NAS Research Test Reactors May 21 2015 BampW Cost Analysis Cost Analysis in 2012 for Projected Costs in 2019 Purpose Utilize the current LEU information and process knowledge to develop a steadystate cost for HEU amp LEU fuel ID: 278976
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Slide1
Babcock & Wilcox Cost & Yield ReviewNAS
Research Test Reactors
May 21 , 2015Slide2
B&W Cost AnalysisCost Analysis in 2012 for Projected Costs in 2019Purpose:Utilize the current LEU information and process knowledge to develop a steady-state cost for HEU & LEU fuelGoal:To develop a process which is cost neutral from HEU to LEU
Maintain HEU Manufacturing capability until LEU manufacturing is demonstrated for all 5 reactors.2010 DOE funded independent study estimated an increase o
f 37%
GSA020.001.020.001
C
ost based on a Set of Assumptions
LEU Steady-State utilizing what we defined as a “Base-line Process”
Compared LEU to HEU in 2019 $$Slide3
Fabrication Processes
Processing Unchanged
HEU Process
L
EU Process
B&W fabricates Powder for ATR, MURR, and MIT
Y-12 fabricates Powder for HFIR and NIST
Y-12 fabricates Coupons/Ingot
The conversion from HEU to a LEU transitions from a cermet to a metal plate fabrication processSlide4
Current HEU Processes
Processes eliminated
Processes eliminated
TBD
TBD
TBDSlide5
“U-Moly Base-line Process”
U-Mo Plate
U-Mo HIP
Can Assembly
U-Mo Foil
U-Mo Coupon
Can Assembly
0.015”
Thick With
~ 0.001”
Thick
Zr
Layer on Both Sides
304 SS
Al 6061
Mild Steel
U-Mo Coupon:
19.75% U-235
~6” x 6” x 0.125”Slide6
AssumptionsSlide7
YieldsYields have not been demonstratedSlide8
Created Cost Estimating ToolProcess flow DiagramWBSTime StandardsEquipment ListRates (variable based on many factors)Cost per AssemblyAssemblies per yearAnnual Operating CostSlide9
Total Manufacturing Hours/PlateSlide10
2012 U-Moly Cost SummaryContract% increase in Cost of HEU
AssemblyATR
17%
HFIR
115% *
MIT
13%
MURR
49%
NIST
60%
* Due to the complex geometry of the HFIR fuel and the lack of manufacturing development, it is estimated that HFIR foil manufacturing will take 2X longerSlide11
Program R&D Projects Slide12
Program LEU Manufacturing CycleRecovery
Recovery
Reduce to LEU Metal
HEU Metal
DU or NU Metal
Mo
Yellow – Y-12
Blue – B&W
Clear
–
Unknown
ZRSlide13
B&W Current Manufacturing Development Efforts
Development FocusSlide14
Foil Standard Process Flow Development Efforts
Homogenize Coupon or Ingot
Pack & Weld (Coupons or Ingots)
Hot Roll with Zirconium
Decan
and Clean
Cold Roll
Vacuum Anneal
Sizing
Hot Roll without Zirconium
Decan
and Clean
Sizing
Cold Roll
Pack & Weld
Hot Roll with Zirconium
Decan
and Clean
Cold Roll
Sizing
Vacuum Anneal
Coupon Process
Ingot Process
Additional Process Steps
Alternate process being developed to minimize
Zr
Coded ScrapSlide15
B&W Cost Analysis 2014 Update2014 Cost Analysis UpdateReviewed 2012 analysis to update assumptions Determined change to 2012 estimateUpdate was Changed to Hours BasedNew Conversion dates beyond 2030Rates too hard to predictCompared reduction in hours from 2014 to 2012
Same assemblies / yearNo Yield ChangesCompared Mfg
& Total Hours
Mfg
hours = Shop & QCSlide16
Assumptions for 2014 Update
Coupon size change - increased foil fabricationSlide17
2014 Assumption Changes
Optimized Pre-formed Hip Can (Not yet Demonstrated)
Capacity change
Eliminated Internal HIP Can Fabrication
Eliminated Plate Thickness machining & UT for
S
upport
T
hickness MachiningSlide18
Total Manufacturing Hours/PlateSlide19
2014 U-Moly Cost SummaryContract% Reduction from 2012 Estimate
ATR15%
HFIR
16%
MIT
16%
MURR
14%
NIST
25%
Overall Reduction
17%Slide20
ConclusionsStill in DevelopmentDedicated Team working on U-Moly ProgramConcerted effort between all OrganizationsY-12, PNNL, LANL, INL & B&WOur Focus is two-foldManufacturing capabilityCost Consciousness (Cost neutral between HEU and LEU)