This paper presents a detailed procedure for implementing the inverted fuel geometry to a fast reactor to improve its safety system and economy. The study is starting from the fuel unit cell, fuel assembly, reactor core, and burnup analysis. A proposed multivariable graph (v, ΔP, TFmax–Dco, VF) introduced at the fuel unit cell level provides comprehensive thermalhydraulic and neutronic parameters in a single graph, allowing for an efficient optimization process. The fuel unit cell study reveals that the inverted fuel design has a higher fuel volume fraction and lower core pressure drop than conventional pin-typed fuel. This is beneficial for the reactor economy and enhances the reliability of the safety system. With the inverted fuel design, the primary loop can save pumping power by up to 40 % and provides an excess driving force for natural circulation. The male–female axial grid structure separating the fuel assembly potentially eliminates coolant flow path restriction and fretting issues. The core is named the Inverted Core Fast Reactor (IC-FR), an LBE-cooled fast SMR designed to generate 60 MWth for at least 40 years of full-power operation without refueling and fuel shuffling. IC-FR is a transportable reactor and has load following capability that can be deployed for many applications, including marine and land-based applications, and stand alone or mixing power grid. The burnup study of IC-FR reveals that the balance of neutron leakage and fissile inventory yields a small reactivity swing (<1$) for 40 years. This study extensively utilizes Monte Carlo (MC) code MCS for neutronic calculation. Owing to the high computational expense of MC code, the approaches to optimize the MC usage are also presented.
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