A heat exchanger to transfer the heat generated from a nuclear reactor to a sulfur-iodine hydrogen production system has been developed. This heat exchanger operates in the extreme environments of a high corrosion, a high temperature, and a high differential pressure. A coating and ion beam mixing surface modification technology are applied to the process heat exchanger in order to enhance its corrosion resistance without loosing the manufacturability of the metal. A Ni-based super alloy is coated with a silicon carbide to enhance its corrosion resistance. The development of heat exchanger including shape design, thermal sizing, ion beam mixing process, stress analysis, and the manufacturing of small scale mock-up heat exchanger are discussed in this paper. The heat exchanger is a hybrid type to meet the design pressure requirements between a nuclear system and a hydrogen production system. A thermal sizing procedure for the process heat exchanger by considering the heat of sulfuric acid gas decomposition is developed. A finite element stress analysis is carried out by using the temperature profile obtained from the thermal sizing calculation. The finite element models were studied to simulate the stress state of the heat exchanger. Two-dimensional analysis was performed at the entrance region of the heat exchanger. A three-dimensional analysis for a single effective heat transfer channel was performed to investigate three-dimensional stress state. Stress analysis results have shown that the developed heat exchanger can withstand the required pressure difference at the elevated temperature condition. A small size heat exchanger was fabricated in order to test it in a high temperature nitrogen-gas loop. The fabrication of the heat exchanger includes a machining of the flow path, a coating and ion beam mixing, and a diffusion bonding of the heat transfer plate.

Very High Temperature Reactors (VHTRs) require high temperature (900–950 °C), high integrity, and high efficiency heat exchangers during normal and off-normal conditions. A class of compact heat exchangers, namely, the Printed Circuit Heat Exchangers (PCHEs), made of high temperature materials, found to have the above characteristics, are being increasingly pursued for heavy duty applications. A high-temperature helium experimental test facility, primarily aimed at investigating the heat transfer and pressure drop characteristics of the PCHEs, was designed and is being built at the Ohio State University. The test facility was designed for a maximum operating temperature and pressure of 900 °C and 3 MPa, respectively. Owing to the high operating conditions, a detailed investigation on various high temperature materials was carried out to aid in the design of the test facility and the heat exchangers. The study showed that alloy 617 is the leading candidate material for high temperature heat exchangers. Two PCHEs, each having 10 hot and 10 cold plates with 12 channels in each plate, are currently being fabricated from alloy 617 plates and will be tested once the test facility is constructed. To supplement the experiments, computational fluid dynamics modeling of a simplified PCHE model is being performed and the results for three flow rate cases of 15, 40, and 90 kg/h and a system pressure of 3 MPa are discussed. In summary, this paper focuses on the study of the high-temperature materials, the design of the helium test facility, the design and fabrication of the PCHEs, and the computational modeling of a simplified PCHE model.

Since the 1980s, the ASME Code has made numerous improvements in elevated-temperature structural integrity technology. These advances have been incorporated into Section II, Section VIII, Code Cases, and particularly Subsection NH of Section III of the Code, “Components in Elevated Temperature Service.” The current need for designs for very high temperature and for Gen IV systems requires the extension of operating temperatures from about 1400°F (760°C) to about 1742°F (950°C) where creep effects limit structural integrity, safe allowable operating conditions, and design life. Materials that are more creep and corrosive resistant are needed for these higher operating temperatures. Material models are required for cyclic design analyses. Allowable strains, creep fatigue and creep rupture interaction evaluation methods are needed to provide assurance of structural integrity for such very high temperature applications. Current ASME Section III design criteria for lower operating temperature reactors are intended to prevent through-wall cracking and leaking and corresponding criteria are needed for high temperature reactors. Subsection NH of Section III was originally developed to provide structural design criteria and limits for elevated-temperature design of Liquid-Metal Fast Breeder Reactor (LMFBR) systems and some gas-cooled systems. The U.S. Nuclear Regulatory Commission (NRC) and its Advisory Committee for Reactor Safeguards (ACRS) reviewed the design limits and procedures in the process of reviewing the Clinch River Breeder Reactor (CRBR) for a construction permit in the late 1970s and early 1980s, and identified issues that needed resolution. In the years since then, the NRC, DOE and various contractors have evaluated the applicability of the ASME Code and Code Cases to high-temperature reactor designs such as the VHTGRs, and identified issues that need to be resolved to provide a regulatory basis for licensing. The design lifetime of Gen IV Reactors is expected to be 60 years. Additional materials including Alloy 617 and Hastelloy X need to be fully characterized. Environmental degradation effects, especially impure helium and those noted herein, need to be adequately considered. Since cyclic finite element creep analyses will be used to quantify creep rupture, creep fatigue, creep ratcheting and strain accumulations, creep behavior models and constitutive relations are needed for cyclic creep loading. Such strain- and time-hardening models must account for the interaction between the time-independent and time-dependent material response. This paper describes the evolving structural integrity evaluation approach for high temperature reactors. Evaluation methods are discussed, including simplified analysis methods, detailed analyses of localized areas, and validation needs. Regulatory issues including weldment cracking, notch weakening, creep fatigue/creep rupture damage interactions, and materials property representations for cyclic creep behavior are also covered.

The alloys Haynes 230 and Inconel 617 are potential candidates for the intermediate heat exchangers (IHX) of (V)-HTR reactors. The behaviour under corrosion of these alloys by the (V)-HTR coolant (impure helium) is an important selection criterion because it defines the service life of these components. At high temperature, the Haynes 230 is likely to develop a chromium oxide on the surface. This layer protects from the exchanges with the surrounding medium and thus confers certain passivity on metal. At very high temperature, the initial microstructure made up of austenitic grains and coarse intra and intergranular M 6 C carbide grains rich in W will evolve. The M 6 C carbides remain and some M 23 C 6 richer in Cr appear. Then, carbon can reduce the protective oxide layer. Then, the alloy loses its protective coating and can corrode quickly. Experimental investigations were performed on these nickel based alloys under an impure helium flow [1]. To predict the surface reactivity of chromium under impure helium, it is necessary to determine its chemical activity in a temperature range close to the operating conditions of the heat exchangers (T ≈ 1273 K). For that, high temperature mass spectrometry measurements coupled to multiple effusion Knudsen cells are carried out on several samples: Haynes 230, Inconel 617 and model alloys 1178, 1181, 1201. This coupling makes it possible thermodynamic equilibrium to be obtained between the vapour phase and the condensed phase of the sample. The measurement of the chromium ionic intensity ( I ) of the molecular beam resulting from a cell containing an alloy provides the values of partial pressure according to the temperature. This value is compared to that of the pure substance (Cr) at the same temperature. These calculations provide thermodynamic data characteristic of the chromium behaviour in these alloys. These activity results call into question those previously measured by Hilpert [2], largely used in the literature.

HTR projects have been launched within the European Union Framework Programmes (FP’s) to consolidate and advance HTR and VHTR technology within Europe. This paper reviews the main achievements arising out of the work in the area of materials and component development. The programme to date addresses material and qualification requirements for the reactor pressure vessel, high temperature resistant alloys and technological development aspects of the power circuit components, material property needs and issues for the graphite core and requirements for Codes and Standards. The experimental programme includes irradiation and feature testing, tests on reduced scale mock-ups and bearings, corrosion, modelling and analysis issues. For the 6th Framework activities which are current, the main European research focus on VHTR is through the RAPHAEL-IP. Results and main conclusions from the work are reported, also a summary of the status of the test work and recommendations for future actions. This programme of work provides important results for the International Generation IV VHTR Materials and Components Research and Development programme as part of the EURATOM contribution.

Several nickel based solid solution alloys are under consideration for application in heat exchangers for very high temperature gas cooled reactors. The principal candidates being considered for this application by the Next Generation Nuclear Plant (NGNP) project are Inconel 617 and Haynes 230. While both of these alloys have an attractive combination of creep strength, fabricability, and oxidation resistance a good deal remains to be determined about their environmental resistance in the expected NGNP helium chemistry and their long term response to thermal aging. A series of experiments has been carried out in a He loop with controlled impurity chemistries within the range expected for the NGNP. The influence of oxygen partial pressure and carbon activity on the microstructure and mechanical properties of Alloys 617 and 230 has been characterized. A relatively simple phenomenological model of the environmental interaction for these alloys has been developed.

Within the framework of the ANTARES program, AREVA NP, EDF and the CEA have launched a joint R&D program on metallic materials for VHTR. Reference alloys for circuit and Intermediate Heat eXchanger (IHX) are nickel-based with about 22%wt. of chromium. Compatibility with the HTR primary helium appears to be a determining property for the material selection and qualification. The coolant is actually polluted by a low level of impurities that can interact with metals at high temperature. Oxidation, carburization and/or decarburization occur, in relation to atmosphere characteristics, temperature and alloy chemical composition. As these corrosion effects can notably influence the mechanical properties, they often are determining to the component service life. Since the corrosion behavior is highly sensitive to environmental conditions, material studies require dedicated facilities that shall allow for a strict control of the environment throughout the entire specimen exposure. AREVA NP, CEA, and EDF have developed experimental loops respectively under the names the Chemistry Loop, CORINTH and CORALLINE, ESTEREL; these high temperature helium flow systems are equipped with high accuracy hygrometers and gas analyzers. A benchmark was defined to cross-validate the lab devices and procedures. It is composed of two tests. The joint protocol sets the operating parameters in terms of material, specimen preparation, temperature and heating program, gas pressure and flow rate, time, gas composition. Corrosion is assessed by mass change associated to observations and analyses of the corroded coupons considering the surface scales (nature, morphology and thickness), the internal oxidation (nature, distribution and depth) and the possible carburization/decarburization (type and depth). For benchmark test 1, AREVA NP, CEA, and EDF produced similar results in terms of operation of the tests as well as about the corrosion criteria. On the other hand, benchmark test 2 showed a difference in the residual water vapor level between loops that was shown to strongly influence the specimen behavior. Discrepancies in the alloy corrosion were studied regarding gas flow rates and effective oxygen potential in helium. As a consequence, the experimental tools and procedures have been upgraded. French laboratories have now efficient corrosion facilities and methods at their disposal to study and qualify the corrosion behavior of structural materials in HTR environment.

The very high temperature reactor (VHTR) materials R&D started as an objective of the development of key technologies for a nuclear hydrogen production funded by the Korea government in 2006. We are performing materials R&D for 5 components: a reactor pressure vessel (RPV), a reactor/process intermediate heat exchanger (IHX) and hot gas duct, a control rods component, a reflector and support structures in the core region and reactor materials for the sulfur-iodine (SI) process. The scopes of our works are focused on a material screening/selection and qualification, codifications of a high temperature structural design to a very high temperature region, and to support the licensing of a system design, material characterizations and database establishments. Current target materials are modified 9Cr-1Mo, alloy 617, graphite, ceramic fiber reinforced composite, Fe-Si and SiC.

Cooling helium of HTRs is expected to contain a low level of impurities: oxidizing gasses and carbon-bearing species. Reference structural materials for pipes and heat exchangers are chromia-former nickel base alloys — typically alloys 617 and 230 — and, as is generally the case in any high temperature process, their long term corrosion resistance relies on the growth of a surface chromium-oxide that can act as a barrier against corrosive species. This implies that the HTR environment must allow for oxidation of these alloys to occur, while it remains not too oxidizing against in-core graphite. First, studies on the surface reactivity under various impure helium containing low partial pressures of H2, H2O, CO and CH4 show that alloys 617 and 230 oxidize in many atmospheres from intermediate temperatures up to 890–970°C, depending on the exact gas composition. However when heated above a critical temperature, the surface oxide becomes unstable: it was demonstrated that at the scale/alloy interface the surface oxide interacts with the carbon from the material. These investigations have established an environmental area that promotes oxidation. When expose in oxidizing HTR helium, alloys 617 and 230 actually develop a sustainable surface scale over thousands of hours. On the other hand if the scale is destabilized by reaction with the carbon, the oxide is not protective anymore and the alloy surface interacts with gaseous impurities. In the case of CH4-containg atmospheres, this causes rapid carburization in the form of precipitation of coarse carbides on the surface and in the bulk. Carburization was shown to induce an extensive embrittlement of the alloys. In CH4-free helium mixtures, alloys decarburize with a global loss of carbon and dissolution of the pre-existing carbides. As carbides take part to the alloy strengthening at high temperature, it is expected that decarburization impacts the creep properties. Carburization and decarburization degrade rapidly the alloy properties and thus result in an unacceptably high risk on the material integrity at high temperature. Therefore, the purification system shall control the gas composition in order to make this unique helium atmosphere compatible with the in-core graphite as well as with structural materials. This paper reviews the data on the corrosion behavior of structural material in HTR and draws some conclusion on appropriate helium chemistry regarding the material compatibility at high temperature.

The program for hydrogen production with high temperature nuclear heat has been launched in Korea since 2004. Iodine sulfur (IS) process is one of the promising processes for a hydrogen production because it does not generate a carbon dioxide and massive hydrogen production may be possible. However, the highly corrosive environment of the process is barrier to the application in the industry. Therefore, corrosion behaviors of various materials were evaluated in sulfuric acid to select appropriate materials compatible with the IS process. The materials used in this work were Ni base alloys, Fe-Si alloys, Ta, Au, Pt, Zr, SiC and so on. The test environments were boiling 50wt% sulfuric acid without/with HI as an impurity and 98wt% sulfuric acid. The surface morphologies and cross sectional areas of the corroded materials were examined by using SEM equipped with EDS. From the results of the weight loss and potentiodynamic experiments, it was found that a Si enriched oxide is attributable to a corrosion resistance for materials including Si in boiling 98wt% sulfuric acid. Moreover the passive Si enriched film thickness increased with the immersion time leading to an enhancement of the corrosion resistance. Corrosion behaviours of the material tested are discussed in terms of the chemical composition of the materials, a corrosion morphology and the surface layer’s composition.

The expected service life of the Next Generation Nuclear Plant is 60 years. Structural analyses of the Intermediate Heat Exchanger (IHX) will require the development of unified viscoplastic constitutive models that address the material behavior of Alloy 617, a construction material of choice, over a wide range of strain rates. Many unified constitutive models employ a yield stress state variable which is used to account for cyclic hardening and softening of the material. For low stress values below the yield stress state variable these constitutive models predict that no inelastic deformation takes place which is contrary to experimental results. The ability to model creep deformation at low stresses for the IHX application is very important as the IHX operational stresses are restricted to very small values due to the low creep strengths at elevated temperatures and long design lifetime. This paper presents some preliminary work in modeling the unified viscoplastic constitutive behavior of Alloy 617 which accounts for the long term, low stress, creep behavior and the hysteretic behavior of the material at elevated temperatures. The preliminary model is presented in one-dimensional form for ease of understanding, but the intent of the present work is to produce a three-dimensional model suitable for inclusion in the user subroutines UMAT and USERPL of the ABAQUS and ANSYS nonlinear finite element codes. Further experiments and constitutive modeling efforts are planned to model the material behavior of Alloy 617 in more detail.