Analysis of Natural Graphite, Synthetic Graphite, and Thermosetting Resin Candidates for Use in Fuel Compact Matrix

Abstract

The AGR-1 and AGR-2 compacting process involved overcoating TRISO particles and compacting them in a steel die. The overcoating step is the process of applying matrix to the OPyC layer of TRISO particles in a rotating drum in order to build up an overcoat layer of desired thickness. The matrix used in overcoating is a mixture of natural graphite, synthetic graphite, and thermosetting resin in the ratio, by weight, of 64:16:20. A wet mixing process was used for AGR-1 and AGR-2, in that the graphites and resin were mixed in the presence of ethyl alcohol. The goal of the wet mixing process was to 'resinate' the graphite particles, or coat each individual graphite particle with a thin layer of resin. This matrix production process was similar to the German, Chinese, Japanese, and South African methods, which also use various amount of solvent during mixing. See Appendix 1 for information on these countries matrix production techniques. The resin used for AGR-1 and AGR-2 was provided by Hexion, specifically Hexion grade Durite SC1008. Durite SC1008 is a solvated (liquid) resole phenolic resin. A resole resin does not typically have a hardening agent added. The major constituent of SC1008 is phenol, with minor amounts of formaldehyde. Durite SC1008 is high viscosity, so additional ethyl alcohol was added during matrix production in order to reduce its viscosity and enhance graphite particle resination. The current compacting scale up plan departs from a wet mixing process. The matrix production method specified in the scale up plan is a co-grinding jet mill process where powdered phenolic resin and graphite are all fed into a jet mill at the same time. Because of the change in matrix production style, SC1008 cannot be used in the jet milling process because it is a liquid. The jet milling/mixing process requires that a suite of solid or powdered resins be investigated. The synthetic graphite used in AGR-1 and AGR-2 was provided by SGL Carbon, grade KRB2000. KRB2000 is a graphitized petroleum coke. The availability of KRB2000 is perhaps in question, so a replacement synthetic graphite may need to be identified. This report presents data on potential replacements for KRB2000.