US and international applications for large onsite cogeneration (steam and power) systems are emerging as a near term market for the PBMR. The South African PBMR demonstration project applies a high temperature (900°C) Brayton cycle for high efficiency power generation. In addition, a number of new applications are being investigated using an intermediate temperature range (700–750°C) with a simplified heat supply system design. This intermediate helium delivery temperature supports conventional steam Rankine cycle designs at higher efficiencies than obtained from water type reactor systems. These designs can be adapted for cogeneration of steam, similar to the design of gas turbine cogeneration plants that supply steam and power at many industrial sites. This temperature range allows use of conventional or readily qualifiable materials and equipment, avoiding some cost premiums associated with more difficult operating conditions. As gas prices and CO 2 values increase, the potential value of a small nuclear reactor with advanced safety characteristics increases dramatically. Because of its smaller scale, the 400–500MW t PBMR offers the economic advantages of onsite thermal integration (steam, hot water and desalination coproduction) and of providing onsite power at cost versus at retail industrial rates avoiding transmission and distribution costs. Advanced safety characteristics of the PBMR support the location of plants adjacent to steam users, district energy systems, desalination plants, and other large commercial and industrial facilities. Additional benefits include price stability, long term security of energy supply and substantial CO 2 reductions. Target markets include existing sites using gas fired boilers and cogeneration units, new projects such as refinery and petrochemical expansions, and coal-to-liquids projects where steam and power represent major burdens on fuel use and CO 2 emissions. Lead times associated with the nuclear licensing process may support early applications in the 2018–2020 timeframe. This paper summarizes the design options likely to shape these emerging steam and cogeneration applications.

The key interface component between the reactor and chemical systems for the sulfuric acid based processes to make hydrogen is the sulfuric acid decomposition reactor. The materials issues for the decomposition reactor are severe since sulfuric acid must be heated, vaporized and decomposed. SiC has been identified and proven by others to be an acceptable material. However, SiC has a significant design issue when it must be interfaced with metals for connection to the remainder of the process. Westinghouse has developed a design utilizing SiC for the high temperature portions of the reactor that are in contact with the sulfuric acid and polymeric coated steel for low temperature portions. This design is expected to have a reasonable cost for an operating lifetime of 20 years. It can be readily maintained in the field, and is transportable by truck (maximum OD is 4.5 meters). This paper summarizes the detailed engineering design of the Westinghouse Decomposition Reactor and the decomposition reactor’s capital cost.

PBMR (Pty) Ltd. is undertaking the implementation of its demonstration project in Koeberg, South Africa with construction planned to start in 2008. Key test facilities have been completed and full-scale tests of first-of-a-kind components are underway. PBMR (Pty) Ltd., as part of a Westinghouse-led consortium, has been awarded the lead contract for the pre-conceptual design of the NGNP project; which could lead to a major demonstration project in the US some time next decade. Also, PBMR is working with Shaw and Westinghouse to develop several important non-power applications, using the high temperatures available from a 500MWt version of the reactor to produce high pressure steam for oil sands in-situ recovery operations, high temperature energy for steam methane reforming, and for thermal water splitting to produce hydrogen and oxygen. Water splitting offers dramatic improvements in coal-to-methane and coal-to-liquids applications by avoiding the inefficiencies of converting coal to hydrogen, with its associated CO 2 emissions. This paper presents an update of the status of this work and the projected uses of this breakthrough nuclear technology.