Spent Fuel Reprocessing

(PROCESS)

J . K . GAYEN
Commissioning Superintendent
Nuclear Recycle Facilities
NRB , Kalpakkam
 Role of Reprocessing
Closed loop Fuel cycle
# Front End : Mining of heavy metals
Fuel Fabrication
Reactor operation
# Back End : Fuel Reprocessing
Waste management
Recovery of valuable materials from spent fuel to
sustain the Nuclear Program in India .
Safe disposal of radioactive waste
 Reprocessing Plants - India
Plutonium Plant ( PP ) , Trombay
- 70 Te/yr ; RR fuel

PREFRE-1 , Tarapur
KARP , Kalpakkam
PREFRE-2, Tarapur
-100 Te/yr each ; PHWR fuel

P3A , Kalpakkam ( construction )

-150 Te/yr ; PHWR fuel
Performance Index
- Repr. Plants

 Throughputs
 Product Quality
 Waste Generation
 Man-rem
Expenditure
 Environmetal Impact
 Performance Index
- Factors

Plant design & layout

Type of Fuel
Process adopted
O&M strategy
 Different Processes

REDOX process
# Not preferred
PUREX process
# Internationally acepted
PYRO process
# Under development
.
 .

HEAD END
PHWR Fuel

URANIUN OXIDE PELLETS

19 PIN CLUSTER

 ZIRCALLOY CLAD

AVERAGE BURNUP-7000 MWD/Te

Spent Fuel Storage Pond

KARP

Pond Size :
(15 X 10 X 7.8 m)

Capacity : 180 Te

SFSF

Pond Size :
(35 X 10.5 X 7.8 m)

Common for P3A & KARP Capacity : 800 Te

SPENT FUEL STORAGE
TRAY
 Dissolution
Mechanical chopping ( 40 mm)
# Progressive chopper
# Gang Chopper
Fuel dissolved in conc. HNO3
Thermo-siphon type dissolver used
 Off gas generated

 During chopping :
Sparging air & Kr-85 gas
 During Dissolution :
oxides of nitrogen, Kr-85 gas,
sparging air, acid & water vapours
 Off gas Treatment system ( DOG )
 Feed filtration System

 During chopping :
Zircalloy fines generated
 Vacuum aided bag filtration :
a)Vacuum is created by air ejector ( 5 – 7 m)
b) Solution moves to receiving tank via bag filter
c) Fines are trapped in bag
d) About 300 gm fines generated per batch
 .

Solvent Extraction
 Solvent Extraction

Flow sheet outcomes

 Choice of solvent

 Choice of equipments

 Choice of working team

 Solvent Extraction

SOLVENT
 30 % TBP
 Remaining 70 % dodecane
 TBP : d = 0.973 g/cc ; µ = 33 mp
 Dodecane : d = 0.746 g/cc ; µ = 14 mp
 30% TBP : d = 0.82 gm/cc ; µ = 17 mp
 Distribution coefficient
 Distribution coefficient ( Kd ) is defined as the ratio of solute
concentrationin organic phase to that in aqueous phase at equilibrium.

 UO2++ + 2 NO3- + 2 TBP = UO2(NO)3.2TBP

 Pu 4+ + 4 NO3- + 2 TBP = Pu(NO)4.2TBP

 Kd = [UO2(NO)3.2TBP] / [UO2++ ]
 Distribution coefficient

 K = [UO2(NO)3.2TBP] / [UO2++ ].[NO3-]2.[TBP]2

Kd = K . [NO3-]2.[TBP]2

 Similarly for Pu:

Kd = [Pu(NO)4.2TBP] / [Pu 4+]

K = [Pu(NO)4.2TBP] / [Pu4+ ].[NO3-]4.[TBP]2
Kd = K . [NO3-]4.[TBP]2
 Feed Conditioning

 Uranium concentration adjustment

@ 300- 350 gpl
 Feed acidity adjustment
@2–3M
 Pu valency adjustment
@ Pu in 4th valence state
Acidity vs. Kd
 Distribution Coefficient Values
Typical Kd values @ 350 gpl U, 3 M acidity :
 U+6 : 4 – 5
 Pu+4 : 1.5 – 2
 U+4 : 1.5
 Pu +6
: 0.6
 HNO3 : 0.06
 Pu+3 : 0.006
 Zr : 0.02
 Nb : 0.002
 Ru : 0.001
 Valency Adjustment

 Pu exists in +3 , +4 & +6 state in dissolver .

 Pu+4 is extractable.

 NaNO2 solution / NO2 gas is for converting

Pu+6, Pu+3 to Pu+4 .

 NO2 gas is preferred option-low salt in raffinate

 Valency Adjustment


With NaNO2

 Pu(NO3)3 +2 NaNO2 + 2 HNO3 = Pu(NO3)4 +2 NaNO3 +NO + H2O

 PuO2(NO3)2 + NaNO2 + 2 HNO3 = Pu(NO3)4 + NaNO3 + H2O

 With NO2 gas

 2 Pu(NO3)3 + NO2 + 2 HNO3 =2 Pu(NO3)4 + NO + H2O

 PuO2(NO3)2 + 2 NO2 + 2 HNO3 = Pu(NO3)4 + 2 HNO3
 Extractor
Different extractors :
 Centrifugal extractor , mixer settler & Pulse column

Why Pulse column chosen

 No Moving parts
 High contractor effectiveness
 C.E. = K ( N.F ) /V ; 65 hr-1
 Low Hold up olume
 Good operation stability
 Pulse Column

 Packed with sieve / nozzle plates

 Pneumatic pulsing
 Standard cartridge specification
1.5 mm thick SS plate
23% free area
2 mm plate spacing
4.8 mm dia hole
1 mm deep nozzle with 3.2 mm dia
 Pulse Column

Why pulsing required

 To facilitate the counter current two phase flow

 To increase the bubble population ; hence interfacial area for mass transfer

 To increase the turbulence

Pulse column
Pulse column operating regime

1. Flooding region for

insufficient pulsing
2. Mixer-settler region
Throughputs

3. Emulsion region
4. Unstable region
5. Flooding for excessive
pulsing

Amplitude*frequency
HA Cycle
 HA Cycle
 HA : Extraction cum scrub column ; org continuous ; Bottom interface

 HS : Scrub column ; Aqueous continuous ; Top interface

 1BX : Partitioning column; Aqueous continuous ; Top

interface

 1BS : organic scrub column; Aqueous continuous ; Top

interface

 1C : Strip column; Aqueous continuous ; Top interface

 HA Cycle

Acidity = 0.2 M
U = 60 g/l
Pu= 1 – 2 mg/l
Acidity = 3 M Activity = 0.1-0.15 mCi/l
U= 300 – 350 g/l
Pu= 1.2 – 1.5 g/l
Activity = 15-20 Ci/l

Acidity = 1.5 M
U = 2 - 5 gpl
Acidity = 4 M Pu= 1.5 -2 g/l
U= 10 g/l , Pu = 10 mg/l Activity = 1 – 5 mCi/l
Activity = 100 Ci/l
 HA Cycle
Decontamination Factor ( DF ) is defined as the ratio
of specific activity in feed to that in product.

DF ( U ) = (15000/300)/(0.12 /60) =25000

DF ( Pu) = (15000/1.2) / ( 5/2) = 5000

 Integrated 2D cycle
Introduction of Uranous scrub column has reduced
cycle operation
recycle volume

Product specification :
Pu ≤ 0.4 µgm/gm U
βɤ ≤ 0.4 µCi/gm U
KEY PLAN - FUEL POOL BULDING
SECTIONAL ELEVATION-POOL
BUILDING
 Fuel Storage : Important parameters

Water quality (pH 6.8 to 7.2, Sp Cond 1uS/Cm,

Turbidity < 1 ppm)

Pool water activity < 185 Bq/ml

Pool water level > 3.0 m above top most fuel

Pool water Temp < 45 deg C

CONSIDERATIONS IN DESIGN OF STORAGE

 Layout :
 To consider vehicle air locks for entry and exit
of trailer
 Separation of active and in-active services and

equipment
 Maximum utilization of fuel pool area for

storage
 Capacity : Fuel burn up and stacking density
 Shielding: Water depth and wall thickness
CONTD.
 Provision for leak detection and collection either
from liner failure or RCC wall failure
 Ventilation system : To maintain negative
pressure inside pool area, filtered supply, HEPA
in exhaust side, RCC stack

Pool water polishing system : To keep pool water
activity low and maintain pool water chemistry

Pool water cooling system : To keep pool water
temperature below 45oC
 CODES AND GUIDES ON THE SUBJECT

AERB Safety Guide No.: AERB/ SG /D-24 Design of Fuel
Handling and Storage Systems For Pressurized Heavy
Water Reactors

ANS 57.7 – 1988: Design criteria for an independent spent
fuel storage installation ( water pool type)

IAEA Safety Series No. 116 1994: Design of spent fuel
storage facilities

IAEA Safety Series No. 117 1994: Operation of spent fuel
storage facilities

IAEA Safety Series No. 118 1994: Safety assessment for
spent fuel storage facilities

IAEA Technical Report Series No. 240 1991: Guidebook
on spent fuel storage
SPENT FUEL STORAGE FACILITY

EXHAUST
VENTILATION
DM SYSTEM
MAKE-UP
WATER
PLANT

POLISHING
UNIT STACK

BY 75 Te
EOT CRANE
SPENT FUEL
STORAGE POOL
REPROCESSING
CASK FOR
SPENT FUEL

SUPPLY
VENTILATION
SYSTEM
COOLING
WATER SYSTEM
 FEATURES PROVIDED IN SFSFs

OBE design of pool and building structure

Use of HPC with micro-silica and box type water
proofing of walls & raft

Design load - 30 stack of trays

Leak detection & collection system having 50 zones

Infiltration gallery for maintaining water table below
pool raft with 200% stand by pumps on DG

3 mm SS lining on walls, 6 mm on floor and 20mm for
cask seating area

Single failure proof 75 Te EOT crane for cask
handling

Mix of regenerated type MBU & disposable Cation

Provision for handling of trays and fuel bundles on
pool bridge on both sides
FEATURES Contd.

 Tray locators to avoid sliding and for automation

 Pull-pull ventilation around pool
 VFD drives for ventilation fans for better control &
energy saving
 A direct viewing facility from control room for cask
loading / unloading operations
 On-line monitoring of pool water chemistry
 Monitoring of all critical parameters in SFSF control
room and also in nearby reprocessing plant control
room
FEATURES Contd.

 Redundancy in Polishing system, ventilation system,

Cooling system

Waste storage( LLW and ILW) facility and effluent
transfer system

75 Te Crane, cooling system, exhaust fans ,lighting
on class-III supply and HP monitors and critical
instruments on class-II/UPS
SS LINING, LEAK DETECTION &
COLLECTION SYSTEM
INFILTRATION TRENCH
 MATERIAL HANDLING SYSTEMS
1) 75/5 Te EOT CRANE
2) 2 Te POOL BRIDGE
3) 10 Te EOT CRANE
SINGLE FAILURE PROOF CRANE
 Failure of any single component in load path shall
not lead to uncontrolled movement of critical load.

Two load paths; each consisting of gear box, rope
drum, brakes and hooks

Seismically designed girders with anti-toppling
lugs and end stoppers

Analysis for swing of load
 Galvanized steel core wire rope
 VFD drives for smooth control of speeds
 POOL BRIDGE

Rack and Pinion drive
 VFD drives for LT,CT and Hoisting
 Provision for Tray handling

Provision for Bundle handling

Safety interlocks for safe handling under min
water level

Provision for automation
POLISHING SYSTEM
POOL COOLING SYSTEM
MUCK CLEANING SYSTEM
VENTILATION SYSTEM

SFSF POOL BUILDING VENTILATION

 SAFETY ANALYSIS
1. NORMAL OPERATION


Radiological safety
 Liner leakage
 Accidental fall of fuel bundles during handling of
trays
 Siphoning of fuel pool water
 Build up of activity & personnel exposure

Area contamination / Air contamination
 Class-IV Power failure
2. OFF-NORMAL CONDITION

 Black-out scenario

Cooling system failure

Ventilation failure
 Swing of 75 Te crane holding the load in seismic
event
 A storage tray falling on a stack of spent fuel
bundles
 Accidental fall of shipping cask in pool
 Fall of stack of trays and bundle failure

Accident management plan is in place in the
event of any seismic event.
COMMISSIONING EXPERIENCE
STEP-BY-STEP COMMISSIONING PROCEDURE
• The fuel pool leak tight integrity has been checked
before and after lining.
• The leak detection and collection headers, SS liners
have been 100 % checked for weld integrity by dye-
penetrant test and vacuum box tests.
• The fuel handling equipment like 75 tonne and 10
tonne EOT cranes and Pool Bridge have been load
tested after installation.
• The fuel handling devices and tools are tested under
water with simulated loads to meet design intent.
• The ventilation system is checked for flow balancing
and filters bank efficiency.
COMMISSIONING PROCEDURE contd…
•The low level and intermediate level liquid lines for
waste transfer are tested with hydrostatic pressure and
flow checks.
•All the safety equipment and control room instruments
are calibrated and tested in the field condition prior to
start of operation.
• The shipping cask with tractor-trailer, waste transfer
casks and fuel bundle handling operation trials are
carried out to ascertain the crane reaches and
handling equipment compatibility.
• The class –IV power failures and automatic switch
over to class-III power mode are also tested with main
loads.
• The training of operators has been carried out
through classroom lectures and field training during
construction and commissioning phase.
PROBLEMS EXPERIENCED DURING COMMISSIONING

• Early replacement of HEPA filters due to dust

accumulation in construction phase

• Failure of pool bridge shaft due to misalignment of rails

during first few consignments of shipping casks

• Stuck up of cask lid with body in water and it’s remote

retrieval.
Some of the important Operation and Maintenance
activities in Spent Fuel Storage Facility

•Receipt, handling and storage of Spent fuel from PHWR

as per the approved check list.

•Monitoring of the fuel pool water level, temperature and

recording in log book. Maintaining pool water level.

•Maintaining pool water temperature below 450 C by

Operation of Fuel pool cooling system and recording various
parameters of Primary cooling water pumps, Secondary
cooling water pumps, Heat exchangers and Cooling tower.

•Maintaining pool water activity below 185 Bq/ml by

operation of Pool water polishing system .
Operation Contd…
•Operation of Muck cleaning unit to clean the floor of the fuel
pool.
•Regular sampling and analysis of Pool water, make up
water, Infiltration well water.
•Physical inspection inside leak detection and collection bay
and ensuring no water collection inside.
•Local verification of alarm status in Area gamma monitors
and Continuous air monitors. Spot air sample analysis
around fuel pool. Changing filter papers for all the
Continuous air monitors. Swipe survey taken at various floor
areas and checking of contamination level. Radiation survey
carried out at various areas.
•Monitoring and recording of supply and Exhaust fans status
including Speed, Bearing temperatures, current, Pressure
drop across HEPA and Pre-filter banks etc..
Operation Contd…

•Monitoring and recording of low level and medium level liquid

waste levels in the tanks.

•Collection, segregation, packing and transportation of CAT-I

(Mops, Shoe covers, hand gloves etc) , CAT II / CAT III
( Cartridge filter & Cation cartridge of Pool water polishing
unit, HEPA filters of E2 system and muck cleaning filters)
solid wastes to Waste management facility for safe disposal.

•Pumping and disposal of liquid wastes CAT-I & II arising

from active floor drains, cask decontamination wastes, CAT III
(MBU regenerant waste of Polishing unit) through waste
transfer pipelines to waste management facility.
Operation Contd…
•Operation of DM water plant for fuel pool make up and
also for cask decontamination unit.

•Operation of Infiltration well pump and recording the hour

meter readings.

•Surveillance of Various systems including Health Physics

monitors, Pool water level and temperature instruments,
EOT Cranes, DG sets, Battery banks, Public address
system, Exhaust filter bank efficiency, Air receiver
pressure testing , fire fighting system and functional
checks of logic of ventilation system and infiltration system
as per the technical specification.
 Major documents Preserved
 DBRs
 Preliminary Safety Analysis Report
 Design Reports (DRs) for civil design for pool, building
& stack
 DRs for piping, cooling system and ventilation system
 Safety manual
 QA manual
 GA drawings
 Technical specifications
 Commissioning procedures & Commissioning reports
 O&M manuals
 Emergency preparedness procedures
 Fire order