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Keywords: This study is carried out within the DEMOnstration Balance of Plant (DEMO BoP) development activities. Despite
DEMOnstration fusion power plant the pulsed operation of the Tokamak reactor, a steady energy output of the DEMO BoP need to be ensured. To
DEMOnstration balance of plant fulfil this requirement, a two-tank Intermediate Heat Transport and Storage System (IHTS) with HITEC molten
Intermediate heat transport and storage system
salt as a heat transfer fluid is applied. The focus of the study is the development of a dynamic simulation model
Indirect Coupling DDesign
for the DEMO IHTS using MATLAB®/Simulink. The customized programme block is developed for MATLAB®,
which is used for the simulation of the temperature dependences of HITEC parameters. The influence of tank
geometry and molten salt temperature on the temperature decrease in the IHTS tanks in due course of service
maintenance is studied. The simulation of fluid filling level as well as mass and energy flows through the IHTS
during the pulse and dwell operation is carried out.
* Corresponding author.
E-mail address: maria-victoria.bologa@kit.edu (M.-V. Bologa).
https://doi.org/10.1016/j.fusengdes.2021.112291
Received 9 September 2019; Received in revised form 26 January 2021; Accepted 27 January 2021
Available online 8 February 2021
0920-3796/© 2021 Elsevier B.V. All rights reserved.
M.-V. Bologa et al. Fusion Engineering and Design 166 (2021) 112291
the storage, conversion, distribution, and consumption of energy [14, turbines [18]. Subsequently the steam is returned back into the circuit
15]. Coupling of the DEMO FPP to the grid network is already in the through the condenser. The efficiency of the PCS can be increased via
focus of the study [16]. The Karlsruhe Institute of Technology (KIT) live mean steam extraction for feedwater preheating from high- and
participates in the international EUROfusion programme [5], devel low-pressure turbines, thus enhancing the IHTS operational stability
oping an efficient DEMO BoP design focused on the Helium Cooled during the dwell time too [19].
Pebble Bed Breeding Blanket (HCPB BB) design option [9–14]. The
scheme of the actual DEMO BoP concept [11] with the Indirect Coupling 3. DEMO Intermediate Heat Transport and Storage System
Design (ICD) is presented in Fig. 1. The stationary simulation of the
DEMO BoP using EBSILON® Professional was successful carried out at The main design challenges of the DEMO BoP are to reduce the risks
the Institute for Neutron Physics and Reactor Technology (INR, KIT) during the Tokamak reactor pulse operation, that could damage the
[18–22]. turbines, causing voltage fluctuations in the electrical grid. To reduce
The DEMO BoP energy transfer chain (Fig. 1) includes the fusion this risk, the DEMO BoP design option includes the indirect coupling of
reactor as heat source, the Primary Heat Transfer System (PHTS), the PHTS to PCS via IHTS [8,18,19]. The two-tank concept supposes the use
Intermediate Heat Transport and Storage System (IHTS), and the Power of a hot and cold tank, which contains a heat transfer fluid (HTF). The
Conversion System (PCS). The PCS is coupled via turbo-generator to the pumps ensure the flow of the HTF between the tanks and through the
electrical grid. Due to the technical complexity and the high impact of pipelines. During the dwell time, the liquid is pumped from the hot tank
design integration, efficiency, as well as operational safety and stability, through the PCS steam generator into the cold tank, so that the heat of
the R&D focuses on the operation and design optimization of PHTS, the HTF is used for steam generation. This design concept allows
IHTS and PCS [9,10,14]. long-term storage of the HTF in the hot tank. Due to the IHTS, the
The Tokamak reactor operates in pulsed mode. A single operation decoupling of pulse/dwell time is feasible, resulting in the decrease of
cycle includes pulse (7200 s) and dwell (600 s) intervals. During the fluctuations of mechanical power output [8].
pulse time, thermal energy of ~2 GWth is generated. The dwell time is The safe and stable operation of the DEMO IHTS depends both on the
needed for removal of ash and dust from the fusion reactor chamber as storage system design and heat transfer fluid properties. The literature
well as the loading of the Central Solenoids [17,18]. survey shows that the molten salts are used successfully in various
The PHTS consists of eight individual cooling loops (Fig. 1). Helium technological processes for effective heat transfer. Molten salts have low
with an inlet/outlet temperature of 573 K / 793 K flows through heat viscosity and vapour pressure as well as high density, thermal conduc
exchangers, ensuring the heat transfer from the Tokamak reactor blan tivity and specific heat capacity [23–28].
ket walls to the Thermal Energy Storage system. Each of the eight In the current study, the HITEC molten salt is used for heat transfer in
Breeding Blankets cooling loops transfers ~274 MW of thermal energy the DEMO IHTS. HITEC is an eutectic mixture of water-soluble inorganic
of through the heat exchangers. salts with a composition of 53% KNO3 - 40% NaNO2 - 7% NaNO3 [29]. It
The Energy Storage System (ESS) of IHTS provides the coupling is a non-flammable and non-toxic salt mixture [30].
between the PHTS and PCS (Fig. 1). It comprises the molten salt storage The HITEC melting temperature is 415 K [30] and it could be applied
tanks, circulation pumps, auxiliary systems for water service and treat at temperatures up to 823 K. Due to high melting temperature, the use of
ment, control sensors, diagnostics, ventilation equipment and pipelines HITEC would impact the maintenance of heating system to prevent salt
[18]. The DEMO IHTS is used to smooth the generated pulsed plasma solidification below 415 K [31,32].
power, ensuring continuous PCS operation with stable power output. As the correlations for HITEC molten salt are not included in the
The PCS is the next process step after the IHTS. The heat is trans MATLAB® libraries, a customized programme block for dynamic
ferred to the steam generator with two stages, that are operated at simulation of HITEC temperature dependent material properties is
nominal pressures of ~58 bar and ~121 bar [18]. The secondary heat developed. For this purpose detail literature survey is carried out which
sources, such as Vacuum Vessel (VV), Divertor Cassettes (DIV-Cas) and shows that there are over 30 analytical equations, proposed for
Divertor Plasma Facing Units (DIV-PFU), are used for heating the describing the temperature dependency of the HITEC thermo-physical
feedwater on the return line to the steam generator (Fig. 1). To increase parameters.
the power output, two fluid re-heaters are installed between the steam The analytic equation, that describes the temperature dependence of
2
M.-V. Bologa et al. Fusion Engineering and Design 166 (2021) 112291
the kinematic viscosity ν [N/m] is obtained via 3rd order polynomial For the simulations, the storage tank roof is a flat dome. The hot tank
approximation of the relation ν = μ/ρ. The volumetric heat capacity is and the pipelines, which connect the hot tank with the PHTS and PCS,
defined as the product of the specific heat capacity and density β=cp⋅ρ are insulated with ProRox® WM950 [45]. The cold tank and the pipe
[MJ/(m3⋅K)]. The correlation for thermal diffusivity α=k/β [m2/s] is lines, which connect the cold tank with PHTS and PCS, are insulated
obtained via the approximation of the numerical data obtained for the k with KlimaRock® [45].
and β. Tanks are manufactured from stainless steel SS 1.4301 with a Cr and
The Eq.s (1)–(8) are selected and included into the customized pro Ni content of about 18–20% and 8–11%, respectively. The density of the
gramme block for the simulation of HITEC parameters using MATLAB®/ steel is 7900 kg/m3 at 293 K and its thermal conductivity of 22 W/(m K
Simulink [33–35,38–41]: at 773 K is chosen [47]. Argon, as cover gas in the storage tanks, is
modelled according to the ideal gas law. Pressure inside the tanks is
ρ = 2279.799− 0.7324 ⋅ T, (kg/m3) (1) assumed to be slightly higher than the ambient one. No leaks and no
[33] chemical reactions of HITEC with the environment are assumed. Inside
the tank, the HITEC surface temperature is 5 K lower than the temper
μ=exp(-4.343− 2.0143∙[ln(T-273)-5.011]) [Pa⋅s] (2) ature of bulk salt.
[34]
4.2. Dynamic Model of DEMO IHTS Storage Tank
ν = 90.655− 0.3659⋅T-0.5⋅10− 3⋅T2-2⋅10-7⋅T3 (3)
cp = 1.560-(T-273.15)⋅10− 3
[kJ/(kg⋅K)] (4) The schematic view of the DEMO IHTS storage tank model is pre
sented in Fig. 2. The exchange of heat takes place between the tank and
[35] surroundings. The tank has an inlet port A and outlet port B. The ports V
and L are used as control elements for regulation of liquid volume and
β = 3.9079− 0.0027∙T (5)
level. The thermocouples via port T are used for measuring the HITEC
− 5 2 -8 3
k = 2.2627− 0.01176⋅T+2.551⋅10 ⋅T -1.863⋅10 ⋅T (420 ≤ T<536 K) [W/ temperature in due course inside the tank. The port H belongs to the
(m⋅K)] (6) implementation of heat losses from the storage tank through the insu
lation to the environment.
[33] For the model the variable-step solver “VariableStepAuto” is
k = 0.4329 + 0.0004⋅T-7⋅10− 7⋅T2 (413 < T < 813 K) (7) selected. The variable-step, implicit solver is better suited for purely
continuous models. It varies the step size during the simulation,
[33] reducing its value. This permits the increase in accuracy, when the states
of dynamic model change rapidly during zero-crossing events. If the
α=-0.0644 + 4⋅10− 4⋅T-3⋅10-7⋅T2 (8)
local error is greater than the acceptable error for any state, the solver
Formulas (4)-(7) are predicted to be decreasing functions with in reduces the step size and tries again. The solver “ode23t” is chosen for
crease of molten salt temperature. The dependency α=f(T) shows a the DEMO IHTS model [44]. It includes minimum and maximum step
slight increase in thermal diffusivity with an increase in temperature T size for the model and implements the trapezoidal rule, using a free
up to 633 K and a decrease for T>633 K. The values of thermal con interpolant. The default error value 0.001 is used for the model, so that
ductivity α vary between (1.77 ± 0.07)⋅10− 7 m2/s. the computed state is accurate to within 0.1%.
The heat transmission mechanisms play a major role for the losses
4. Description of Dynamic DEMO IHTS Model through the “wetted” wall, which is in contact with the molten salt, and
via the “dry” wall, which is in contact with the cover gas. The heat losses
4.1. Design and Operation Data of DEMO IHTS due to conduction take place via the tank walls and thermo-insulation.
The radiative and convective processes through the tank dome and to
The hot and cold tank are cylindrical steel containers (see Table 1). the environment are also considered. The convection heat losses through
the tank bottom are assumed to be low, so it is not taken into
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M.-V. Bologa et al. Fusion Engineering and Design 166 (2021) 112291
consideration. For the simulation of heat losses via heat transfer through 5.2. Impact of Thermo-insulation Layer Thickness
the wetted tank bottom as well as the wetted and non-wetted walls and
roof, the blocks for convective, conductive and radiative heat transfer To avoid the cooling of the HITEC molten salt below its critical
from the MATLAB®/Simulink custom library are applied. temperature during service maintenance, the impact of the thickness of
thermo-insulation layer on the temperature development in the IHTS
4.3. Dynamic Simulation Model of DEMO IHTS tanks is analysed. For the simulation, the HITEC freezing point of 415 K
is taken. It is assumed that during the service maintenance, the molten
The scheme of the DEMO IHTS model is shown in Fig. 3. The IHTS is salt temperature in the tanks must remain always well above the
connected with the PHTS via a helium circulating heat exchanger sub freezing point. For the IHTS the critical operating temperature of 473 K
system and with the PCS via a steam generator. The model includes is considered [45]. The temperature decrease in the tanks is simulated in
blocks for PHTS cooling loops, 2 storage tanks, pipe heat losses, 2 fixed- due course until the critical value is reached.
displacement pumps and a steam generator. The effects of fluid inertia, The simulations are carried out for the storage tanks with height of
elevation, and external leakage are neglected [44,46]. Regulation of 7.5 m and diameter of 24 m. The min./max. tank filling level of 5/95% is
pressure fluctuations inside the pumps is created via the pump control established. In the cold tank, the initial maximum HITEC temperature
blocks. 543 K and in the hot tank the maximum temperature 763 K is assumed.
The simulations are carried out for variable thermo-insulation layer
5. Simulation results thickness between 0.2− 0.5 m (Figs. 4 and 5).
In the cold tank with 0.2 m thick thermo-insulation, the critical salt
5.1. Influence of Storage Tank Height temperature is reached after ~20 days (Fig. 4). The increase in thermo-
insulation thickness up to 0.5 m results in time increase up to ~45 days.
The increase of tank height rises the manufacturing and maintenance
costs. On the other hand, a larger tank height extends the flexibility for
maintenance of the measurement equipment inside the tanks. The in
crease in the cold tank height from 7.5 m to 8.4 m (~12% increase)
results in a ~3% increase in the tank mass and ~4.2% rise in mass of the
thermo-insulation material. The rising height of the hot tank from 7.5 m
to 10 m (~33% increase) increases the mass of the tank up to ~8% and
the mass of insulation material up to ~13%. The increased tank height
results in an increase in the tank side–wall area, thar should accelerate
the heat losses due to contact with the environment [41,42]. The sim
ulations show, that the increase in the height of the cold tank from 7.5 m
to 8.4 m at Tcold,in = 543 K results in a reduction of the time for tem
perature decrease of ~29%. The increase in the height of the hot tank
from 7.5 m to 10 m at Thot,in = 738 K results in a reduction of time for
the temperature decrease of ~21%. As higher is the tank, as faster the
molten salt is cooled down.
Fig. 4. Temperature development inside cold tank in due course.
4
M.-V. Bologa et al. Fusion Engineering and Design 166 (2021) 112291
pulse operation, the HITEC level in the tanks changes in a gradual way.
During the dwell time, the filling level changes with a steep slope.
The peak hot tank filling level is higher than in the cold tank, what
can be attributed to the temperature dependence of HITEC density. For a
given mass of molten salt, the volume of HITEC in the hot tank is larger
than in the cold tank. In percentage ratio, the peak-to-peak difference of
~5% between the filling levels in the tanks corresponds to the difference
in percentage between the salt density at various temperatures.
The fluid filling level was successfully simulated for 24 h (~11
charge/discharge cycles of Tokamak reactor) confirming the operation
stability of the simulated DEMO IHTS.
Fig. 6. Filling level in IHTS tanks. Fig. 7. Development HITEC mass flow rate at the inlet and outlet of cold tank.
5
M.-V. Bologa et al. Fusion Engineering and Design 166 (2021) 112291
6. Conclusions
The focus of the current study was the dynamic simulation of the
DEMO IHTS. After the comparative analysis of analytical dependencies
and experimental data, analytical equations for HITEC molten salt
thermo-physical parameters are selected. The novel customized pro
gramme block is developed for the simulation of HITEC properties using
MATLAB®/Simulink.
The influence of the IHTS tanks design parameters and HITEC tem
perature inside the tanks in dependence of service maintenance time is
investigated. At a constant salt mass, the increase in the height of the
tank results in decrease in time, needed for the molten salt to reach its
critical operational temperature. The increase of the insulation thickness
increases the time of temperature drop, until the critical temperature is
Fig. 8. Energy flow at the input and output of hot tank with cp,HITEC =
1290 J/(kg⋅K). reached. Moreover, the simulations via MATLAB®/Simulink allow the
6
M.-V. Bologa et al. Fusion Engineering and Design 166 (2021) 112291
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