is about
15.2 kW/fta | |

 
 

22

Rare Earth Str;pplng

 

- Rare earths and alkallne earths are contlnuousxy strlpped from LiCl

by passing the salt countercurrent to Bi-Li alloys contaln;pg h1gh,L1
~ concentrations in two,packed.coluMhs as shown in Fig. 3. The entire
salt stream flows through one contactor in which trivalent rare esrths
and a small amount of divalent rare earths are stripped-into Bi-S at, &
S Li elloy,by reduction.wifih lithium, About two percent of the,salt frop
this;celumnis diverted to a_second‘eolumh where divaleht rare earths
~ and slkaline earths are stripped into Bi-50 at.‘%Alithium alloy. The
‘divalent spec1es are more difficult to strip and requlre the hlgher
lithium concentration, Salt streams from the two columns are recombined
end returned to'the primary extractcg compieting the cyCIe.
| Trlvalent f1351on products are held for dec&y in the metal and sent o
| to waste by semlcontlnuously hydrofluorlnating small. batches of the B1-L1—'
fission product solution in the presence of waste salt, The divalent -
nuclides:are'purged via the protactinium dec&y system by periodieally
| hydrofluorinatlng batches of the metal in the presence of the clrculatlng
_protactlnlum decgy salt, This mode of operatlon also serves to add
11th1um to the protactinium decay salt, a necessary requirement to
malntaln an acceptably low-melting composition (llquldus temperature
~568°C), Equilibrium concentrations ofVREE_’+ and RE®* in bismuth of

the trivalent stripper system are about 0,46 at, % and 0.013 at, %
respectively;-corresponding values in the divalent stripper system are
~ gbout 0,19 at. % and 0,96 at, ¥. About 27 £t> of Bi-S at, % lithium
alloy and 18 £t° of Bi-50 at, % lithium alloy are required to reduce
heat generation to tolersble rates whlch at steady state, are 40,8
'kWVft9 and 23,5 k‘W/ft3 respectlvely. |

 

Chemical Reactions in Reduetive Ektractioh and'MetalsTransfer. |

We can'more eesily_understend the reductive extraction--metel trans-
~ fer process by summarizing the reactions that occur at each step, - Using

a trivalent rare earth as an example, we obtain for |

" Reductive Extraction:

RE®" (fuel salt) + 3Li(Bi)B1-0’2 atf'% 13

3Li* (fuel salt) + RE(Bi)
 

-

a) .

23

Metal Trensfer to 1iC1:
RE(Bi) + 3Li* chloride s&lt)
Stripping into Bi-Ii Alloy:

Rz (chlorlde selt) + 3L1(B1)
RE(Bi)

Hydrofluorlnotlon to Waste:

REéBl) + 3HF(gas)<EEEEE—§2£3 rE>Y (waste salt) + 3F" (waste salt) +
1.5H, »

Other fission products arevsimilarly transferred, If we add the above_

LiCl salt 3 Li(Bi) + RE®* (chloride sealt)

Bi-> at, Z L 314+ (enloride salt) +

reactions, we find that the net effect is to transfer z RE®* atom from
the fuel salt to a waste fluoride salt and to add three lithium atoms to
the fuel salt..'Aléo 1.5 molecules of H, gas are produced,

| Fuel Reconstitution

After removal of rare earths, the fuel salt is reconstituted with

recycled uranium in the reduction column. The UF,-F, mixturo is &bsorbed

- in UF,-bearing salt and contacted with hydrogen reductant at about 600°C
forming UF, dlrectly in the molten salt, Wetted surfaces of the column

are protected from corrosive attack by a layer of frozen salt, Gaseous
reaction products. primerily hydrogen and hydrogén'fluoride, are contam-
inated by small amounts of volatile fission products, principally compounds
I, Br, Se, ahd Te., It is belleved that most of the volatile noble metal
fluorides accompanylng the UF will be reduced to metals in the reduction
column and remain in the salt, However, the fluorides of I, Br, Se, and

Te will probably be'redfioed-to HI; HBr, H,Se, and H,Te, compounds that

- are very volatile, The gas is-treated to remove fission products and .

recycled.
Small amounts oflnoble“gasés, formed by decay in the processing
plant, would be‘removedifrom the salt at this point,

'ijtal Reduction and Bismufh Removal

Reconstituted fuel Salt“flows'to a second gas/liquid contactor where

it'is‘tfeatod with hydrogen'gas to reduce corrosion'products to metals,

to reduce some of the UF, to UF;, and to strip any residual HF from the

 

 
 

 

 

o

'sali Since there might be entralned.blsmuth in the salt the stream is
" passed through a bed of nickel wool for bismuth removel Blsmuth must
be removed before fuel enters the reactor c1rcu1t because of its reactlv-

1ty with nlckel-base allqys ‘of which the reactor is constructed,

Flltratlon and Velence Adgustment

 

_ Reduced metal partlculates ‘are flltered from the salt and, if nec-
essary, a further treatment with hydrogen reductant is made to obtzin
the proper'U5+/U4+ ratio, The salt thenfenters aifeedgtank, which holds
ahout a 304min supply of fuel;,where occasional semples are taken‘for

‘laboratory_analysis.VrThe processed,fuel then returns to the reactor.

Gas Recycle

Process gases.used in MSBR salt processing are treated to remove
fission pfoducts and recycled, -Mixtures of Hy-HF from the UF, reduction
column, sparge columns, and.hydrofluorlnators are compressed to gbout |
two atmospheres pressure and cooled to 11que£y HE which is then dlstllled
at essentially total reflux to separate more volatlle flsS1on product
compounds (prlmarlly HI, HBr, and probably H,Se &nd HéTe) from hydrogen
fluoride, The condenser for the still is kept at -hO C to minimize the
loss of hydrogen fluoride. A portlon of the HF is recycled to the hydro-
fluorinators and the remainder is electrolyzed in a fluorine'cell‘to make
Fy and H,, which are reused in the fluorinators and sparge columns re-

spectively,

 

. Halogen Removal |

~ The hydrogen stream containing the volatile fission'products passes:‘
through a potass1um hydroxide scrub solutlon to remove hydrogen bromlde,
hydrogen iodide, and the equlllbrlum quantity of hydrogen fluorlde.
~ Selenium and tellurium compounds are not expected to react wlth the '
caustic solution, but pass out with the effluent_hydrogen. About 20 ft°
of.solution is required to naintain»a tolerable.specificfheat generetion
rate, which, at-steady state, is about 210 kW, primarily frofi”iodine deceay.
The solution is»reCycled through the scrub column until the KOH.concentra-'
tion decreaSes from fOM to O.SM;_then it is evepofeted to & solid waste

~and stored. .

r
 

%)

25

Noble Metel and Noble Gas Removal

 

Most of the hydrogen stream is dried in regenerative silica gel
units and recycled to the UF, reduction column, However, about five

percent is withdrawn to purge volatile selenium and tellurium compounde'

~ and noble gases,. The stream.passes through granular, activated alumina

for sorption of selenium and tellurium (prdbably HQSe and H,Te) and
through charcoal. for sorptlon of krypton and xenon, The purified hydrogen

is vented to the stack

‘Waste Accumulation

 

Fluoride Salt Waste
Most of the waste is withdrawn from the'procese at fouf points and.

accumnlated as a molten fluoride salt in retentlon tanks. ‘Two of the

‘streams are Bi-Ii alloy solutions contalnlng dlvalent and trlvalent rare

earths, and two are fluoride salt streams, one from the *>®Pa decay sys-

tem and one from barren fuel carrier discard. The.divalent.rare earths

‘are hydrofluorinated into the 23®Pa decay salt semicontinuously and re-

moved when 25 ft® batches of the salt are discarded'ahd.combined_with

_ fuel carrier sdlt discard. The trivalent rare earths are hydrofluorin- -

ated intO'eombined'protectihifim discard selt'and fuel carrier discard,
The total waste volume is sbout 92,5 f1t> every 220 operating days, The

batch is then fluorinated. to recover traces of uranium that mlght have

-entered the waste from a process 1neff101ency, and sent to & waste accu-
-mulation tank, Waste is accumulated for six batches (about L.5 calendar

yeare) and set,aside‘te dede_en'additional 9 years befOre'permanent

: disposal.

The eompositiongand,heat generation in a filled waste tank is given

in Table h,_and*a deeayecurye for the fission products is shown in Fig. L,

Weste From Gas Recycle System

Wastes generated in the gas recycle system come from the neutrali-

zation of fission product bromine and iodine in KOH solutlon, the_

~ sorption of selenium and tellurium compounds.en activated 2lumina, and

 

 

 
 

 

 

2

' Téble'h Comp051t10n and Heat Generatlon in 1000-Mw(e) MSBR Fluorlde'waste

 

 

Waste volume =554, 8 ft®
Liquidus temperature & 625°C : |
~ Accumulation time = 1320 operating days
o | = 1650 calendar days
Molar density = 1580 g mole/ft°
S . Heat Generation®
', Mole % : (watts/£12)
LiF . | . 73.8
' BeF, | = 11,3
ThF, - | S | - 13.4 . -
Divalent rare earth and &lkaline ' '0,2 - bs,2
earth fluorides (Sr, Ba, Sm, Eu) L L
Trivalent rare earth fluoridesd | | 0.7 192
(Y, La, Ce, Pr, Nd, Pm, Gd, To, Dy, Ho, Er) | o
ZrF, . 0.6 - 15.2
Noble and seminoble metal fluorides 0.009 - 28.3

(Zn, Ga, Ge, As, Se, Nb, Mo, Te, Ru, Rh, Pd,
Ag, Cd, In, Sn, Sb, Te) _ _
- Other fission products ' - negligible

 

®Heat generation at completion of filling period.

bYttrium is included because it behaves like a trivalentrrarevearth.
HEAT GENERATION (kw)

 

.

»

ORNL-DWG-71-12795

 

 

 

T II-IIIIII-. T T T

[

1

 

 

 

L ] 1T 1T 1T 77117 l , I I - T 17T T 1 l] | i ', LIRS
B 2250 mw (1) MSBR 7
- 554.8 ft* WASTE VOLUME -
| 2806 g fp's/ft3
HEAT GENERATION AT COMPLETION
. OF FILLING PERIOD
103 -
[02; -
o o o | - = = =
= = > = > , -
= 0 - :; 0 o 8 8 .
10 g ol | Lt i ||||||nl ll ||' 1[11|| ! INNEEY
I 10, 103 10% 10°

DECAY TIME (days)

Fig. L.

Heatheneration by Fission Products ih Waste Tank,

The

waste tank is filled by adding the waste in 6 batches of 92.5 3 each,
A batch of waste salt is added every 220. operatlng days (275 calendar

days). .

Le
 

28

accumulation‘of miscellaneous fission products.inthe,electrol&te of the ,
,fluorlne cell, The latter two'wastes are smell' and only infrequent -
changlng of the 2lumina end electrolyte is required., However, abou£

20 ft° of caustic solution must be evaporated to & solid residue every
'BL,dsys;v Condensate from the evaporatlon is reused to make fresh KOH j

- solution. A L5-dzy decay period is necessary before evaporatlon so that
intolerable temperatures in the cake cen be avolded. The waste is evap-
orated and'shipped’in the lergest permissible container (2 ft OD x 10 ft
long)11 for salt mine storage, thus mlnlmlzlng the cost of cans, shipment,
end mine storage. About 2.1 cans of waste are produced per year,

" The curves in Fig, S show heat generation in the KOH scrubber solu-

~ tion durlng fission product accumulation and subsequent decay. The

equilibrium hezt generation is sbout 210 kW, reached in sbout 1000 hours
of on-stream operation. The composition of material in the reservoir at

completion of the 3L-day accumulation period is given in'TablelS;

Teble 5, Composition of Caustic Scrubber
Solution in Gas Recycle System

 

 

Accumulation time = 34 days-
Volume = 20. 1t
Mole % =
(water-free basis) -

KOH " 5,0

KF - | ol 7 S

KI | | 70,06 o,

Xe® 0.1 | .
. CsF o 0.06

KBr | | 0,02

Kr2 - o - 0,0009

 

&Noble gases from decay of bromine and iodine assumed to remaln in
solut1on.‘ ,

Process Losses

Loss of fissile material from the fluorlnatlon--reductlve extractlon—-'

o metal transfer process can be made as small as desired without any modi-

f;catlons to the conceptuel\des;gn. Referring to the process flowsheet
-
=

HEAT GENERATION (k

L

103 oy

 

" *) . ) » C

 

BT T

| A IlTllll 1 - T T 1 T1TT1 T I IIIIIII]

 

102

 

 

ORNL DWG 71-12797
T T 17 T TTT]

1

 

Il]lil

1

Illlll

1

 

 

~ Fig. 5.
- System,

1 £ gl 1 L1l 1 o1 il 1 L1
- , 10 , 102 103 104
TIME (hours) ‘ . .

Heat Generation in KOH Scrubber Solution of Gas Recyclé
 

 

30,7

(Fig. 3), it is'seen that only three waste streams rofitine1y=leave the
plant--a fluoride waste salt‘from the large retention tanks, the evap-

~ ‘orator residue from the KOH scrubber, and the hydrogen discsrd.stream
from the gas recycle system, The only one of these waste areas into
which very small emounts of uranium and/or_protactinium_normally flow
 is the large fluoride salt waste tank, | ' |

Fluorlde Salt thte

 

The 220- -day holdup of combined 233py decay salt and carrier salt
discard allow gbout 99, 6% of the ®3°Pa to decay, and . the subsequent
batch fluorination can recover &ll but sbout 1 ppm 2350’1n the salt
without difficulty, There are sbout 10,023 kg of waste salt in the
‘batch so that the %22V remaining is approximately 10 grems;, Undecayed
'23%pa is an additional LS g, making about 55 g of unrecovered fissile
'materlal in the salt sent to waste retentlon. Since the excess 233y
production is gbout 165 g/dey, the unrecovered materiel (55 g/220 days)
represents only 0.15% of the breed;ng gain, However, the waste salt is
held in‘the large retention tank for 9 years'after.filling'before ship- '
‘ment to permanent disposal, At the end of this time (13,5 years) the
salt cafi be fluorinated sgain to recover &ll.but 1 ppm'ZBSU from the.-l
.betch ~Thus, only about 60 g 2337] would remain in the final waste, be1ng
an in31gn1f1cant loss of about 0, 007&% of the breedlng galn.'

KOH Scrubber Waste

 

Thelprobability of uranium loss via the KOH scrubber--evaporator'

- waste is extremely small Before UFg can reach the caustic scrubber it
must pass through three unit operatlons in series that are very effectlve
'iat remov1ng UFg: . first, the primary UF,-to-UF, reduction unit must fall
to function properly thereby allowing UF; to enter the gas recycle - system;
secondly, NaF sorbers, 1nstalled es a safeguard agalnst such a malfunction,
would have to be ineffective at trapplng the UFg;. and thirdly, any UF,

in the gas after the NaF sorbers would remain in the bottoms of the HF
still and be trapped in the electrolyte 1n the fluorlne cell, ‘Since dis- .
carded electrolyte is routed through the fluoride salt waste system,~

descrlbed ebove, any uranium 1n the salt would be recovered by fluorlnatlon.:
 

ot

»

oy

)

v)

Hydrogen Discard

 

There is practically no opportunity for UFy to leave the plant in
the hydrogen discard stream, In order to reach this point UF; would -

‘have to pass throfigh all the gas treating operations described gbove

plus additionsl sorbers for'trapping selenium and tellurium fission

l products and noble gases,

' DESIGN AND COST ESTIMATE

The first step in preparlng the cost estimate was to define the .
sequence of operations that constitute the flowsheet as shown in Fig, 3.
and in more detail on the draw1ngs in Appendix D, These operatlons were

based upon laboratory and small-scale engineering data for batchwise

, pefformance of the various unit‘processes, and it was assumed that the

steps could be successfully operated on a continuous flow basis. Para-

‘metric studles were made to determine the breedlng performance of the

MSBR for various ways of operatlng the process;ng_plant, and from this
work basic conditions for the flowsheet were established, The computa-
tions did not necessarily determine the optimum economic processing cycle

since that presupposed kndwledge of processing costs, A computer pro-

gram® was used to calculate material and energy balances for each process

-operation, g1v1ng the ba31c data for equlpment de51gn.

A preliminary, highly simplified design was made for each major

equipment item in order‘feAesteblish its size, geometry, heet transfer

_surface, and special-featureslfrom which the amounts of materisls requir-

ed for the vessel could'be'eelculated Materials of construction were

"selected u81ng the general criterla that all vessels contalnlng blsmuth

' would be constructed of molybdenum and that vessels contalnlng only
emolten,fluorlde saltlwould,be made of,Hastelloy N. In other areas,

. particularly for auxiliaryflequipment,-nickel,-Stainless steel, and mild
”'steel were used, The timeischedule'for the cost estimate did not permit

us to make_thorofigh'stfidieslef-eachevessel, and, for expedieney,‘certain -
shortcuts were adofited‘to'preclude making lengthy Stress’and heat trans-

fer calculations, .The principal time-saving assumptions were:
 

32

Small tanks, columns, and vessels to be made of 3/8- in. plate,
larger ones of 1/2 -in, plate

" Heat exchanger tublng to be 1/2-1n. OD x 16 gauge for all ves-
sels

‘Overall heat transfer coefficients to be in ‘range 50 200 Btu/hr-
£t°-°F depending on fluids and.whether natural or forced
convection -

‘Annular space in Jacketed vessels to be & nom1na1 one-1nch
thickness : :

Den31ty, thermal conduct1v1ty, and specific heat values ‘for proc-,
ess fluids to be average values rather than temperature dependent

Freeboard volume standardized at 25% of required process volume
for tanks with fluctuating levels and 10% for tanks with constant
levels '

Number of nozzles and thickness and number of supports and baf-
fles for heat exchanger bundles estimated from & cursory
examination of the vessel diameter and length

'-All heat exchanger bundles to be U-tube constructlon

The cost of each installed vessel was estlmated using the unlt costs
for materieals glven in Table 6, A single price of $200/pound was used o
for all moLdeenum structursal shapes. -The fabricetion.ofAmolybdenum -
into conventional shapes and vessels is extremely difficul£ and is not
current technology; the $200/pound figure represents & "best guess" of
the cost.

Unit costs of Hastelloy N were taken from the conceptual design

~ study® .of the 1000-Mi(e) MSER power plant and are, therefore, character-
istic of the fabrication of large vessels., In our case, components are -
generailysmall‘and\intricately constructed, factors tha£ are conducive-'
to higher unit costs. However, we believed'that'refining the costs was

5un3ust1f1ed in view of other. uncertalntles 1n the estimate,

Our study did not contain a sufficiently detailed de81gn for d1-
rectly estimating the cost of a1l items in the plant, For the cost of
‘some items, for exampie, piping, instrumentation, insulation, and elec-
trieal connections; we estimated charges by taking various percentages‘
offthe installed equipment cost{r In nsing_this procedure the high cost
of molybdenum equipment was teken into-account by.notfusing as ierge a

- percentage on the molybdenum eqnipment_cOSts_as was used for nonmoiybdennm
 

ol

@

)

o)

w)

33

‘Table 6, Unit Costs‘of Installed Equipment

 

Hastelloy N, Nickel, and Stainless Steel

Plate .=

Flanges

.Heads

Pipe _

Tube - - :
Nozzles, tube sheets, baffles

: Molzbdenum -

Cost for all structural shapes
3/8 in, Raschig rings

$/1b

13
10
20
25
30
25

200
35

 

 
 

3L

_‘equipmeut Auxlliary equipment 1tems were estlmated.by determlning
quantltles and sizes (e.g., pumps, heaters, gas supply stations, sam-
'plers, etc,) and u51ng avallable cost data from other areas of the MSR
program. Parazllel lines of equlpment for 1mproved operatlng rellablllty
- were not 1nc1uded except that gas compressors were dupllcated because
diaphram lifetimes are known to be very,short Also.two spare high

' level waste storsge tenks were included, No ellowances were made for
safety related features such as'redundant cooling circuits, prevention
of iiquid metal coolant-selt reactions, etc. No facilities are provided
for cleaning up fuel salt should it become contaminated by NaBF4'coo1ant
or vice verse, nor is there equlpment for processing routine (p0331b1y
contamlnated) liquid waste that orlglnates in the reactor system.'

The results of our study are summarized in Tables Ts 8 and 9;
these tables divide the equipment into three types--molybdenum, Hast-
elloy N, and auxiliary equipment'respectively.r The total installed cost
~of molybdenum process vessels- is $h,578'750 ; ebout 65%dof7this cost is ._
for the three largest vessels, which are the lithium chloride extraction ,
column and the: two large reservoirs for Bi-Li alloy in the rare earth
1solatlon system, Hastelloy N process equipment costs $3,091, 370, The
most costly items are the 233Pa decay tank ($710, h90),'ihich has‘a heat
‘ duty of about 5.9 Mw, and the three waste tanks, which cost $h66 600

each,

" The auxlllary equipment of Table 9 costs $2,486,290, These items
are essential for startup and/or smooth operation of the plant. In
several cases the costs were computed for entire systems which consisted
.of & number of individual operations, The costs were estlmated from -
‘data for similar systems and no flow dlagrams or design calculations

were made,
CAPITAL COST OF THE PLANT
A summary of our cost study is given in Table 10, 'We'estimated‘di-

rect costs for the fabricated and installed equipmentgof.$20.568 million_
‘and indirect costs of $15.046 million for a total plant investment-o£
o

 

35

Table 7, Description of Molybdenum Process Equipment

Fuel Cycle Time
Reactor Power

= 10 days
= 1000 MW(e)

; Fission Product

NaK Coolant

 

(Continued)

 

 

 

B T ‘ - Heat Transfer . Heat Generation Installed
Equipment Item and Principal Function Description Surface® (£t?) | Rate® (kW) Flow® (gpm) Inventory - Cost ($)
| T | |
zsapa EXTRACTION COLUMN:--packed column Bi/salt con- é in, ID x 10 ft packed 0.7 9.2 3.4 Mo g U 127,670
tactor for extracting **°Pa, U, and Zr from salt section; 8 in, ID x 1 ft ' g 0.62 (**>Pa) 26| g “°Pa
into Bi-Li alloy enlarged ends; cooling g 0.99) £1° salt
- | . o ‘ tubes. in packing ‘ . _ ! , 0.3p £1t3 Bi
RARE EARTH EXTRACTION COLUMN--packed column Bi/salt 7 in, ID x 6 £t packed .2 9.5 3.2 2,37| £t° salt 119,400
contactor for extracting rare earths, alkali metals, section; 12 in, ID x 16 ‘ 0.85| ££° Bi
and alkaline earths from salt into Bi-Li alloy " in, enlarged ends; cooling .
, o , tubes in packing - !
_ BISHUI‘H DUMP TANK--reservoir to hold Bi-Li alloy 1.6 £t ID x 4.8 ft; shell- 12.9 3 13.0 4,5 985 g,V 151,100
upon dump of extraction columns and-tube construction i L.0o (*®®Pa) 78 % 253 pa
: 8 £t° Bi
, | | o (on dump oénly)
14C1 EXTRACTION COLUMN--packed column Bi/LiCl con- 14,5 in, ID x 6 ft packed 225 o 49,8 52,3 9,78 ££* LiCl 509,790
tactor for metal transfer of fission products from section; 20.5 in, ID x 2 ‘ ! 2,74 £1° Bi
Bi/Li alloy into Licl : ft enlarged ends; cooling !
tubes in packing '
ms:'** STRIPPER;-packed columm Bi/LiCl contactor for 13,75 in, ID x 2 ft packed 227 161.5 53.0 6,43 ££° Lic1 377,780
stripping trivalent rare earths from IiCl into section; 20,5 in, ID x 2 - 2,0 £t® Bi ‘
Bi-5 at, # Li alloy ‘ft enlarged ends; cooling -
o : o . tubes in packing
RE®* STRIPPER--packed column Bi/LiCl contactor for 1,75 in, ID x L ft packed ° L3 L8 1.7 0.22) £t LiC1 26,300 (Mo)
stripping divalent rare earths and alkaline earths . section; ! in, ID x 1 ft - 4.3 (jacket) - : 0.07| £t Bi 4,630 (Hast N)
from LiCl into Bi-50 at, % Ii alloey enlarged ends; completely ' ;
' ‘ enclosed in Hastelloy N
jacket; cooling tubes in
enlarged end sections ;
RE®* BISMUTH RESERVOIR--tank for holding Bi-5 at. % 2.9 £t ID x 8,75 ft; 1230 1230 L3t 271 £4° Bi 1,684,580
Ii alloy and trivalent rare earths shell-and-tube construction 12.6 kg 1i
RES*+ BISMUTH DRAWOFF TANK--gauge tank for batchwise 13,9 in, ID x 67 ing 38,85 :
removal of Bi-Li alloy containing fission products shell-and-tube construc- 23.3 (jacket) 61.8 21,6 L.5p £t Bi 152,440 (Mo)
to be hydrofluorinated into waste salt tion; completely jacketed (at drhwoff only) 7,530 (Hast N)
' _ ' ‘ ‘ , with Hastelloy N | ‘
RE®* BISMUTH RESERVOIR--tank for. holding Bi-50 at, 2.3 £t ID x 6,8 ft; L35 L3k 152 18 £4° Bi 797,690
- ¢ 14 alloy and divalent fission products shell-and-tube construc-
: ‘ - ' : "tion
RE?* BISMUTH DRAWOFF TANK--gauge tank for batch- 4.4 in, ID x 5 ft; 37.1 : 56 19,6 LUl £4° Bi - 146,200 (Mo)
wise removal of Bi-Li alloy containing divalent shell-and-tube construc- 21,1 (jacket) | (at drhwoff only) 6,720 (Hast N)
fission products to be hydrofluorinated into Pa tion; completely jacketed ! :
~decay salt with Hastelloy N
BISMUTH SURGE TANK--tank for flow and level control 6 in,-ID x 21 in,; Mo 2.8 2.2 2.0 66 g U 13,510
in Pa extraction colum cooling coil brazed on 1L g **%Pa :
: . outside 0.170 £° Bi

 

 
 

Table 7. (Contimued)

 

. Heat Transfer

Fission Product

NaK Coolant

Installed -

 

i - - o - ' ' i Hhat ngeration .
Enuipmant Item and Principal Function Description Strface® (£t3) : Flow® (gpm) Inventory Cost ($)
923 pa HYDROFLUORINATOR--packed column Bi/salt/HF 8 in. ID x 5 £t packed 1.7 8 25.0 2080 g %33Pa 178,960 (Mo) . -
contactor for oxidizing zaapa’ u, Zr, Rm? from: section; 16 in, ID x 2 _ P, 9 (jacket) 103 (%%3Pa) 236 gU 10,230 (Hast N)
Bi into Pa decay salt ft enlarged ends; cooling | 3 . ‘ '
: tubes inside colump also
b completely jacketed with.
o o Hastelloy N -
WASTE HYDROFLWORINATOR--tank for batchwise contact 15,7 in, ID x 59 in,; 2.2 168 73.8 2 £4° salt 225,900 (Mo)
‘of Bi/waste salt/HF to oxidize from Bi into shell-and-tube construc- P1,0 (jacket) - : 2.3 £t° Bt 5,910 (Hast N) =
salt : : tion; Hastelloy N jacket ‘ : '
- on straight side ' :
BISMUTH SKIMMER--tank for separating Bi-Li alloy 13.4 in, ID x L0 in.;- 12.7 (Jacket) 0.7 2.7 £t° Bi 67,430 (Mo)

from LiCl upon dump of metal transfer system
Total for process vessels {

 AUXILIARY HEAT EXCHANGERS--units installéd in
bismuth pipe lines for teuperature control of

" streams entering or leaving process vessels (9

‘required)

BISMUTH PUMPS--pumps for Bi-Ii alloy (5: required)

Bxsuuwu PUMPS--punps for Bi-Li alloy (L required)

Hastelloy N jacket on
sides and bottom

Small shell-and-tube heat 
"~ exchangers

101 to 0.2 gom; 20-ft Bi

head

8 to 15 gpm 20-£t Bi head,'

' Total for process vessels and auxiliary Mo equipment

‘ values refer to area of 3/8- in. OD x 0,065 in, wall cooling tubes;: area of jacket is denoted by "(jacket)"

b

®In some equipment, other coolants than NaK are used,-if so, it is so designated,

 

Vhlues refer to fission product decqy heat unless otherwise designated 'such as "(?33pa)h,

 

i3.0

 

|

 

0.6

‘, (upon dump only)

 

2,610 gHast'Nj -

4,578,750 (Mo)
37,630 (Hast N)

90, 000.

125,000

120,000 '

4,913,750
 

 

-

37

Table Bf

 

 

Description of Hastelloy N Procéss Equipment
1

1
Fuel Cycle Time = 10 days
Reactor Power = 1000 MW(e)fi

 

. : 'Fission Product
Heat Transfer Heéat Generation

 

{Continued)

tridge to hold Ni wool;
completely Jacketed

 

}

l

 

- _ ‘ . _ : NeK Coolant _ ‘ Installed
Equipment Item and Principal Function Description Surface® (ft®) 'Rate” (lW). Flow® (gpm) . Invéntory Cost ($)
¥ :
_ : - , ]
FEED TANK--vessel for receiving irradiated fuel 16,75 in, ID x 6 ft; 15,6 13,2 5.5 1,380 g U 12,390
salt from reactor and holding 30 min for fission  shell-and-tube construcs 2.4 (®®3Pa) : L7 g|*°®Pa
product decay tion : ' 3,86 £t® salt
PRIMARY FLUORINATOR--salt/F§ contactor for €,5 in, ID x 12 £t fluor- 29,3 {jacket) '! 12,4 54.8 903 g U 35,590
removing about 95%¢ of U, Br, and I from fuel salt ination section; all 0.94 (*23Pa) _ 18 g|*°®Pa.
' ‘ ‘ wetted surfaces protected 17.9 (reaction heat) 1.52 It® salt
by ~1/2-in,-thick layer ' ' :
of frozen salt on wall;
17 in. ID x 2 ft enlarged
_ top; completely jacketed
PURGE COLUMN--salt/H, contactor for reducing F, £,5 in, x 2 ft gas/liquid 29.3 (jacket) - o1 10.6 86(g U 35,590
and UF, dissolved in salt - contact section; 17 in. ID ' . 0.94 (*3%Pa) 18 g|*°>Pa
: x 2 ft enlarged top; all
wetted surfaces protected :
by ~ 1/2-in,-thick layer
of frozen salt on wall;
completely jacketed - é
SALT SURGE TANK--vessel for flow control between 9,%.in, ID x 2 ft; shell- 7.9 : ! 4.88 1.9 8lg U L,590
purge column and 2*®Pa extraction columm and-tube construction: ‘ 0,41 (233pa) - 8 g|***pa-
- : - - | 0,67 % salt
SALT SURGE TANK--vessel for flow control between 9.3 in., ID x 2 ft; shell- 5.5 ‘ 3,68 1.3 C.67 t° salt L4,5%0

. Pa extraction column and rare earth extraction - and-tube construction . “ .

. column . _ . ) _
SALT MAKEUP TANK--vessel for dissolution of 9.75 in, ID x 19.5 in.; 6.0 (jacket) 1.79 0.6 0.67 ft° salt 8,530, (tank)
BeF,-ThF, makeup salt jacketed vessel equipped ‘ ‘ ‘ , 20,000 (agitator)

with agitator )

SALT DISCARD TAN’K--vessel for holding 3-day batch 10.4 in, ID x 21 in, 6.2 (jacket) : 2.5 0.9 0,95 1Lt'~" salt 7,390

of disoarded fuel salt : completely jacketed tank ' ‘ (on drafloff only)
UF, REDUCTION COLUMN--salt/UF o/ Fa/Ha contactor for . 9.5 in. ID x 12 ft gas/ 36,6 £t* (jacket) I 6,3 11,1 1650 g 3k,510
reducing UF, to UF, directly into molten salt; also liquid contact section; % 2.09 £t° salt
converts excess F. to HF .- 13,5 in, ID x 2 ft en-

larged top; all wetted

surfaces protected by

~1/2-in, -thick layer of

frozen salt; completely

Jacketed
STRUCTURAL AND NOBLE METAL REDUCTION COLUMN--salt/ 8 in, ID x 12 ft gas/ 29 (jacket) 6.7 2.4 3080 g U 37,960
H, contactor for reducing metallic ions to metals liquid contact section; 2,68 ft° salt

‘ , : 12 in, ID x 2 ft en- '

larged top; completely

Jacketed
SALT SURGE TANK--vessel for flow control in 9,75 in. ID x 19,5 in,; 6.0 (Jacket) : 1.7 0.6 § 7,030
reduction column ' completely jacketed : 0. 67 t° salt '
BISMUTH TRAP--vessel packed with Ni wool for 5 in, ID x 50 ft pipe with 65.6 (jacket) 14,6 5.1 7310 g U 83,790
removing entrained Bi from salt (2 required) interior perforated car- _ 6,36 £t° salt
 

 

Table 6. (Contimued)

38

 

Heat Transfer

Fission Product

NeK Coolant

Installed

 

_sion of NaK in coclant circuit i‘or Pa’ decay. ta.nk
(continued)

 

 

S . ' X L . _ Heat Ggneration _ :
Equipment Item and Principal Function " Description Surface® (£t?) Rate” (W) Flow® (gpm) Inventory Cost ($)
 SALT CLEANUP FILTER--porous metal filter for 15 in, ID x 3 ft; contains 3.1 11,2 3.9 5870 g U 30,Lk0
removing metal particulates formed in noble metal © porous Ni filter; com- 13.7 - (jacket) E : S.1 £t salt
reduction column (2 required) pletely jacketed and : :
: contains cooling tubes o
REACTOR FEED TANK--vessel for 30-minute salt 1.5 £t ID x 3 f£t; com- 1 19,2 (Jacket) 7.2 2.5 - 4020 g U 19,8L0
holdup to allow. sampling before salt. returns to pletely jacketed ‘ : - : 3.5 £t% salt
reactor : o, - ‘ _
SAI.T DIMP TANK--tank to receive i‘uel salt upon 2,7 £t ID x 8 ft; shell- 36l 238 85 33 £1° salt 6§,h00
- dump of primary salt 1oop and-tube construction 5 (233pa) - (only on dump)
LiC1 RESERVOIR AND DUMP TANK--vessel for holding 2,b £t ID x 7,2 ft; shell- 460 306 107 20 £t° LiCl 8L, L70
. LiCl inventory as well as LiCl from eztraction and-tube construction . (22,7 ££°> on dump)
" column on system dump ‘ ‘
LiCl WASTE TANK--tank for storage of 1iC1 sent to 1.6 £t ID x 7.2 ft; shell- S 230 153 - 53,5 10 £ LiCl 38,780
waste . ) ~and-tube comstruction - ’
‘ }-l2 -HF COOLER--heat exchanger to cool HQ-HF gas 1.5 ft x U £t; finned 27 , 0.16 8.8 scfm 15,470
from UF, reduction column tubes inside shell ‘ 0.18 (sensible heat air
' ‘ in gas)
180°C NaF THAP--somtion bed to catch UFy that 8 in, ID x 6 ft; finned 3.8 é.4 1.6 20,760
might not be reduced in UF; reduction colu.mn tubes inside shell; NaF ' -
(2 required). , inside tubes o
STILL FEED CONDENSER--heat oxchanger for condensing 21 in, ID x 4 ft; finned RINY . 0,33 . 0.5 ton 17,120
HF-HI-HBr mixture at -LO°C for feed to HF still tubes inside shell i ; .‘ 1,38 (sensible heat) Freon .
'HF STILL--packed column for distilling volatile 1 in, ID x 15 £t packed 5.3 {jacket) 0.12 0.3 6,560
fission products (HI, HBr, SeF,, TeFa) from HF section; L in. ID x 1 ft ‘
solution - still pot; complet-ely
! Jacketed
HF CONDENSER—-heat exchanger for condensing HF at 17.5 in, ID x L £t finned . €,0 | 0.17 - 0.1 ton 13,300
-»hO'C from HF still tubes inside shell = 0.13 (latent heat) Freon
KOH SORBm--a.bsorption column for scrubbing recycle 5.6 in, ID x 6 ft packed 13.6 8.6 2,9 (water) 17,690
H, gas with 10M KOH to remove HF, HI and HBr section; 7 in, IDx 1 £t , ‘ ' :
' : enlarged top. ‘ .
KOH RESERVOIR--accumulator for fission product I 1,7 £t ID x 10 ft; shell- - 2Lk 210 1.7 L3,860
and '&' in 1OM KOH solution (2 required) and-tube construction (water) _ -
" GAS COOLER--heat exchanger to cool recycle Hy to 7.5 in, ID x 5 ft; shell- 10,9 0,16 0.1 ton 9,140
0°C to remove moisture . and-tube construction - 0,17 (latent heat) Freon ‘ :
COLD TRAP--heat exchanger kept at -LO°C to freeze 6 in, ID x 10 ft; finned 0.029 0,01 ton 16,8L0
moisture from recycle H, (2 required)L tubes inside shell Freon
SILICA GEL DRYER--sorber for removing last traces L in. ID x 5 ft; regener- 6,240
of moisture from recycle Hg (2 required) : - ative bed o
ALUMINA SORBER--activated alumina bed for Sorbing 26 in, ID x. 4.6 .ft; 4'&1,0;5 : 4.8 13,0 1.8 - 31,390
. SeFq and TeF, from H; discard streem in annular space; cooling ' (water)
' o - ) . tubes inside and outside
annulus
NaK EXPANSION TANK--vessel for volumetric expan- 1,6 £t ID x 6,5 ft; 88 304 10,210
&

 

 

 

 

39
|
Table 8, (COntinped) |
: _ Fission Product ‘ .
‘ ) ' Heat Transfer . Heat ngeration - NaK Coolant . Installed
Equipment Item and Principal Function’ Description Surface® (£t?) - | Rate” (kW) Flow® (gpm) Inventory Cost ($)
NaX EXPANSION TANK--vessel for volumetric expansion 1.2 f+ ID x 5,2 ft; SS 204 6, 380
of Nak in coolant circuit for RE®” bismuth system ' . ; «
NaX EXPANSION TANK--vessel ror volumetric expansion 10,8 in. ID x 3 € Tt ! 3,190
of NaK in coolant circuit for RE** bismuth system S35 204
Nak EXPANSION TANK~~vessel for volumetric expansion 7.5 in. ID x ?.6 ft; i 2,810
of NaK in coolant circuit for fluorinators S8 304 ";
NaK EXPANSION TANK--vessel for volumetric expansion 6.1 in, ID x 2,1 ft; l 1,780
of NaK in coolant circuit for extraction columns, S8 304 i L
Bi trap, and cleanup filters - 7 3
NaK EXPANSION TANK--vessél for volumetric expansion 11,6 in, ID x 2,9 ft; : 6,100
of Nak in coolant circuit for LiCl system ss FOL ' o '
NakK EXPANSION TANK--vessel. for volumetric expansion 8,7 in, ID x 2.9 ft; _\ 3,.570
of NaK coolant circuit for fuel salt dump tank- SS 30)4 f
SALT SURGE TANK--vessel for level and flow control 8 in, ID x 2 ft; com- o 5.0 : g.2 2.5 Mgl 5,220
-at Pa m'drofluorinator pletely jacketed - 14.1 (®>®Pa) 276 |g 23°Pa
. , | 0.59|ft® salt
SECONDARY FL[DRINATOfi--salt/Fa contactor for 7,5 in, ID x ‘C ft gas/ , 18.7 9.5 £0.8 $gU 23,270
removing U from Pa decay salt liquid contact section; : ‘ 25,8 (®55Pa) 508|g *>>Pa
: . ‘¢ in. ID x 1 ft enlarged’ 0.15 (reaction) 1,08{ft® salt
top; all wetted surfaces " o
-protected by ~1/2-in,-
thick layer of frozen salt;
‘ completely Jjacketed ‘
PURCE COLUMN--salt/H, contactor for reducing Fp - 5.5 in, ID x 10 £t gas/ 18,7 - 9.5 , £0.5 fgU 23,270
and UF, dissolved in Pa decay salt liquid contact section; 25,8 (®*3Pa) 508|g 2*3pa '
: ‘ 10 in, ID x 1 ft enlarged 1,08|ft® salt
top; all wetted surfaces
protected by ~ 1/2-in, -
thick layer of frozen salt;
‘ completely Jacketed
233pa DECAY TANK--vessel for isolation and decay 3,73 £t ID x 18,7 ft; ‘ 20l 1743 21,70 2618 g U 710,490
of *33pa, also accumulator for Zr and RE®™ fission shell-and-tube construc- 4150 (2°3py) 81,670 g 2>>Ppa ‘
' products ‘ tion; jacketed 150-115 £1® salt
‘ (varialhle volume)
22C-DAY 2°®Pa DECAY TANK--vessel for holding waste 25 in, -ID x 10 £t bottom 1477 249 370 uis g U 113,150
salt from Pa decay tank for ®**®Pa decay, also "section; L ft ID x 6,4k ft 675 (333Pps) 11,679 g 2*°Pa |
accumulates trivalent rare earths and fuel salt enlarged top section; 25-92, 4 £+3 salt
discard shell-and-tube construction; (varialjle volume)
Jacketed bottom section
WASTE FI'..II)RII‘ULTOR---s'n}.t./F2 contactor for removing 2.32 £t ID x 4.6 ft gas/ 85,3 1139 2Ll 18,5 |43 salt Lk, 510
. last traces of U from waste salt; batchwise liquid contact section;
operation 2.83 £t ID x 2 ft enlarged
top; top and bottom sections
Jacketed
(Contimed)
 

Table 8. (Continued) -

L0

 

' Hea'l';_‘ Transfer

Fission Product -

NaK Coolant

 

 

 

| ®In some equipmeht, other coolants than NaK are used; if so0, it is so desigmted.'

t

 

S ‘ - . : . ’ ' Heat Generation ' ‘ JInstalled
Equipment Item and Principal Function o Description ‘Surface® (ft3) - Rate” (kW) Flow® (gpm) Inventory Cost ($)
WASTE TANK--accumulator for all fluoride waste £,2 £t ID.x 22 £t shell- 835 1114 L90 - 555 £t° salt 1,399,800
streams; holds waste for fission product decay and-tube construction; . ' (filled) '
(3 required) ' , : S filled batchwise over ‘
: ‘ - : ‘ L.5-yr period
. 20% NaF BED--scrber for UF, withdrawn as product ' 4 in. ID x ¢ £t sorber . L, 360
o ‘ S . section filled with NaF '
pellets
- 3,091,370
4values refer to area of 3/5-1in. OD x 2.065 in, wall cooling tubes; area of jacket is denoted by ."(jacket)",
Plalues refer-to fission product decay hest unless otherwise designated such as "(**PPa)", ' '
AN

 

 
 

Table 9. Description of Auxiliary Equipment.

 

 

o ' : Installed
Pquipment Item Description and Function Cost (%)
Electric Héaiers' "Resistance elements embedded in ceramic; heat for vessels and - 5L2,190
- N lines : -
Auxiliary Heat Ekchangérs' ' .Assorted sizes for temperature cohtrol éf NaK cdblant; 25 réquired : 250,000
Refrigeration System 10-Ton system for cold trap; B | 3,800
lNéK Purificgtion Sjstem vaide refioval unit operating‘continuously on sideétream-of‘NaK 10,000 ,
510, Supply and fiémov#l‘&ystem Equipment for drying Si0O, pellets, charging to unit in cél11 and . 10,000
" _ . o removing from cell
-A1,04 Supply and Removhl'Systém . " Equipment for charging A1,05 to TeF, + Ser trap and removal 10,000
Fa Disposal_sfstem . ‘-fquiggent for reacting discarded Fé with Hé followed by sorption 5,000
‘ n
H, Disposal System Final cleanup of discarded H, before g01ng to stack 8,000
fnert Gas System ;' Inert gas supply and cleanup system for process. vessels 100,000
UFe Product fiithdrfiwfil Stqtioh BEquipment for removing UF, from process and putting into cylinders 7,500
Inert Gas Syétem for‘Cell' Continuously. recirculating inert atmosphere for cell, 0y, Fp, and ~ 175,000
. . 7 HF removal
F,, HF, and'HE.Supply Sysiems' - Purification of makeup process gases 3,000
Lithium Hbtal‘Handling Eqfiipment,‘ 'Equipment for receiving, storing, and adding 1i metal to process 15,000'
: o _ : o streams
BeF, + ThF‘ Additibn Systefi -.Facilitles for storing and preparing makeup salt iO,DOO
Coolant (NakK) Pumps | Electromagnetic pumps for circulating NaK in the several coolant 736,000
o - circuits; 15 required 7

ProcessISalt Pufips Pumps for fluoride carriér salt, waste salt, and Lici; 13 required 270,000
KOH Pump Recirculation of KOH thrbugh sorber in gaé treating system | 800
Compreséors :Compressors for uée in H,, HF, and Fé gas systems; 22/required‘ 330,000

2,186,290

 

 

-L"{
 

h2

Table 10, Capital Cost of a Fluorination--Reductive Extraction=-
| Metal Transfer Processing Flant for a 1000*MW(e)%MSBR )

 

Reactor Fuel Volume = 1683 ft®
Fuel Cycle Time = 10 days
10° §
Installed Mblybdenum Process Ehulpment ' S - - L4579
- Installed Molybdenum .Pumps S - . 25
Installed Molybdenum Heat Exchangers o e 90
' Installed Molybdenum Piping - . L7
Installed Hastelloy N, Stainless Steel, and Nlckel Ehulpment ‘ 3091
Installed Hastelloy. N Jackets on Mblybdennm Vessels | o | 38
Installed Auxiliary Equipment - L | 21,86
Process Piping (other than molybdenum.piplng) ' S ..o 2342
- Process Instrumentation - ] I 2711
Cell Electrical Connections - A Lok
Thermal Insulation : ; .- 588
Radiation Monitoring | o | o 150
Sampling Stations - - ’ | 1275
Fluorine Plant . - i - ' 1005 -
Total Direct Cost | | B | 20568 -
Construction Overhead : | ' ,. | oy
Engineering and Inspection - . | 3790
- Taxes and Insurance . o ' 86l
Contingency ' ' 2836
Subtotal , | B o 32172
Interest During Construction | - - S 3L, -'

Total Plant Investment S . - 3561L

 
L3

 $35.614 million. These costs do not include the cost of site, site prepe
aration, buildings, end facilities shared with the reactor plant such as
heat sinks, maintenance equlpment and emergency cooling, The cost of
these facilities were estlmated by Robertson® .and are 1ncluded in the
design and cost study of the 1OOQ—MW(e) MSBR,

Items of direct cost that were not obtained from preliminary designs
were estimated as percenteges of the installed equipment cost, The per-
centages were based upon previous experience in the design of rediochemical
plants, Pifiing,.instrumentation, electrical connections, and insulation
costs were estimated in this wey, Charges for radiation monitoring de-
vices, sampling stations,”and a remotely operated fluorine plant were
estimated from other ififOrmatien. The discussion below describes our

method of finding these costs.

Process Piping

| Pifiing,costs for a remotely eperated processing plant are normally
in the range L0 to 50% of the.cost of installed process equipment. We
estimated the costs separately for moljbdenum, Hastelloy N, and auxiliary
piping, choosing factors of 30%, 50%, and L0% respectively. The low per-
centage value was used for molybdenum because of the relatively small
amount of this piping and the uncertalnty in the base prlce ($200/lb)
chosen for molybdenum, The calculated costs are:

[ (cost of installed Mo process equipment) + (cost

of Mo pumps) + cost of Mo heat exchangers)] (0. 30)
[$L,578,700 + 245,000 + 90, 0001 (0. 30) —
$1,47L,100 —

[cost of 1nsta11ed Hastellqy N equlp-
ment] (0,50)

[$3,091,000 + 38, ooo1 (0. so)

$1,561,500

[(cost of. installed auxlllary equ1pment) -
(cost of electric heaters)] (0.L0)

182,186,290 - 5L2, 90] (0.ho)

$777 6bo |

Mo piping costs

A n4

ll

| Hastelloy N plplng cost

II'

~ Auxilisry piping cest

 

 
 

 

b

Process Insfrumentation

Process instrumentation refers to devices for monltorlng and con-
trolllng the operatlon of the plant through measurements of flowrates,
temperatures, pressures, concentratlons, 11qu1d 1evels, or other pertJ.- |
nent quantities, Generally the 1nstrumentatlon cost is sbout 30% of the |
insfialled equipment cosfi. Instrumentationicost for-molybdenum equipment |
was charged st'10%'of the installed equipment cost, The lower percentage
allows for the inordinately high cost of fabricated molybdenum vessels,
‘-Heater instrumentation was charged at only 15% of the installed heater
cost because such instrumentation is stralghtforward. We determ;ned the
cost as follows: | o | | ‘

Instrumentatlon cost for Hastelloy N equipment ' '
[ (cost of installed Hastelloy N equlpment) + (cost of Hastellqy
N piping)] (0. 30) - |
1$3,091,000 + 38,000 + 1 Séh 500] (o. 30)
$1,L08,000

Instrumentation cost for suxiliary equipment

[ (cost of installed auxiliary equipment) - (cost of electric
heaters)] (0.30)

[$2,u486,290 - 542,190] (0.20)

$583,2oo

Instrumentation cost for heaters
[cost of heaters] (0,15)
[$5h2 1901 (0.15)

81,300

Instrumentatlon cost for Mb equlpment ‘

= [ (cost of Mo equipment) + (cost of Mo pumps) + (cost of Mo
heat exchangers) + (cost of Mo piping)] (0.10)

[ $4,578,750 + 245,000 + 90,000 + 1,47k,100] (O, .o)

$638, 800

Total cost of instrumentation = $2, 71*,300 :

n ll

it u

v nn

Cell Electrical Conneotions‘

These connections are the power receptacles and lesds inside the
processing area for supplying power to heaters, electric motors, and
 instruments, The cost was taken to be 5% of Hsstelloy N end guxiliary
equipmenf and piping costs plus !.5% of molybdenum equlpment and piping

costs,
L5

Cost of cell electrical connections o :
= [(cost of Hastelloy N equipment and p1p1ng) + (cost of auxll-

'~ iary equipment and piping)] (0.05) + [cost of Mo equipment

and piping] (0,015)

[ $3,091,000 + 38,000 + 1,56L,500 + 2, hsé 290 + 777,6L0] (O, 05)

+ [$h,579 000 + 2h5,ooo + 90,000 + h?h,?OO] (o 015) |

$h93 700

1

'Thermal Insulation -

| The thermal insulation cost for & chemical processing‘plant_is usu-
ally about 5% of the equlpment and piping costs, We calcfilated the cost
‘of insulation for Hastelloy N and auxiliary equipment in this way; how-
ever, we excluded the costs of the cell inert gas system, fluorine and
hydrogen‘supply system, ahd inert gas blanket-system since'this.equipment
does not need insulation. Also we used only 50% of the piping cost
($388,820) for auxlllary equipment because it was estimated that only
- gbout one—half of this plplng would need insulation, For insulation on
moledenum equipment we factored the equlpment and piping costs at 3.5%,

Cost of thermal insulation.
= [(cost of Hastelloy N equipment) + (cost of Hastellqy N piping) +
~ (cost of auxiliary equipment) + (cost of auxiliary piping) -
(cost of inert gas blanket system) - (cost of cell inert gas
system) - (cost of Fy and H, supply system)] (0,05) + (cost
~of Mo equipment) + (cost of Mo piping)] (0.035)
[$3,094,000 + 38,000 + 1,564,500 + 2,486,290 + 388,820 -
100, ooo - 175,000 - 3, ooo1 (o 05) + 4,913,750 + 1,L7k,100]
(0.035)
$588, 100

N

Radietien'Mbnitoring -
Radlatlon monltorlng equlpment refers. to 1nstruments for enV1ron-

:mental monltorlng inside the processing cell, The post_of_these

,.'1nstruments_was,estlmated to be_$‘50,000.

Sampllng Statlons

A flowsheet rev1ew of plant operatlons 1ndlcated that salt and blS-'
B muth samples will be needed at elghteen places &nd gas samples at fifteen
places to ensure proper control over the plant, Each sample station is

- a shielded, instrumentated facility designed for remotely securing and

 
e o R it s i e e ot Y e .

 

kb6

trensmitting samplés without ccstaminating either the process or the

 environment. Seversl sampling points would be in each station to mini-

mize shielding costs'and_containment problems, Our estimete of the cost'-

' is'based'upon designs of similar'installations for engineering-experi-

ments and for MSRE installetions We estimated the cost of liquid

‘Vsamplers to be $50,000 each and gas samplers to be $25,000 each for a )
" total cost of $1 275,000 |

Fluorine Plant

The cost of mannfacturing fluorine and hydrogen on site by elec-

- trolyzing recycled hydrogen fluoride was compared with the cost of

purchasing these gases and disposing of unused excess &s waste, - Our

‘supplementary cost study (Appendix A) showed that once-through. operation

contributed about 0,11 mills/kWhr to the fuel cycle charge for the cost
of waste containers, shipping, salt mine disposal, fluorine, other chenm-
icals, and capital equipment, On the other hand, the corresponding'fuel-

. cycle charge for recycle operation including the fluorine plant was

gbout 0,02 mills/kWhr

We have estlmated the capital cost of a remotely. operated fluorlne

plant to be $1. 005 million; the cost includes labor, materlels, piping,

and 1nstrumentat10n.5 The‘plant is de81gned to produce 148 1bs Fé/day,

which allows about fifty percent utilization in the fluorinators, Hy-
drogen output.of the plant 'is used in UF, reduction and salt sparging.

Indirect Costs -

Indirect costs include construction overhead, engineering and in-

spection charges, taxes and 1nsurance, contingency, and 1nterest durlng

- construction, These costs were dbtalned &s descrlbed below.r”

‘Construction Overhead

On the basis of past experience for'the cost of chemical processing
plants this cost was ‘taken as 20% of the total direct cost and equal to
$h 114 mllllon. '
C

L7

Engineering and Inspection Charge

 

This charge was computed by the guidelines of NUS-531° which was
written specifically for reactor plants but was used in this study,
Plant engineering charges ere based upon the total direct costs of the
installation, which is $152,3 million* for the reactor plant plus
$20.568 million for the processing plant, The specified charge is 5.3%
of the direct cost of the processing;plant; | |

In addition, the cost guide specifies that a premium be added to
the agbove amount to account for the "novel" feature of the design, This
charge is also a function of the direct cost and for this filant is
$2,700,000. Although the use of a '"novel! design surchafge rather than
the lower-"prcven" design charge of $1,600,000 appears to violate the
condition that'the'cost estimate was to be for a plant'based.on developed
MSBR technology, it is our opinion that the complexlty of the plant is
such that the higher premlum'W1ll be required,

The total engineering charge ‘
($20,568,000) (0,053) + 2,700,000

nou

Taxes and Insurance

 

This account covers property and ell-risk insurance, state &nd local
property taxes on. the site and improvements durlng the construction pe-
r;od, and sales taxes on purchased materials, Using NUS 531 as & gulde
and taking the total direct:ccstof'thevinstallatlon as & ba31s, the
charge rate was found tofbefh;é%;; For taxcs and insurance the cost is
($20,568,000) (0,042) = $863,800, | o

Contingency

The contingency charge was tazken as 20% of the total direct cost
minus the ccst of molybdenum ccmponents."Wé'felt that the $200/pound
charge for fabr1cated mclybdenum equipment already contained a sufficient

contingency factor.
 

 

 

18

Contingency charge
B (cost of Mo pumps) - (cost of Mo heat ex-
changers) - (cost of Mo plpe)] (0.20) -
[ 20, 568 000 - 4,579,000 - 2&5,000 - 90,000 -
1 h?h,OOO] (o. 20)
$2 836,000 )

Interest, During Construction
, It was assumed that the procéssing plant would be built conéurrently
'Wlth the reactor plant over & three-year construction perlod " The in-

terest rate on borrowed money was taken &t 8%/year, end the total amount
to be borrowed during this time is the totel of direct and indirect

__costs equal to $32,172,000, Over 8 three-year period et & rate of B%fiyear,J

‘the interest charge is equivalent to 10. 7% of the total borrowed money
or $3,hh2 LOO |

FUEL CYCLE COST

- Inventory and use charges were valued at the unit costs given in
Table 11; inventory, net wofth Operéting charges, &nd fuel qycle costs
are given in Table 12, The gross fuel cycle cost is 1.21 mllls/kWhr
about 58% of this cost is contributed by fixed charges on the processing
plant and another 32% by the reactor inventory. The fuel yield of
3.27%/yr gives & production credit of &bout 0.09 mills/kWhr which is |
slightly more than the operating charges of about 0,08 mllls/kWhr The
net fuel cycle cost is about 1.12 mills/kWhr,

CAPITAL GOST VERSUS FLANT SIZE

' The usefulness of & cost estimate is greatly enhanced if the capital
cost can be related to plant throughput so that the most economic opera-
tion of the reactor system c&n be determlned . In this case we have &
 power station of predetermlned size [1000- MW(e)] so that, strlctly speak-
ing, cost-versus- throughput deta will apply only to & single 1000-MN(e) |
 MSBR. With these data, paremetric studies of the reactor plent-processing

plant complex can be made to find the optimum throughput and the lowest

[(total direct cost) - (cost of Mo equlpment) -

W
L9

Table 11, Basic Costs for Calculating
Inventory and Operating‘charges_

 

 

Item : " Tnit Cost
33y | | - 13 ¥e
236y = . 11,20 $/g
239 pg, | 13 $/g
284y | _ no charge
- R%8&y S o ~ no charge
LiFa - 15 $/1b
BeF, | o 7.50 $/1b
ThF, . 6,50 $/1p
Licl L 15 $/1b
Ii metal® 0.12 $/g
Bi | - 6 $/1b ,
HF. . 0.41 $/1b
CFP | 5.00 $/1b
H, - | 1.4l $/1b
KOH (45 wt,% solution) o 0.04 $/1b
Waste shipping® © 0,052 $/ton-mile
Salt mine storaged L4590 $/container

 

Isotoplc comp031t10n 99.995 at.% 7L1.

bFluorlne cost not needed for finding costs in
Table 12; used in computatlons of Appendlx A.

Rall shlpment

dBased on heat generatlon rate = 360 w/ft.of con-

tainer length, Data from "Siting of Fuel Reproce531ng -

Plants and Waste Management Fac111t1es," ORNL—hhS1,-
pp. 6- h7, Table 6 9 (July 1970)

 
Table 12. Net Worth and Fuel Cycle Cost for & 1000 Mi(e) MSBR
Fuel Cycle Time = 10 dgys ' '

 

 

 

 

 

 

 

Net Fuel Cycle Cost

Plant Factar = 80%
mills/kwhr
Fixed Charges at ‘13.71)year _
o ' - Value ($) A 7
‘Processing plant 35,614,000 " 0.6962
Reactor Inventory” at 13.2%/year
. Amount !kEZ
LiF 47,460 1,569,600 0,0296
BeF, 19,070 315,250 ~ 0.0059
" 93,720 1,342,940 0.0253
2337 1,223 . . .15,899,000 0.2995
::: 12 5 b 1,25h,too 0. 0226
Pa 20,57 - 267,410 0, 0050
: %0, 615, 600 0, 3569
Processing_Plént ‘Inv'en'tory at 13, 2%/year o
© LiF 4,583 151,570 0,0028
BeF, 372 6,160 0.0001 -
ThF 16,240 232,670 0.00LL
2337 33.5 435,500 . 0,0082
23861, 1.7 19,040 0.0204
235pg 81,84 1,063,920 0.0200
1iC1 ; ,016 33,600 0, 0026
Bismuth 15,920 210, 600 10,0040
5: 153,635 0
Qgen'at;i_qg Charges 7
Amount (kg/year) Cost ($/year)
714 metal 999 ©119,940° 0.0171
BeF, makeup 1,026 16,970 0.0024
ThF, makeup 9,020 129,260 - 0.018) -
HF makeup 920 3,530 10.0005
H, makeup 561 1,307 0.0002
KOH makeup 2,723 240 0. 0001
Waste disposal 87,000 0.012k -
Payroll 200,000 0.0285
?;B"‘ITT,z _._'7‘60.0 9
Gross Fuel Cycle Cost 1.2052
| Production Credit (3.27%/year fuel yield) : o
o Amount (kg/year) Income ($/year) - -
233y : 48,18 626, 340 . =0,089,
1,1158

 

g, c. Robertson, ed,, "Conceptual Desigh Study of & Single-Fluid Molten-Salt Breeder
Reactor," ORNL-4541, pp. 180, Table D.2 (June 1971).

bInven‘t,ory of 23%Pa is for equilibrium on a 10-day processing cycle. Above reference

gives *>°Pa inventory as 7 kg, which is for equilibrium on a 3-day cycle,"
 

51

- fuel cycle cost, Andthér way of decreasingrfuel cycle cost is to asso-

ciate a larger power plant, for example, two or ‘more 1000-MW(e) MSER's,
with a 51ng1e proce581ng faclllty, however, such a2 consideration was

beyond the scope of thls study,

‘We chose to estimate the capital cost of the fluorination—-reductive

extraction~--metal transfer proCesSing'plant for a throughput that is three

- times the rate used gbove, corresponding to & 3,33-day processing cycle

for the 1000-Mi(e) MSER, .The shorter cycle time was selected because it
was believed that, at cycle times longer than 10 days, the breeding gain
would be adversely affected by hlgher parasitic neutron losses to R33pg,

Our estimated capltal cost is given in Table 13, Direct costs are $28.5

 million, and indirect costs are $2O Oh mllllon for a total 1nvestment of
$h8 54 mllllon. o |

Capital costs for the plant for a 10-day (O 874 gal/mln) processing
cycle and the plant for a 3,33-day (2,62 gal/mln)rprocessrng-cycle are
plotted in Fig, 6, and & straight line is drawn between the points. The
curve is extrapolated to cover processing rates from 3 gal/mln to 0.24
gal/mln (cycle times = 3 to 37 days). Below & rate of O, 2h gal/mln, the
curve is drawn: horizontally at a capital cost of $25.m111;on.‘ It was

‘felt that $25 million'probably repreSents ahlower'limit‘for the cost of
~a plant of'the:present deSign. |

The cost-versus- throughput line has 2 slope of 0,28 which indicates

hthat the capital cost is not strongly affected by throughput However,
) the economic: advantage in fuel cycle cost of proce531ng a 1000-MW(e)
'MSBR on longer or shorter oycle ‘times than 10 days has not been caloulated.

It is apparent though that lower fuel cycle costs can be obtalned by proc-

_e531ng several 1000-MW(e; MSBR's in one proces51ng plant Although thls
HlS undoubtedly true, the curve of Fig. 6 is not an accurate representa-
'tlon of ‘the cost of proce551ng ‘several reactors because the addltlonal
-radloact1v1ty that would be handled by the plant would 1ncrease the cost
_'above that shown. : T L

 
 

o

Table 13, Capital Cost of a Fluorlna.tion—-Reductlve Eb:tractlon-_-

 Metal Transfer Process:.ng Pla.nt. for a 1000 MW(e) MSBR

Reactor fuel volume = 1683 ft"’ |
- Fuel cycle time = 3.33 days

 

Installed Molybdenum Process Equipment
Installed Molybdenum Pumps : _
Installed Molybdenum Heat Exchangers

- Installed Molybdenum Piping

Installed Hastelloy N, Stainless St.eel and Nickel Equlpment

. Installed Hastelloy N jackets on Molybdenum Vessels
Installed Auxiliary Equipment | |

Process Piping (other than Mo P:Lplng)

Process Instrumentation

Cell Electrical Gonnections

- Thermal Imnsulation

Radiation Monitoring

Sampling Stations

Fluorine Plant

Total Direct Cost

- Con_s'tx"uc'tion Overhead® b

- Engineering and Inspection
Taxes and Insurance® =
Contingencyd'

- Subtotal .

Interest During Construction

Total Plant Investment

3,581A
3,215
3,692
Lol

827

150
1,275
1,94

 

- 28,500

5,700

1,197
3,870

L43,8L9
Iy, 692

 

 

. 18,5u1

 

8504 of total direct cost

by 24 of total direct cost + '"novel" design premium of $3.1 million

h 2% of total dlrect cost

20% of total dlrect cost minus cost of Mo components
 

53

ol

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e J0J qndydnoayl Y3 TM JuUeld mnflmmmoonm JI9JSUBL], TB}S|--UOTIOBILXY

8ATRONPSY~-~UOTIBUTIONT B JO 3800 Tejtde) JO UOT}IBRTJBA 9 *3tq

(NINZIV9) 31vd OSNISS3O0Hd L1IVS

 

 

  
  

-82°0= 3d0TS

ol

 

dos

 

 

€466-12 9MA INYHO

00l

-~ ($g01) 1SOD TWLIAVD
 

gy

Cost Estimate for a 3, 33-Day Fuel Cycle Time

A complete rede51gn of the proce551ng plant wes not attempted to
- obtain the capital cost at the greater throughput However, the cost of
each item of equipment listed in Tables 7, 8, and 9 was recomputed.hy the
- following general procedures: ‘

Redesign and estimate the cost of- a few vessels that are typical

of the several types of equipment, e.g., tanks with internal heat
exchange surface, columns with frozen salt on walls, liquidfliquid |
contactors with internal heat exchange surface, etc, Compare the
cost of the redesigned vessel with its counterpart in the 10-day
cycle case and determine 2 scale factor from the relationship

'_ Ee@?\

' where n = scale factor ‘ ' ,
Cp= febricated vessel cost for 3. 33 -day cycle
C,= fabricated vessel cost for 10-day cycle :
Rz— flow rate through proce551ng plant for 3,33-day qycle ~
flow rate through processing plant for 10-day cycle

Determine the fabricated cost of the remaining vessels by using
~ the appropriate scale factor, the previously calculated cost for
the 10-day cycle cese, and the gbove equation, ’ -
Scale-factors for individuel pieces of equipment were in the range
0,52 to 0;82, however, ‘& number of items had & scale factorfeQual to
zero because their sizes were independent of processing rate, Typical
examples of vessels having zero scale factor are the *>®Pa decay tank,

the divalent rare earth accumulator, and the trivalent rare earth accu- |

mlator, Thus.the overall scale factor (0.28) for the plant is considerably -

below the velue of about 0,6 customarily associated with chemical'plantsQ

Installed costs for moledenum, Hastelloy N, and auxiliary equlp-
‘ment are given in Tables 1k, 15, and 16. An overall scale factor was
determined for each group of equipment by comparing the total costs from -
~ the above tables with the corresponding total from Tables 7, 8, and 9.
It was found that the molybdenum equipment scaled by & factor of 0. 31,
Hastelloy N equipment by a factor of O, 26 and the auxiliary equipment
by a factor of 0,33, These factors were used to determine some of the

direct»eosts given below,
 

55

Installéd Cost-of“Mfllybdénfifi Process Enuipment

 

 

Table 1k,
‘Fuel cycle time = 3,33 days
Reactor power . = 1000-Md(e)
- - Installed Cost
Item ($) '
233pg Extractlon Column 252,400
Rare Esrth Extraction Column 236,050
Bismuth Dump Tank _ 372,310
1iCl Extraction Column 1,256,120
RE®* Stripper " 930,090

RE2+_Stripper

RE®* Bismuth Reservoir |
RE5+-Bismuth Drawoff Tank

RE?* Bistuth Reservoir
- RE®* Bismuth Drawoff Tank

Bismuth'Surge Tank
233 pa Hydrofluorinator

Waste Hydrofluorinator
Bismuth Skimmer |
»

 Tota1 for‘Mb ProceSé Enuipmént:

- Auxxllary Heat Ekchangers
Blsmuth Pumps :

| Total for Mo Auxiliary Ehuipmént]_fi

51)990‘(Mb)_
8,200 (Hast N)

1 68h,580

152,540 (Mo)

7,530 (Hast N)_

797,690'

146,200 (Mo)
6,720 (Hast N)
26,710

208,490 (Mo)
11,920 (Hast N)

- 225,900 (Mo)
5,910 (Hast N)
133,310 (Mo) |

5,160 (Hast N)

6,071, 380 (o)

hS th (Hast N)
90 000 |

173,830 N
563,830

 
 

. 56

Table 15 Installed Cost of Hastellay N Process Enulpment

Fuel qycle time = 3.33 days
Reactor power . = 1000-MW(e)

 

Installed Cost

 

Item _($)
Feed Tank ) 30, 500
Primary Fluorinator - 63,030
. Purge Column : 63,030
Salt Surge Tank 11,300
Salt Surge Tank 11,300
"Salt Makeup Tank .50,530
Salt Discard Tank . . 9,640
' UFg Reduction Column 61,120
Structural and Noble Metal Reduction Column a \67 230
Salt Surge Tank . | 12,450
Bismuth Trap (2 requlred) : 1h8,390
Salt Cleanup Filter (2 requlred) 53,910
Reactor Feed Tank 35,140
'Salt Dump Tank 170,860
LiCl Reservoir and Dump Tank 8h,h7o -
LiCl Waste Tank 38,780
H,-HF Cooler 38,090 |
100°C NaF Trap (2 requlred) 51,110
Still Feed Condenser 42,150
HF Still 11,620
HF Condenser 32,740
KOH Sorber 25,370
KOH Reservoir (3 required) 43,860
Gas Cooler 22,500
~ Cold Trap (2 required) h1,460
Silica Gel Dryer (2 requlred) 11,050
Alumina Sorber "31,390
NaK Expansion Tank 10,210
NaK Expansion Tank - 6,380
NaK Expansion Tank 3,190
. .NaK Expansion Tank - L,980
- NaK Expansion Tank 3,150
NaK Expansion Tank 6,100
NaK Expansion Tank 6,320
Salt Surge Tank 5,220
~ Secondary Fluorinator 33,370
- Purge’Column 33,370
233pg Dect - 710,490
220-Day =3 Pa Decay Tank 169,720
Waste Fluorinator _ - 57,550
Waste Tank (3 required) 1 809 oL0
' 20 C NaF Bed . h2360
Total for Hastelloy N Process Equlpment - 4,127,370

 
57

Table 16, Installed Cost for Auxiliary Ehuipment‘

Fuel qule time
Reactor power

non

3.3
100

3:dqy5
000-MW(e)

 

Installed Cost

 

' Total for Auxiliary Equipment

Item ($)
Electric Heaters . 762,320
Auxiliary Heat Exchangers 300,000
Refrigeration System 5,760
NaK Purification System 10,000
Si0, Supply and Removal System 19,340
Al1;0, Supply and Removal System 10,000
. F; Disposal System 5,000
Hé Disposal System 8,000
Inert Ges Blanket System 100, 000
- UF; Product Withdrawal Station - 7,500
Inert Gas System for Cell 0 175,000 -
F,, H,, and HF Supply Systems 3,000
Lithium Metal Handling Equipment 20,400
BeF, + ThF, Addition System 13,600
Coolant (NaK)'Pumps . 979,620
Process Salt Pumps 523,730
Compressors - 638,220
3,581,490

 

 
 

 

58

Process Piping - B P
Piping costs were calculated as explained gbove for the plant oper-'
ating on a 10-day processing cycle,

[{cost of installed Mo process equipment) +. (cost
of Mo pumps) + (cost of Mo heat exchangers)] (O 30) .
[$6, 474,400 + h73,800 + 90,000] (0. 30)

$2,111,500

[cost of installed Hastelloy N equip-‘
- ment] (0,50) :

[ $4,127,370 -+ L5, hho] (0. 50)

$2,086, 1,00

[(cost of installed auxiliary equipment) -
(cost of electric heaters)] (0,40) ,

[$3,581,490 - 762, 320] (0.40) B

- $1,127,700

- Mo piping cost

Hastellqy N piping cost

ll.

Auxiliary piping cost

Process Instrumentation’

 

‘We assumed that instrumentation cost for the 3.33-day cycle plant‘:'
'could.be scaled upward from the corresponding cost for the 10- day'qycle

plant by the scaling factors found gbove for the three types of equlp- |
ment, Thus ‘ :

Ca.zz = Cio [ 331
where the subscripts refer to the value for the 3.33-day cycle and 10~
day cycle. The ratio of the plant throughputs is 3.

Instrumentation cost for Hastelloy N equipment
$1,L08,000 (3)°-%6
$1, 87&,050

Instrumentation cost for aux111ary equlpment
= $583,200 (3)°**
= $838,060

Instrumentation cost for heaters (scale factor taken to be zero)
= $81, 300 : -

Instrumentation cost_for Mo equipment |
$638,800 (3)°°31 .
$898,150 .

Total 1nstrumentation cost for 3.33- day—qycle plant = $3,691 560

tou
4

. W

59

_Cell Electrlcal Connectlons

 

The cost of cell electrical comnections was taken to be $.93,700,
the.same‘asxfor the processing plant operating on the 10-dsy cycle,

 Thermal Insulation

 

~ The cost of thermzl insulation was calculated using a scale factor
of 0.31. o |
Thermal insulation cost = $588,100 (3)°-3*

- $826,870

nu

 

Radiation Monitoring

The cost of environmental monitoring equipment should not be affecté

~ ed by prooessing'rate. Therefore, the cost was taken as $150,000, the

same as estimated for the 10-day cycle plant

'Sempllng Stations

 

The number of sampllng statlons was not considered to be & function
of throughput, The charge is $1 275,000 for elghteen liquid samplers
and flfteen gas samplers, -

Fluorlne Plant .

In estlmatlng the cost for the hlgher throughput the fluorine plant

- was treated as conventional chemlcal plant equlpment even though it is a

remotely operated faolllty, and the cost was scaled upward by the 0,6

.power applied to the throughput ratlo.

Fa plant cost = $1 00)4,900 (3)0 .6
| - $, 93,500 |

Indirect Costs

'Indirect costs were calculated by the procedure discussed Ebove for

__the 10-dey cycle plant,

 
 

60
NEEDED DEVELOPMENT, UNCERTATNTIES AND ALTERNATIVES

' There are sufflcient l&boratony and englneerlng deta tc show thet
chemical principles for the fluorlnation—-reductive extraction--metel
transfer process are fundamentally sound Except for fluorlnatlon, most
of the development has been in relatively small-scale experlments, end
design studies which, in addition to’ giving encouraglng results, have
~ identified problem areas, The more importent'problem areas &nd uncer- :

tzinties are discussed below.

Meterlals of Constructlon

'The most basic problem to thls process 1s that of a meterlal for
contalnlng molten bismuth or b1smuth-salt mixtures.. Molybdenum has
excellent corrosion resistance to both phases but is a very dlfflcult |
‘metal to fabricate, For example, in making welded jolnts therheat-
‘affected zone becomes very brittle due to recryStalization,'and'ductility
can be restored only by cold.worklng which is normally not practlcal on
fabrlcated equlpment Considerable progress has been made in the maklng
_of molybdenum shapes and joints, and in time, we feel that fabrication
'technology will be perfected The task will be difflcult even for small
molybdenum equipment, and, for large items that are required in parts of
this plant, the job is formidable, ~However, molybdenum equipment will
almost surely be expensive, | ' - |

Graphite is being considered as e.possible alternete'material of
construction, Also it may be possible to apply molybdenum coatings to &
- more eas1ly fsbrlcated material such &s a nickel-base alloy. Tungsten
~ coatings would also be satlsfactory. ‘ '

Continuous Fluorination

, Fluorination.of molten salts for uranium recovery has_been success-
fully demonstrated on severaloccasions7’9’9§1°hin~batchwise, pilot
plent operations, and the development of a continuous method- is in prog-
rress. Successful contlnuous fluorination depends upon ma1nta1n1ng a
, prctectlve frozen salt layer on wetted surfaces of the fluorinator to
 

 

 

&

C

61

prevent catastrophic corrosion, Establishing and maintaining this pro-
tective coating is a developmental problem that must be solved, The
solution is compllcsted by the difficulty of S1mulat1ng an internal heat

. source in the nonradloactlve salt of an englneerlng test, Experlmental o

: results have been encouraging, and the frozen-wall fluorinator ~should be

practical to bu11d &nd operate.'

Bismuth Removel From Szlt

Nlckel—base alloys are rapldly corroded by molten bismuth, e&nd ves-
sels that normally contain only salt, 1nclud1ng the reactor vessel &nd
prlmary heat exchangers, must be protected from chronic or recurring

exposure to the metal entreined‘in salt, A cleanup device for the salt

- stream, consisting of a vessel packed with nickel wool, exists only in

~ concept, and its effectiveness cennot be evaluated until tolerance

1im1ts for bismuth‘in salt have been determined as well as suitable
analytical methods for detecting low concentrations (<! ppm Bi) in salt,

The magnltude of bismuth entralnment cannot be completely assessed until

1 bismuth-salt contactors have been developed and tested, and cleanup

measures could be mandatory for the salt stream from each contractor if

bismuth entrainment‘is unacceptable, The allowable bismuth concentration:
in salt will almost surexy'be qulte low, and it is believed that blsmuth-
salt separatlon after each contact will be sharp. If not, a dependable

and practicable bismuth removal method must be developedQ

Instrumentatlon for Process Control

The continuous 1nterchange of salt between the reactor and proce581ng

,plant requlres quick and relisble analytlcal technlques for. salt composi-
_s't1on, uranium and protactlnlum content ‘and U5+/U4+ ratlo. -If on-line
- methods are not developed laboratory analyses could be used but these
are slow, 1nvolve the hazard and expense of . sample handllng, and requlre

holdup tanks wlth addltlonalrlnventory at the sample points, Similarly,
oneline monitoring_of.reductivefextraction and metal transfer-operations

by readings on the salt and/or bismuth phases would 2llow firm process -

control; however, we believe that these operations can be propErly con-

-ducted without sophiSticated instrumentation,

 

 
 

 

62

| Aocldental loss of f15511e materlal from the fluorlnatlon——reductlve
extractlon--metal transfer process is extremely unllkely Msloperations
~in all units except UF reduction will either return uranium and protao- :
tinium to the reactor in the recycle salt or dlvert each. into an area '
where f15$1on products are accumulated for dispossal. ‘Malfunction in the
UFg reductlon operation could route UFg toward the Hé-HF recyole systen,
‘and adequate mon1tor1ng and traps must be prov1ded to prevent such an
‘occurrence. The process already includes means of reooverlng f13311e
values from waste salt s;nce 211 waste is held for decey and fluorinated
‘before ultimate disposal - ’ - |

Some, but not all, process 1nstrumentation is requ1red to funotlon
in a 600° to 6LO°C enviromment, This condition will undoubtedly neces-
“sitate 2 development progream for 1nstrument oomponents, for example,

- gensors and transducers..r

Noble and Semlnoble Metel Behavior

Noble and seminoble metals constitute about 20,3 wt, % and 1, 6 wt, %
respectively of all fission products and account for_25.2%,and 2,06% of
_the'fission product decéy energy~st.equilibrium.v The behavior of these
‘fission products in the MSBR is not fuliy,understood;-however,fdata from
MSRE operation indicate that they are probably removed by attaching
themselves to reactor surfaces amd/or'ieaving uithlthe inert sparge gas.
Our treatment of the flowsheet is based on this premise;'and we have |

designed the processing plant to handle only & small amount of noble and

" seminoble metals, Most noble and seminoble metals have volatile fluorides :

. and would be removed in fluoriuation. If the behavior is not as assumed
and large amounts of noble and seminoble metals enter the process1ng
 plant, exten51ve redesign of the gas reoycle and salt cleanup systems
fwould be requlred -Heat removal problems would be more severe and
| add1t10na1 treatment would be required to remove reduced rioble. metal
~ particulates from the reconstituted fuel salt A better understandlng
- - of the behav1or of- thls class of f15$1on products in the reactor system

- is very 1mportant.

I
o~

63

‘Operational.and Safety.Consideratibns

When operational and saféty considerations for the processing plant
are examined in detail,flit will prdbably be found that their influence
on equipment aésign will bg’appreciqble. There is & volume heat source
due to decaying radiocactive nficlides"in practically every vessel in the
plant;’requiring’continuouS'cOOIing end fail-safe syétems. In some ves-
sels, high heat removal rates sre required because concentrations of the
radionuclides are relatively'high; A criticel design analysis is neces-
sary fbr_evéryjpotentially dangerous area to ascertain-the_conseduencés
of abnormal operatioh,'especially in regard to interruptions in coolant

flow,

ACKNOWLEDGMENT

.During‘this study we had meny helpffil di scussions with L._E; McNeese
concerning flowsheet details and process analy81s. On several occasions,
we enlisted the aid of M, J. Bell and his MATADOR program to compute
reactor and proce351ng plantfperformance,for different modes of,operation,
Wé_thank R; C; Robertson and M, L. Myers of the Reactor Division for
basic cost data on materials of cOnstrfiction and for instructing us in
accbunting procedures to pfit this estimate'on the same basis as the
reference 1000 Mi(e) MSBR. We &lso appreciate the efforts of Robert E,
MbDonald; A, Cf Schaffhafisér, and Jfimes R. Distefano of the Metals and

_Ceramics Division in estimating the cost of molybdenum,
 REFERENCES
1. R. C. Robertson (Ed.), Conceptual Design Study of a Sigle—Fluid
Molten-Salt Breeder Reactor, ORNL-4541 (June. 1971) ”

2, M, J, Bell, ORNL personal communicatlon of unpubllshed data
S r(Fébruary 1971) -

3, M,-J, Bell ORNL, MATADOR computer program, unpubllshed data,

L, W, L. Carter, ORNL,‘BUNION_computer program,-unpub11shed‘data.

 
9,

10,

11.

" 12,

13,

J. H Pashley, Oak Rldge Gaseous D1ffu81on Plent, personal commu-'
nication (Aprll 1971).

NUS Corpbratlon, Guide for Economic Evaluatlon of Nuclear Reactor

Plant De51ggs, NUS-531 (January 1969), p. C-L,

W. H Carr, "Volatlllty Prooe551ng of the ARE Fuel " Ghem.uEngr.
Symp Ser,, 56 (28), 57- 61 (1960) -

" Chem. Technol. Div. Ann, Progr. Rept. June 30, 1962, 0RNL-331h, |
| pp. 39~ hS. '

W, H. Carr et al,, Mblten-Salt Fluoride Volatllity Pllot Plant:
Recovery of Enriched Uranium From Alumlnum-CIaa Fuel Elements,
ORNL-ESTh (Aprll 1971). '

R ‘B, Lindaver, Processing of the MSRE Flush and Fuel Salts,

| ORNL-TM-2578 (August 1969).

'Staff of the Ozk Ridge Natlonal Laboratory, Sltlng of Fuel Reproc-

essing Plants and Waste Mhnagement Faclllties, ORNLth§1, pp. 6-LiL
to 6-47 (July 1970). ‘

'W' R, Grimes, "Mblten-Salt Reactor Chemlstry," NUcl Appl Technol

8 (2), 137-55 (1970).

M. W, Rosenthal et al., "Recent Progress in Molten-Salt Reactor
Development " At, Energy Rev. 9 (3), (1971)
 

65

APPENDIXES

 
 

 

66
Appendin A: Economic Cemparison‘of Process Gas
Systems for the MSER Processing Flant
| Gases used in precessing MSBR fuel salt are fluorine for removing
uranium from the selt, hydrogen fluoride for oxidizing metels dissolved
1n,blsmnth to fluorides for extraction into salt, &nd hydrogen for re-
ducing UF, to UF, and for sparglng fuel salt after fluorlnatlon. In
- addition a ‘considersble smount of UF, is handled in fluorlnatlon and
reduction. The principal react1ons of the process gases are:
Fluorination
UF, + F, -+ UFg
‘Reduction

UF, + Hy o UF, + 2HF
F_z-l-H2 - 2HF .

. Hydrofluorination

Pa (Bi) + LHF + PaF, (salt) + 2H,
U (Bi) + LHF - UF, (salt) + 2H,
FP (Bi) + xHF ~ (FP)F_ (salt) + (x/2) H,

arging
2UF, + H, "->2UF;+2HF' | S
Fp + Hy ~ 2HF : I . -
The net effect of the first, second, end'feurth'operatione is to.eonsume' -
H, and Fy wh11e making HF, whereas, the third operation consumes HF and
produces Hz. Since the smount of HF consumed in hydrofluorlnatlon is
" much Smaller than the amount produced in the other operations, the prpc-'"
essing plant must dispose of the excess hydrogen fluoride either,as .
waste or hy.cenversion to hydrogen and fluorine for recycle, The first
alternative requires the purchase of the three gaseS'plus the eost‘of
converting large quantities of contaminated hydrogen fluorlde to & solid -
waste for salt mine storage, the second alternative reqplres the instsl-
lation of a remote fluorlne plant with a considerably smaller mekeup and
waste dlsposal cost, ' - | o | |

The two ch01ces for treat1ng the process gases were studled to
determine the more econom1c‘method The 51mp11f1ed flow dlagrams in
- Figs, A-1 and A-2 show the processing stepe and the nass_flow rates of - | R
reactant and prodnct°g33es;' ln;eaeh;diegfen fluorine'ntilieation'in o o _fgfiijfl

fluorinators is taken as 50%, hydrogen fluoride utilization in hydro-. '
fluorinators and hydrogen utlllzation 1n the reductlon column are teken
~ as 10% |
 

ORNL DWG 71-12796

" o_FUEL SALT 472400 g KOH/day .
. . TO REACTOR 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

: i ‘ . : I0OM KOH
. UFes ~oUFa
181310 ¢ U/doy » 192980 g Urgay [REDUCTION| NEUTRALIZER] S
31180 ¢ Fa/day - 33080 g Ferday | COLUMN'| ST390 8 RR/dey o ‘ WASTE GAS
- ; - g $8390 ¢ Hg/day
T ) . .
28
L P 34000 9-Hy/day o
D' | .
ceo| ™ u|
e8| : gz 3
=) ' wy .
T & x
P2 N ot o
) ol 8
57 g Usdoy ol .o
9 q Fp/doy o ~
- D : A , EVAPORATE
VTV B ey ' TO DRYNESS
o Bi-Li ' ) - |
ALLOY
1
L
| . .
! , . SOLID WASTE TO
He ‘ _l_.. | b ‘ - . '“‘ SALT:HNE STORAGE
PRIMARY . | pyYRG PasU 1 SECONDARY| Me Pa WASTE | . - | puReE [ waste: ' 23640 g KOH/day
*|FLUORINATOR cowu‘n sxnac';non "'yuno. FLUORINATOR| PURGE DECAY HYDRO- con.u?m TANK | ‘ -+ 4GATE0 g KF/day
: ] -] COLUMN" £ omiNaTOR COLUMN TANK  [FLUORINATOR wasTE _el.ag 5(/«.,
FUEL SALT | 1 ) FLUORINATOR (0.64 113 7day)
190850 ¢ U/day : ‘
52 ¢ I/day S
l 1 l I i I
- ]
- - | ‘
3640 g Mp/day i 3640 g Hy/day ’ : L5 ¢ Hp/day
. | . - o
' eiss0g Fe/doy . . . * 3790 g Fg/day . ' g p/doy

| ,- 89810 ¢ Hf/dfly . 12820 ¢ Hfrday

-~ - Fig, A-1. Once-Through Cycle for Gases in Processing Plant for
MSBR Fuel Process Requirements of H,, F,, and HF are Purchased; Excess
Amounts After ‘Use are Converted to -Solid Waste for Disposal; - Uranium,
in the gas stream as UF,, is quantitatively returned to the salt in the
reduction column, Values show requirements for a 1000-Mw(e) MSER.

 

L9
~ ORNL DWG 71-12792

   
 

9324 o WASTE o
’ 9

 
 
  

    
  
  

  

: 10 M KO
WINO g N
00 NEUTRALIZER |

  
  
   

{C?OOO 9 HFII.,
306009 Mg /doy

  

UFg —= UF,
"z’.o;' U/doy REDUCTION

33080 /doy

       
  

  

     

 
 

>~

s» . _

e 09850 g HF SOLID WASTE TO

= SALY umz smuo:
ot ' 66 g K 'dey
Cel . %80 . l(rluy

25 7.4 g K1 doy

e {0411 mmyl -

MAKEUP
9

    
    
 

q Usday
82 g 17doy

 
 
 

7282

  

‘a8170

. | Fig. A-2, Recycle of Gases in Processing Plant for MSER Fuel
| L . - Reaction Product. HF is Electrolyzed to Furnish H; and F, for Recycle to
| | - Process Operations; a Small Amount of H, and HF is Not Recoverable and
' is Replaced with Makeup, Uranium, 'in the gas stream as UFg, is quanti-
tatively recovered in the reduction column, Values show requirements
for a ‘IOOO—].VM(e) MSER, ' : ' - =

89

 
 

;shown‘by the curves of . Flg. A-B.‘ The KOH concentratlon is reduced from
10'M to 0.5 M in the *OO hr perlod ' o

69

Fission product contamination in the gas stream is primarily from |
iodine and to a less extent from bromine, Small amounts of noble gases
and volatile noble hetale gre present, but, as expleined earlier, the
short removal time for these”huclides in the reactor greatly limits the

quantity, Heat generatlon in the neutrallzed waste is due almost entlrely

"to iodine and daughter products.

Since.this'cost study was‘for comparison purposes; only major ele-
ments‘of the cost were considered, For example, plplng.lnstrumentatlon,
1nsulatlon, auxlllary equipment, etc. were not 1ncluded in the estimate,
The study was limited to comparlng the costsrof major pieces of equip-
ment, consumed chemicals; and waste disposal, |

Once-Through Procees'Cycle

In the once-through treatment (F1g A-1), gases from the ‘reduction
columm, hydrofluorlnators, and purge columns flow into & caustlc neu-

tralizer contalnlng ‘aqueous KOH where hydrogen fluoride and halogen

flSSlon products are removed, Hydrogen leaves the neutralizer, passes

through alumina and charcozl beds for removal of small amounts of vola-

'Atile noble metals and noble gases, and exhausts to the atmosphere, Five

neutralizers; each holdingrabout 135 £t of 10 M KOH solution, are needed,
One tank is on-stream for a ?OO?hr cycle while the neutralized contents
of the remaining_tanks are in,various stageshof fission product decay.
The batchwise cycle is necessery_to:elloudecey before the solution is
evaporated to dryness."At’the:end of'the'*OO—hr°reactiOn period the

 fission product decay energy is 153 kW thls decays rather qulckly as

o, ,
After h00~hours decqy the aqueous solution is evaporated to a solld

'waste residue in 2)- 1n. D x 10-ft- long/waste contalners Condensate is

reused to make fresh KOH solutlon - If the waste contalner‘is'held about

32 days, its heat emlssion 1s sufflclently low to quallfy the can for

salt mine ‘storage &t the mlnlmum cost of $300 per can, 1

 
 

70

 

onm. DWG 7112798 Rl
103 104

 

      
    

 

  
  

 

 

 

 

 

or 1 | ll-i[il T T l.llll T T IIIIIT_.l‘o
L ' | IS3 kw AT EN b OF 100-hr. B
/ ACCUMULATION | i
N -0l
3 1 £
2 z ] =
z o ] s
: - e
o _ ';
o «
w - w
z W
o ©
L s
5 1 g
g T
Y 00! -
' 10 Ly 1 111 Lo gl ,

: 10 102 ' 103
¢ ) DECAY TIME {hours) : ‘

Fig, A-3, Flssmn Product Heat Generatlon Rate in KOH Neutrallzer.
Solution volume = 135 ft° '

\

P>
 

T

The»2h-in. D x 10-ft-long/can is the‘largest permissible can for
storage in‘a salt mine; andvthe usable length, excluding nozzles; lifting
bails, etc., is approximately 8 ft, About 8,6L ft® solidiwaste_is pro-
duced each day, hence; foroperetion at 80% plant factor,:105 cans must

be'sent to'permanentvstorage each year."

Gas Recycle System

In the recycle system (Flg. A-2), gases from the reductlon column,
- purge columns, and hydrofluorlnators are compressed to about 2 atm
pressure and chilled to -40°C to condense hydrogen fluoride from the
H,-HF mixture;- Some of the*fission products, primarily volatile com-
pounds of I, Br, Se, and Te, are expected to condense to a large extent
with the hydrogen fluorine, These compounds are more volatile than
hydrogen fluorine and can be separated by distilling the mixture at low
temperature at sbout 2 atm pressure.r Vepor pressure data are shown in
Fig, A-l, ' The overheed_condehser is'kept at -L40°C so thet hydrogen
fluoride loss with the'noncondensabie gases .is minimel, Part of the
liquid hydrogen fluoride flows from the still to an electrolytic cell
to regenerate Hé'and”Fz; the remezinder is recycled to the hydrofluorinators.

The H,-rich gas from the:distillation.colqmn'is bubbled through a
caustic scrubber similar to the one used in the once-through system to
remove halides, The gas’isfdried in regenerative silica gel sorbers and
recycled to the reducfiion and purge columns, About 5% of the hydrogen
is removed from the’ system on each cycle to purge selenium and tellurium

-iby sorptlon on actlvated 2lumina and noble gases by sorptlon on charcoal,

The neutrallzatlon system con51sts of a scrubber column and three,
-20-ft5 reserv01rs for 10 M KOH 'Each reservoir is on-stream for 3l days
_untll the concentration is reduced to 0.5 M KOH; the heat generation
rate attains equlllbrlum at about 210 KW (see Fig, 5, page 29). The
spent ‘solution is set aside for f1$$1on product decay for 45 days before
,'belng evaporated to dryness in 2h-1n. D x 10-ft- 1ong waste contalners.
The volume of solld.waste produced 1s 4.83 £t° every 3l days, requiring
only 2,07 waste containers per year for reactor operation at 80% plant

factor,

 
 

 

 

  
 
  
 
 
 
    

 

 

 

 

 

72
ORNL DWG 72-131 -
103 ‘ : )
: — BOILING POINT
_ AT § ATM (°C)
~ CHF 4197 ~
~ HoTe ~ 2.0
- HI  -35.1
HpSe — 41,1
— HBr -66.5
— A
102 -
> -
T —
€ -
E
W - i
@
: .
m e
L7g]
Wl
o
o | .
o
-0
a
g
= ¥
10
I 1 1.1 _
3.0 ' . 4.0 7 C 5.0 .
. l s
|
. T(OK) x O
Fig. A-L. Vapor.Pressuref-Terrxperature Relationsh_ips for HF, HI,

HBr, HySe and H,Te. -
 

L 73

The waste container needs to be held only about nine days'after the

final batch is evaporated in order to qualify for the minimum interment

cost of $300, This cost is for a meximum heat evolution of 30 w/ft of

container,

Fuel Cycle Cost Comparison

Costs for the two gas'treatment methods were compared.by examining
only the 1tems for which there would be a 81gn1flcant cost differential,
Prellmlnany de81gns Were made of major equipment 1tems, and instelled
costs were estimated, The costs of chemlcals were calculated from the -

| requirements shown on the flousheets, Figs@ A-1 and A-2

In the case of the oncevthrough gas cycle, the costs of purchased

: gases were calculated 1n two ways., One calculatlon was made -for the

purchase of all requlred fluorine, hydrogen, end hydrogen fluorlde from
outside sources. In the second case, hydrogen fluoride and some hydrogen
were purchased and fluorlne and hydrogen were manufactured on-51te from

HF in a nonradloactlve fluorlne plant. For complete gas recycle opera-

.tion, only the equlllbrlum hydrogen fluoride lost in the noncondensable

gas from distillation and that-consumed in hydrcfluorlnatlon are pur-

chased, The requlred hydrogen makeup is equlvalent to that discarded

less the’ hydrogen produced in hydrofluorlnatlon.

The costs of the two methods for treating the gases are compared in
Table A-1, The once-through gas cycle costs about 0,115 mllls/kWhr and

is almost flve times more expenslve than the recycle system, due primarily

1o the hlgher charges for waste. disposal and purchased fluorine. The

most 51gn1f1cant charge in the recycle system is the amortization of the

'remote fluorine plant. A small reductlon in costrcan be made in the
~ once- through gas cycle when fluorine-and hydrogen are manufactured on- .
's1te from hydrogen fluorlde, however, the fuel cycle cost 1s still four
| tlmes that of the recycle system.f S '

. On the bas1s of thls comparlson, the gas recycle system was selected

for the MSBR fuel reprocess1ng flowsheet

 
 

Table A- Fuel Cycle Costs for Two Methods of Treating
Process Gases in MSBER Fuel Processing :

Fuel cycle time = 10 days
" Reactor power = 1000 MW(e)
= 80%

Flant factor

 

Fuel Cycle Cost (mills/kWhr)

 

 

0,0956

Once- Through Gas Cycle b Gas Recycle
Case 1% . Case 27
Waste Disposal .
Waste containers 0.0L85 0,0485 0,0009
Shipping 0.0050 °0,0050 0.0001
Carriers ' 0,0022 0,0022 - . 0,000L
Salt mine storage 0. 0045 0.00L5 © 0.,0001
- o 0. 0602 0,0602 0.0015
- Equipment and Chemicals
KOH tanks | 0.012L 0,012 10,0013
Fluorine plant o - 0,0098 0.0196
Fluorine | - 0.0304 L .
Hydrogen ~ 0,0055 . 0.0050 . 10,0002
Hydrogen fluoride. 0,0026 - - 0,00LL 0,0005
Potassium hydroxide 10,0038 0,0038 0.0001 -
HF distillation-equipment. ’ / 0..0007
- S 0.05L7 0.035L 0.022L
‘Total 0.0239

 

All gases purchased

Hydrogen fluoride and some Hé purchased- F2 and the remaining H, made on-site from hydrogen

fluoride in nonradioactive fluorine plant,

l v .
. g . .

~

14

 
 

75
- . Appendix B: USeful-Déta-for'the
MSER and Processing Plant
- Table B—1Summafizésdata“from reactor physics ca&lculations, prop-
erties of process fluids, and hesat generation data for various areas of

the processing plent,
 

'(6

 

 

 

 

 

 

 

 

 

 

) . v 7 . - . .‘ S . . - - 6 -1 -
Table B-1. 'Useful.nata for the MSBR and Processing Plant . - _ ‘ 7 \J
 Reactor Facts (MATADOR caleulations by M. J. Bell) o
~ Thermal power ‘ L ' L 2250 MW ' L s
Fission product production B . 2,355 kg/dey |
"Fission products entering processing plant o 2,143 kg/day -
Noble gases removed in reactor 7 ER 0.621 kg/day
: - Noble metals removed in reactor . ‘ 0.471 kg/day
. ‘Seminoble metals removed in resctor ‘ 0,036 kg/day
Fission products removed in processmg plant i - 1,226 kg/dsy
- 233pa produced ] _ o 2.59 kg/day
Breeding ratio ‘ : : 1.0637
233ps inventary in reactor at equilibrimn ‘ . 20,57 kg -
233pa inventory in processing plant at equilibrium .= : 81.8L kg
- Molar Densities at 640°C (g moles/ft°) .
- LiF-BeF,-ThF, (72-16-12 mole %) | ‘ 1467
: LiF-Bng-ThF.-UF‘-FP' s ( equilibri\nn composition) - 1489
1icl - ' 995 o
Bismith | o | - 1298 -
Bi-50 at, % Li - L - - 1336 | . ‘
Bi-5 at. % Li o . 1323
LiF-ThF,-ZrF,-PaF, (71-26 2, 8-0. 2 mole £) o - 1192 (at 6oo°c)
Liquidus Tergperat.ure (°c) ‘ _ ,
.LiF-Bng-ThF-UF‘ (71.7-16,0-12.0-0,3 mole %) - . 499 *
IiC1 , o © 81
_ Bismuth ' ' 2M : : o
LiF-ThF,-ZrF,.-PaF, (71-26-2,8-0.2 mole %) , : cé8 o - .
- Nak (78-22 wt.%) : =11 ‘
Inventor_v in Processing Plant o 7 _ , _
, Fuel salt = a | 33,7 £t
Bismth E . 58,4 £43
1401 - - - 20 £13
' NaK , L 200 ft°
71i in Bi-50 at.¥ Li alloy : , 8L.2 kg
7Li in Bi-S at.% Li alloy o , 12,5 k
233pa decay salt : ' 150- 175 £t°
Heat Generation in Prooessing Plant (kW) ‘ ‘
_ Fission Products - 232Pa
Fuel salt circuit® (33.7 £1°) | - 238 ‘ 5
- Bismith in extraction columns and surge tanks (8 72y 13 . :
253pa decay system salt (150-175 £1°) 1800 _ L4150
LiCl (20 f£t3) : e
Bi-50 at, % Ii alley (27 £t°) : 439
Bi-5-at,$ Ii alloy (18 £t3) . - , 1382
: Waste tank (555 f‘l:"é no decay) | . 111
. . KOH solution (20 ft°, no decay) ; o 210
: A1.0, bed (2.5 £t°) ‘ , L L - : s
' ' ' ' ' 5665 s -t
85a1t in feed tank, fluorinator, purge oolumn, extraction co_lmfins, 'r’eduotion-colthnnv, L . o
salt cleanup units, and reactor feed tank, - b - . ' \g -
 

 

77

Appendix C: Steady State Concentrations
' in the Metal Transfer System

The metal-transfer system consists.of-captive‘bismuth and lithium
chloride phases that circulate in closed 1oops,-receiving fission pro-
ducts on one side of the loop and transferring them to a second phase at
the other side, Throughout the system the donor and acceptor flulds
operate wlth steady state concentratlons of . all metels being transferred,
the equ111br1a depending upon the dlstrlbutlon characterlstlcs of each
. species and the purge rate from the acceptor fluld - This system has
been carefully analyzed by Bell,: nd his date are glven in. Flg. Cc-1.

The purge of fission products from the Bi- 5 at, % L1 reservoir is
" shown as & continuous 5 669 gal/day stresm, thlng the rate continuous
~ was a convenience for calculatlons, 1n actual practlce the withdrawal
of such & small amount would be batchw1se on perhaps & two-day cycle.-
Slmllarly, the 1nd1cated w1thdrawa1 from the Bi-50 at, % Ii .reservoir
would probably be on & 30 day cycle._.,

' The divalent rare earths, designated RE®* in the flgure, include
* Sr, Ba, Sm, and Eu, Trivalent rare earth, designated RE®*, include Y,
la, Ce, Pm, Nd, Pr, Gd, Tb, Dy, Ho, and Er, -
 

FUEL SALT RE

18

 

 

RERE 2IAE -0

e
. HTSHE-08

?375

 

 

 

 

 

 

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ORNL DWG TI1-10787

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

    
 

 

 

 

 

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

e vrmemmate st tatmd e e mmmm e m— e ———————————

TURN + - ‘.
?O‘l‘;. .Exgc“o" - 0.074 SPM REM THETE-O8 .
___________ e ; - “_ BISMUTH + BISMUTH +
s Byl —— | e e i L n:oucnu‘r--—-—-q Li REDUCTANT-~ =+
t 85 g mele Lisdey 53 gm mols Lisdoy !
i L ISE t S
v Th | S48IE~02 Lol r )
' U |.2sE-1L ¥ '
JOSSE-0%3 1
| REte] 1720E-06 [ ¢ '
1 REI) QSSIE-O6| ¢ '
' "k L
! ———— e ' —— §
i r 1 ' 1 '
. 1 i
’
1
L
] : I
:
RARE
: p, i EART, gl RETe
FUEL SALT FROM EXTRACTION ! EXTRACTION EXTRACTION 0.66 GPM STRIPPER
FLUORINATION e -~ .- —— 2O .
i .
. A I
: |
1 1 :
1 | -1 I
i i i i i )
; ' - RRNPM_I____ RN APM ] beees E /1
1 ™ 1!13!-!! . = :
. ' T Pe =} |
i ™ S~ . ,,“ - = 1 1
1 U | 2445E-11 Ee !
- | e S ren . v
i RES+| [2365E-03 !..!'...!.’."__ e s s = e e Y i
1 : i
! : [
' i ™ xo‘u 3 -:
ISE~-
- : [ '
Li REDUCTANT—el 1 F3 +UFy TO agre | Testo0
S600E -02
37 g mole/day ! . REDUCTION COLUMN et | 2611932-08
t .
N
! .
* gy o
WYORO- py DECAY TANK
FLUORINATION FLUORINATION iF=ThFe-2rFs -Pake
) P P T-2597-2.84-019 mols % .,
1. bl 8000 .
1 ™ ITMHE-0 |-
P 3299€-10 [
[ BEZE-I8
NF s RERS JOT2E-C1
* a—— e RENS 3S0IE-03
Lo d
T ————
0779 aPM | ' 6 ]
DISCARD TO FISSION PRODUCT PURGE FISSION PRODUCTY PURGE
'A!‘I’t 5.689 goirdey 0.994 gul/dey
23 r13 /220 tapn .
FUEL SALT .
SISMUTH

 

{DATA FROM CALCULATIONS BY M.J. BELL
USING MATADOR CODE)

‘Fig. C-1,

In Metal Transfer Systemn,

Calculated Ehulllbrium Concentrations (atom fractlon)

o

 
 

 

 

A\ (!hi‘

 

79

Appendix D:  Flowsheet of the Fluorination--Reductive
‘Extraction--Metal Transfer Process [1000-Mi(e) MSER]

The attached flowsheets [Dwgs. No, F12173-CD-173E and No. F-12173-
CD~17hE] glve pertinent material and energy balance data for processing
the_reference MSER on & 10- -day cycle, During the course of the de31gn
and cost study, significant.design improvements.ln the original concept
of the plantfbecsme'epparent. As these changes were made to the flow-.
sheet, it was not always possible to fully investigate effects upon
other areas of the plant because of the urgency to complete the cost
Study on schedule._,Thus,.the reader might not elways obtain a satis-

factory material balance in specific areas of the flowsheet; however,

 the authors believe that such 1ncon31stenc1es are minor and do not

affect the results or conclusions of this study

Although the draw1ngs do not show englneering features with respect
to 1nstrumentat10n, coolant flow, aux111ary plplng, service lines, etc,,
these items were included in the cost estimate, Equipment. and vessels
for startup, shutdown, and standby operatlon of the plant were also

- included in the cost, however, they are not shown,

 
 

 

 

 

 

 

 

  
    
 

 

 

 

   
 
 
        
    
   

 

 

 

 

      
       
    
  
  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 
 

 

 

 

 

 

 

 

 

 

 

    
 

 

 

 

  
  
 
   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

  

 

   
 

 

 

 

 

   

 

 

  

 

 

 

 

 

 

    
  

 

 

   
   

 

 

 

 

 

 

 

 

   
 
 
 

 

 

 

     
 
 
 
   

 

 

 

   
  
     

 

 

  
  

 

 

 

 

  

 

 

 

    
  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 
    

       
 
 
      

 

 

      
    

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

. 1
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|
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BT e s “‘5%5:.,, ‘ ‘ ‘ REFERENCE DRANINGS | mowmen
‘ . ‘ . ‘ Ur15.28 #n/ P . #ix Emae Rimexa Livenaremy
L e s i s 2t i, o e S — — T — — —— . i —————— o~ — — . o i Zre D16 sw/ PR . -
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METHES OR FRCOISS DISOLOSID 3t THESE SIANUWS MaY NOT IFAeE | PRACTIONS & T T e — [\009. MWy MS!K]
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SUOIMTION, APPARTUS, METHOD O PROCEES MBCLOBED I THESK "'IW‘ VRV R [ ST S A
P R A e (8 ] Can i : T
w-mm“?@mm [ 1 R ‘T S| e IE AT ICD—, \741'
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"3

 

 

 

 

 

 

 

i

 
 

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