Arkal Shenoy

H2-MHR PRE-CONCEPTUAL DESIGN SUMMARY FOR HYDROGEN PRODUCTION

Hydrogen and electricity are expected to dominate the world energy system in the long term. The world currently consumes about 50 million metric tons of hydrogen per year, with the bulk of it being consumed by the chemical and refining industries. The demand for hydrogen is expected to increase, especially if the U.S. and other countries shift their energy usage towards a hydrogen economy, with hydrogen consumed as an energy commodity by the transportation, residential and commercial sectors. However, there is strong motivation to not use fossil fuels in the future as a feedstock for hydrogen production, because the greenhouse gas carbon dioxide is a byproduct and fossil fuel prices are expected to increase significantly. An advanced reactor technology receiving considerable international interest for both electricity and hydrogen production, is the modular helium reactor (MHR), which is a passively safe concept that has evolved from earlier high-temperature gas-cooled reactor (HTGR) designs. For hydrogen production, this concept is referred to as the H2-MHR. Two different hydrogen production technologies are being investigated for the H2-MHR; an advanced sulfur-iodine (SI) thermochemical water splitting process and high-temperature electrolysis (HTE). This paper describes pre-conceptual design descriptions and economic evaluations of full-scale, nth-of-a-kind SI-Based and HTE-Based H2-MHR plants. Hydrogen production costs for both types of plants are estimated to be approximately

H2-MHR conceptual designs based on the sulphur–iodine process and high-temperature electrolysis

2 per kilogram.

Steam Cycle Modular Helium Reactor

For electricity and hydrogen production, the advanced reactor technology receiving the most international interest is a modular, passively safe version of the high-temperature, helium-cooled reactor referred to in the USA as the Modular Helium Reactor (MHR). Because of its ability to produce high-temperature helium, the MHR is well suited for a number of process-heat applications, including hydrogen production. Two hydrogen-production technologies have emerged as leading candidates for coupling to the MHR: (1) thermochemical water splitting using the Sulphur–Iodine (SI) process and (2) High-Temperature Electrolysis (HTE). In this paper, we provide an update on conceptual designs being developed for coupling the MHR to the SI process and HTE. These concepts are referred to as the SI-based H2-MHR and the HTE-based H2-MHR, respectively.

Development of the GT-MHR Vertical Turbomachine Design

Abstract The Next Generation Nuclear Plant (NGNP) project is being conducted by the U.S. Department of Energy (DOE) to demonstrate the technical and licensing viability of high-temperature gas-cooled reactor (HTGR) technology as a CO2 emission-free source of energy to displace the use of natural gas, petroleum, and coal for production of electricity and/or high-temperature process energy for a wide range of industrial applications. The DOE selected the HTGR as the reactor type for the NGNP project primarily because HTGRs can produce heat energy at much higher temperatures than other reactor types due to their use of ceramic, coated-particle fuel, helium coolant, and graphite as the core structural material. The DOE is considering a number of candidate HTGR designs for the NGNP demonstration plant; the DOE or a DOE-industry partnership will ultimately select the design to be licensed and constructed. The HTGR design option being advanced by General Atomics for the NGNP demonstration plant, and for follow-on commercial deployment, is the Steam Cycle Modular Helium Reactor (SC-MHR). The SC-MHR, which is the subject of this paper, uses fuel elements in the form of hexagonal blocks, which are stacked together to form the reactor core. This type of HTGR is referred to as a prismatic HTGR, as opposed to a pebble bed HTGR, which uses billiard ball-size spherical fuel elements. The above-noted generic features of HTGRs coupled with the modular helium reactor design features of the SC-MHR allow for adequate removal of residual heat from the reactor by completely passive means in the event of a loss of forced cooling or loss of coolant pressure. This ensures that the fuel remains below time-at-temperature limits at which fuel damage could occur during such events, thereby ensuring radionuclide retention within the fuel particles. Thus, the safety of the SC-MHR (as well as other modular HTGR designs) is inherent to the design, and the rare, but severe, accidents postulated for light water reactors and other advanced nuclear concepts are not possible with the SC-MHR. It is anticipated that design, licensing, and construction of the SC-MHR demonstration plant could potentially be completed to enable plant operations to begin in 2022.

Hydrogen Generation Using the Modular Helium Reactor

The high-temperature gas-cooled reactor technology is the only nuclear technology capable of achieving coolant temperatures as high as 950 °C and at the same time ensuring safe and efficient production of both electricity and hydrogen. OKBM and GA started independent research in this area in the 1990s. In 1995, OKBM in cooperation with GA started development of the GT-MHR design which combines a safe modular reactor and a power conversion unit based on the high-efficiency Brayton cycle. The power conversion unit in the GT-MHR design has integral configuration, with vertical arrangement of the turbomachine consisting of a synchronous generator and a turbocompressor. Active electromagnetic bearings are used as supports. In order to select optimal technical solutions, the effect of the following factors on the design was considered: vertical or horizontal arrangement, submerged or remote generator with oil bearings, and different turbomachine rotor speeds. Application of electromagnetic bearings and diaphragm coupling between the rotors, integral arrangement of the turbomachine inside the power conversion system vessel, and use of helium as coolant required performance of comprehensive analyses and experiments. For this purpose, the helium turbomachine technology demonstration program was developed and is currently being implemented. This technology demonstration program aims at validating the quantitative and qualitative characteristics of such turbomachine components as electromagnetic and catcher bearings, control system, computer codes, generator, diaphragm coupling, turbocompressor, etc. At the concluding stage of the technology demonstration program, a full-scale turbocompressor model will be tested at a helium test facility. The present paper lists the main parameters of the GT-MHR turbomachine and describes the status of experimental validation of its components.Copyright

H2-MHR Pre-Conceptual Design Report: SI-Based Plant; HTE-Based Plant

Process heat from a high-temperature nuclear reactor can be used to drive a set of chemical reactions, with the net result of splitting water into hydrogen and oxygen. For example, process heat at temperatures in the range 850°C to 950°C can drive the sulfur-iodine (SI) thermochemical process to produce hydrogen with high efficiency. Electricity can also be used to split water, using conventional, low-temperature electrolysis (LTE). An example of a hybrid process is high-temperature electrolysis (HTE), in which process heat is used to generate steam, which is then supplied to an electrolyzer to generate hydrogen. In this paper we investigate the coupling of the Modular Helium Reactor (MHR) to the SI process and HTE. These concepts are referred to as the H2-MHR. Optimization of the MHR core design to produce higher coolant outlet temperatures is also discussed.Copyright

Ways to Increase Efficiency of the HTGR Coupled With the Gas-Turbine Power Conversion Unit

Hydrogen and electricity are expected to dominate the world energy system in the long term. The world currently consumes about 50 million metric tons of hydrogen per year, with the bulk of it being consumed by the chemical and refining industries. The demand for hydrogen is expected to increase, especially if the U.S. and other countries shift their energy usage towards a hydrogen economy, with hydrogen consumed as an energy commodity by the transportation, residential, and commercial sectors. However, there is strong motivation to not use fossil fuels in the future as a feedstock for hydrogen production, because the greenhouse gas carbon dioxide is a byproduct and fossil fuel prices are expected to increase significantly. For electricity and hydrogen production, an advanced reactor technology receiving considerable international interest is a modular, passively-safe version of the high-temperature, gas-cooled reactor (HTGR), known in the U.S. as the Modular Helium Reactor (MHR), which operates at a power level of 600 MW(t). For electricity production, the MHR operates with an outlet helium temperature of 850 C to drive a direct, Brayton-cycle power-conversion system (PCS) with a thermal-to-electrical conversion efficiency of 48 percent. This concept is referred to as the Gas Turbine MHR (GT-MHR). For hydrogen production, the process heat from the MHR is used to produce hydrogen. This concept is referred to as the H2-MHR.

MHR design, technology and applications

The paper deals with the issue of increasing efficiency of nuclear power plants with the modular high-temperature helium reactor (HTGR) and direct gas turbine cycle. It should be noted that only this combination can highlight the advantages of the HTGR, namely the ability to heat helium to about 1000°C, in comparison with other reactor plants for electricity generation. The HTGR has never been used in the direct gas turbine cycle. At present, several designs of such commercial plants are at the stage of experimental validation of main technical features. In Russia, “OKB Mechanical Engineering” together with “General Atomics” (USA) are developing the GT-MHR project with the reactor power of 600 MW, reactor outlet helium temperature of 850 °C, and efficiency of about 45.2%; the South African Republic is developing the PBMR project with the reactor power of 400 MW, reactor outlet helium temperature of 900 °C, and efficiency of about 42%; and Japan is developing the GTHTR-300 project with the reactor power of 600 MW, reactor outlet helium temperature of 850°C, and efficiency of about 45.6%. As it has been proven by technical and economic estimations, one of the most important factors for successful promotion of reactor designs is their net efficiency, which must be not lower than 47%. A significant advantage of a reactor plant with the HTGR and gas-turbine power conversion unit over the steam cycle is considerable simplification of the power unit layout and reduction of the required equipment and systems (no steam generators, no turbine hall including steam lines, condenser, deaerator, etc.), which makes the gas-turbine power conversion unit more compact and less costly in production, operation and maintenance. However, in spite of this advantage, it seems that in the projects currently being developed, the potential of the gas-turbine cycle and high-temperature reactor to more efficiently generate electricity is not fully used. For example, in modern reactor plants with highly recuperative steam cycle with supercritical heat parameters, the net efficiency of electricity generation reaches 50–55%. There are three methods of Brayton cycle carnotization: regeneration, helium cooldown during compression, and heat supply during expansion. These methods can be used both separately and in combination, which gives a total of seven complex heat flow diagrams. Besides, there are ways to increase helium temperature at the reactor inlet and outlet, to reduce hydraulic losses in the helium path, to increase the turbomachine (TM) rotation speed in order to improve the turbine and compressor efficiency, to reduce helium leaks in the circulation path, etc. The analysis of GT-MHR, PBMR and GTHTR-300 development experience allows identification of the main ways of increasing the efficiency by selecting optimal parameters and design solutions for the reactor and power conversion unit. The paper estimates the probability of reaching the maximum electricity generation efficiency in reactor plants with the HTGR and gas turbine cycle with account of the up-to-date development status of major reactor plant components (reactor, vessels, turbocompressor (TC), generator, heat exchange equipment, and structural materials).Copyright