India Civil Nuclear Program

Rajendra Chola

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Kudos to you both @Gessler @Gautam .

Earlier thread with some previous info (I go into neutron economy and related):


I might archive this there too over time.

===========================



Yes PFBR is facing big challenges and delays now.

Recently they come out that the target date is now oct 2022, the related fuel cycle facility will come online around 2027:



Singh said installed nuclear power capacity had increased by 40% in seven years and that the 500MWe Prototype Fast Breeder Reactor (PFBR) being built by Bharatiya Nabhikiya Vidyut Nigam Limited (Bhavini) at Kalpakkam is at the integrated commissioning stage. “The project was originally sanctioned in 2003 and expected completion was September 2010. According to the latest approval, the revised completion target for the project is October 2022,” he said.

He added that the fast reactor fuel cycle facility (FRFCF) project is currently being executed by the Nuclear Recycle Board, the Bhabha Atomic Research Centre and the Department of Atomic Energy. The progress of the project as of 30 November was 32% and it is expected to be completed by December 2027.

I studied in a college in ECR, and many students came in Kalpakkam. We had no issues bringing guests in for Symposium. Most of the time it would be from IGCAR. Being a def bluff myself, I would try to understand what they explain. Sometimes they would come with slides to explain to us kids what they do in their bid to inspire us.

I remember PFBR presentation back in 2012. He told us it will go online in 2015. After seeing the report, I googled some info. Original year was supposed to be 2010. But construction started late only by 2007 or so it seems.

It was also back then if you had followed TN media, the allegations of beach sand mining to the tune of 4lakh crore loss (it was fashion to term any losses in lakh crores against UPA2 :p) and how the thorium resources are sold illegally to foreign nations. I just hope we start processing Thorium plants now before litigations become worse in the future.
 

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India To Build 10 Nuclear Power Plants In "Fleet Mode" From 2023​

In 2017, the centre, for the first time, approved building 10 nuclear power reactors in one go with an aim to reduce costs and speed up construction time.


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New Delhi: With the first pour of concrete for a 700 MW atomic power plant in Karnataka's Kaiga scheduled in 2023, India is set to put in motion construction activities for 10 'fleet mode' nuclear reactors over the next three years.

The first pour of concrete (FPC) signals the beginning of construction of nuclear power reactors from the pre-project stage which includes excavation activities at the project site.

“The FPC of Kaiga units 5&6 is expected in 2023; FPC of Gorakhpur Haryana Anu Vidyut Praiyonjan units 3 & 4 and Mahi Banswara Rajasthan Atomic Power Projects units 1 to 4 is expected in 2024; and that of Chutka Madhya Pradesh Atomic Power Project units 1 & 2 in 2025,” officials of the Department of Atomic Energy (DAE) told the Parliamentary panel on science and technology.

The Centre had approved construction of 10 indigenously developed pressurised heavy water reactors (PHWR) of 700 MW each in June 2017. The ten PHWRs will be built at a cost of ₹ 1.05 lakh crore.

It was for the first time that the government had approved building 10 nuclear power reactors in one go with an aim to reduce costs and speed up construction time.

Bulk procurement was underway for the fleet mode projects with purchase orders placed for forgings for steam generators, SS 304L lattice tubes and plates for end shields, pressuriser forgings, bleed condensers forgings, incoloy-800 tubes for 40 steam generators, reactor headers, DAE officials said. Engineering, procurement and construction package for turbine island has been awarded for Gorakhpur units three and four and Kaiga units five and six, they added.

Under the fleet mode, a nuclear power plant is expected to be built over a period of five years from the first pour of concrete.

Currently, India operates 22 reactors with a total capacity of 6780 MW in operation. One 700 MW reactor at Kakrapar in Gujarat was connected to the grid on January 10 last year, but it is yet to start commercial operations.

The PHWRs, which use natural uranium as fuel and heavy water as moderator, have emerged as the mainstay of India's nuclear power programme.

India's first pair of PHWRs of 220 MW each were set up at Rawatbhata in Rajasthan in the 1960s with Canadian support. The second reactor had to be built with significant domestic components as Canada withdrew support following India's peaceful nuclear tests in 1974.

As many as 14 PHWRS of 220 MW each with standardised design and improved safety measures were built by India over the years. Indian engineers further improvised the design to increase the power generation capacity to 540 MWe, and two such reactors were made operational at Tarapur in Maharashtra.

Further optimisations were carried out to upgrade the capacity to 700 MWe.


@Nilgiri @crixus
 

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Fusion power is seen as an important part of India’s long-term energy supply. The government hopes to build domestic demonstrators by mid-century. Saurav Jha reports

In January 2020 India’s first Tokamak, the Aditya, completed 30 years of safe operation. Those thirty years saw India making steady if limited investments in nuclear fusion research. Apart from creating some tokamak ‘assets’ such as the Aditya and the Steady-State Superconducting Tokamak (SST-1), India’s fusion-related activities have been heavily focused on domestic sub-systems development, given the country’s history of being subject to abrupt technology denials. Domestic efforts in sub-systems development and basic research related to advanced tokamaks since the 1980s have positioned India to be a major partner in the International Thermonuclear Experimental Reactor (ITER) project, which is expected to yield the world’s largest tokamak-based reactor.

India’s Department of Atomic Energy (DAE), which believes that fusion power is an important component of the country’s long-term energy security, aims to fund a few demonstrators of its own with a view to commence building two 1000MWe grid-connected fusion reactors by 2050.

The key DAE-supported organisation leading fusion research in India is the Institute of Plasma Research (IPR). with its main campus in Gandhinagar.

India’s indigenously developed tokamaks are all sited on the main IPR campus. (A unit imported from Japan is at the Variable Energy Cyclotron Center, Kolkata.) IPR’s leading light was the late Predhiman K. Kaw, who drove this fledgling organisation to leapfrog directly to contemporary tokamak technology, instead of pursuing what turned out to be less-promising approaches to confining a hot and dense plasma (which is at the core of fusion) in the conditions necessary for thermonuclear fusion to take place.

Under Kaw’s leadership, IPR, which had initially started off as a small effort under India’s Department of Science & Technology, managed to become a full-blown institute. It commissioned India’s first tokamak called the Aditya in 1989. Aditya’s first ‘shot’ was conducted in the same year.


Aditya and SST-1​


Aditya was set up as a tokamak with copper coils with a major radius of 0.75m and minor radius of 0.25m. It was designed to generate a circular plasma and operate with a toroidal field of 0.75-1 tesla (T), a maximum plasma current of 250kA and a pulse duration of up to 250 milliseconds. Its heating and current drive is provided by a combination of ion cyclotron resonance heating (ICRH), electron cyclotron resonance heating (ECRH) and lower hybrid current drive (LHCD).

Besides becoming a mothership for developing the relevant human resources within the country, Aditya has also yielded rich scientific dividends for IPR. Some very important results on turbulent processes in tokamaks, which are of considerable interest to the global tokamak effort have been obtained through its use.

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Aditya tokamak at IPR, circa 1990s

Aditya was the first to establish that transport plasma was not a steady ooze but was instead ‘bursty’. Experiments conducted using Aditya have also yielded important ways and means to mitigate plasma instability issues such as magnetohydrodynamics-generated disruptions and runaways.

As an aside, disruptions lead to the rapid loss of the plasma’s stored thermal and magnetic energy, which in turn necessitates the introduction of mitigation systems that shield plasma-facing components (PFCs) from the heat flux and forces thus created. A disruption can also lead to generation of very high energy electrons or ‘runaways’, which in turn can cause the first wall (ie PFCs) of the tokamak to melt, followed by leaks in water cooling circuits.

To ensure that Aditya kept ‘giving’, it was decided to upgrade it to a divertor configuration with a view to carrying out experiments with shaped plasmas relevant to contemporary tokamak designs. The philosophy behind this move was that small and medium-sized tokamaks are a convenient tool for testing new concepts, technologies and materials, which cannot be conducted on larger machines without preliminary studies, given the risks involved.

However, there are actually very few small and medium-sized tokamaks operational that have the advanced features required for providing experimental support relevant to large, advanced tokamaks. So Aditya-U (literally Aditya-Upgrade) was born, whose assembly from the disassembled Aditya was completed by December 2016 with operations beginning in January 2017.

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Render of Aditya-U

In comparison to its old form, Aditya-U has a circular X-section vacuum vessel and buckling cylinder, safety and poloidal ring limiter, toroidal belt limiter, besides three sets of divertor coils.

The modification to divertor configuration was achieved by replacing the square cross-section vacuum vessel with the circular X-section type, creating space for the divertor coils. It has been designed to reach high temperatures (45keV or about half a billion degrees) and demonstrate good power exhaust efficiency.

Aditya-U has already delivered a result that is significant for ITER. An electro-magnetic pellet injection system that fires Li2TiO3 pellets has been successfully demonstrated as a viable method for disruption control. Significant suppression of runaway electrons has also been demonstrated in Aditya-U, through the use of periodic gas puffs that suppress edge density and potential fluctuations in the plasma.

IPR’s larger tokamak, SST-1, was equipped with a divertor configuration right from its inception – designed, as it was, to explore the interaction between the plasma and the first wall of the tokamak in steady-state discharges. SST-1 has a major radius of 1.1m and a minor radius of 0.2m, elongation of 1.7 and triangularity of 0.4–0.7, toroidal field of 3T and a plasma current of 220kA. Auxiliary heating and current drive is carried out using a LHCD mechanism while primary heating is done by ICRH and neutral beam injection (NBI). SST-1 of course has superconducting magnetic coils instead of the copper ones seen on Aditya-U, a steady-state current drive and heat and particle exhaust, all of which facilitate a long pulse operation.

SST-1 was given a short-term upgrade, beginning in October 2019, which included installation of a pair of PF-3 current leads — required for moderately-shaped plasmas — a radio frequency (RF) spiral antenna assembly for alternate pre-ionization and startup experiments and various diagnostics. Whether lower hybrid absorption can be realized by modifying loop voltage, as has reportedly been observed in other tokamaks such as Japan’s TRIAM is currently being explored on the SST-1. As such, long-duration plasma discharges of around 650ms have been obtained in SST-1 using both single long-pulse LHCD and multiple short-pulse LHCD.

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SST-1 Tokamak at IPR

Though SST-1 was set up with a mix of indigenous and imported systems, IPR has worked intensively since then to ensure that future systems and upgrade packages for its existing assets are executed using domestically sourced components.

For instance, while the original conductor for SST-1 had been imported from Japan during the late 1990s, it is now available from domestic sources. As such, IPR’s sub-system development effort in partnership with Indian industry has yielded domestically sourced large-volume ultra-high vacuum (UHV) systems, copper and superconducting magnets, cryogenic systems (both liquid helium and liquid nitrogen based), large cryostats for testing at low temperatures, plasma surface-cleaning methods, high current pulsed, shaped, regulated power supplies, control, monitoring and data acquisition systems, plasma diagnostics, very high power RF heating & current drive systems and neutral beam systems for heating and current drive.

A lot of this has also been catalysed through India’s participation in ITER, which saw New Delhi emphasising domestic developmental work in the areas of magnet, divertor and cryopumping systems.


ITER-India​


India’s contribution to ITER, dubbed ‘ITER-India’ is being run as a special project under IPR. It was in December 2005 that India became the full seventh member of ITER with a 10 per cent ‘in-kind’ contribution share out of a total of 150 distinct procurements.

India’s Larsen & Toubro supplied the ITER’s cryostat, which is the world’s largest vacuum application stainless steel vessel. It weighs 3850 tonnes, with a height of 30m and a diameter of 30m. The cryostat was installed in 2020.

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The ITER Cryostat, the largest fusion-containment structure in the world, manufactured by India's L&T

ITER-India is also responsible for supplying a number of other critical components and sub-systems, such as cryolines and a cryodistribution system for ITER’s cryoplants; in-wall shielding, which requires around 9000 blocks from 70,000 precision cut plates; a cooling water and heat rejection system; ICRF source system; diagnostic neutral beam system to detect He ash during the D-T phase of the ITER plasma; plasma diagnostics; power supplies for DNB, ICRF and ECRF systems; two gyrotron sources of 1MW power output at 170GHz for 3600s pulse length; X-ray crystal spectroscopy; electron cyclotron emission as well as various optical fibers, detectors, visible spectrometers and opto-mechanical components.

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Elements of the ITER complex's cooling system being installed. Pic credit: The ITER Orgnization

Participation in ITER has led to significant blanket and divertor technology development initiatives in India. In particular, identification of special materials that provide long life and low induced radioactivity in the extreme environments associated with tokamak operations has been emphasized.

In fact, a Cu-Cr-Zr alloy with total impurity levels not exceeding 0.1 per cent has been developed as a back plate material for mounting PFCs used in ITER.

Alongside research into blanket materials there is also a thrust toward towards developing fusion fuel cycle and tritium systems.

With India now confident of being able to scale up tokamak size, field strength, heating power and pulse length, the focus is inevitably shifting towards fusion reactor design, materials and remote handling. After all, the ultimate aim is to be able to build an optimized power generating reactor that is affordable, reliable and maintainable in a cost-effective manner.


India's plans for SST-2 and then DEMO​


In a bid to consolidate all that has been achieved via homegrown tokamaks and participation in ITER, India’s fusion community is now looking forward to construction of a large tokamak based fusion reactor called SST-2, due by around 2027.

SST-2 is likely to be a low fusion gain reactor that will have a fusion power output of 100-300MW and may use Indian lead lithium ceramic breeder and helium-cooled ceramic breeder (HCCB) blankets for tritium breeding, besides a He-cooled divertor.

The fusion-fission hybrid approach may also be explored via SST-2, especially given India’s three-stage nuclear programme, which aims ultimately to breed a large fissile inventory of U-233 from the country’s Th-232 deposits.*** The transmutation of long-lived nuclear waste from fission reactors and the possibility of using fusion neutrons as a driver in thorium-based sub-critical fission reactors will also be investigated.

Ultimately, SST-2 alongside what is gained from ITER operations will pave the way for realizing and qualifying technologies related to a Deuterium-Tritium fusion cycle for India’s own DEMO programme.

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DEMO reactors are envisaged as a real-world application following up the experimental science of ITER

For instance, IPR is planning to perform an integral test by ‘covering the out-board side of SST-2 with a breeding blanket while the in-board side is covered with a shielding blanket’ in a manner similar to what will take place in a DEMO reactor. India intends to attract foreign partners for setting up a DEMO reactor beginning sometime in 2037.

Seen as a power source leveraging virtually inexhaustible fuel supply (due to the ready availability of deuterium in seawater and the prospect of breeding tritium), attractive safety characteristics and muted environmental impact, fusion may yet emerge as an element of India’s move towards a net-zero carbon economy by 2070.


++++​

Further reading:



*** For reference, previous two-part post on the Three-stage nuclear program:


 

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Kakrapar_Atomic_Power_Plant.jpg

Kakrapar Atomic Power Station

India's first indigenously developed 700 MW nuclear power reactor at the Kakrapar Atomic Power Project (KAPP) in Gujarat started commercial operations on Friday, a senior official said. "With great pleasure, this is to inform that our first indigenous 700 MWe Unit, KAPP-3, has become commercial on 30th June 2023 at 1000 Hrs," a senior KAPP official said.

Presently, the unit is operating at 90 per cent of its total power, he said.

The Nuclear Power Corporation of India Limited (NPCIL) is building two 700 MW pressurised heavy water reactors (PHWRs) at Kakrapar, which is also home to two 220 MW power plants.

Various commissioning activities were underway at KAPP 4, which had achieved 96.92 per cent progress by May end, according to officials.

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KAPP 3 & 4 during construction phase, 2016

The NPCIL plans to build sixteen 700 MW PHWRs across the country and has granted financial and administrative sanction for the same.

Construction of 700 MW nuclear power plants is underway at Rawatbhata in Rajasthan (RAPS 7 and 8) and at Gorakhpur in Haryana (GHAVP 1 and 2).

The government has sanctioned building of 10 indigenously developed PHWRs in fleet mode at four locations -- Gorakhpur in Haryana, Chutka in Madhya Pradesh, Mahi Banswara in Rajasthan and Kaiga in Karnataka.


The IPHWR-700 builds on the previous IPHWR-220 & 540 MWe models - of which 14 and 2 are in operation respectively.

 

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Kalpakkam (Tamil Nadu), Mar 4 (PTI) India is a step away from entering the second stage of its nuclear programme with the initiation of core loading at the home-built 500 MWe Prototype Fast Breeder Reactor here, a move described as "historic" by the government.

Prime Minister Narendra Modi witnessed the initiation of core loading at the Prototype Fast Breeder Reactor (PFBR), which generates more power than it consumes and uses the nuclear waste -- Uranium-238 -- as fuel.

The prime minister toured the reactor vault and the control room of the PFBR along with National Security Adviser Ajit Doval, Atomic Energy Commission Chairman A K Mohanty, Bhabha Atomic Research Center Director Vivek Bhasin and Indira Gandhi Centre for Atomic Research Director B Venkataraman.

This 500 MWe fast breeder reactor has been developed by Bharatiya Nabhikiya Vidyut Nigam Limited (BHAVINI).
"Upon completion of the core loading, the first approach to criticality will be achieved, leading to generation of power subsequently," an official statement said.

"In the spirit of Aatmanirbhar Bharat, PFBR is indigenously designed and constructed by BHAVINI with contributions from more than 200 Indian industries, including MSMEs," the official statement said.

India has been running a Fast Breeder Test Reactor experimental facility since 1985. The FBTR was operated for about 120 days at 40 MWt and generated 21.5 million units of electricity last year.

The reactor core consists of control sub-assemblies, blanket sub-assemblies and fuel sub-assemblies.

The core loading activity consists of loading of reactor control sub-assemblies, followed by the blanket sub-assemblies and the fuel sub-assemblies which will generate power.

India has adopted a three-stage nuclear power programme with a closed fuel cycle. In the PFBR, marking the second stage of the programme, spent fuel from the first stage is reprocessed and used as fuel.

"A unique feature of this sodium-cooled PFBR is that it can produce more fuel than it consumes, helping in achieving self-reliance in fuel supply for future fast reactors," the statement said.

The PFBR will initially use the Uranium-Plutonium Mixed Oxide (MOX) fuel, an official statement said.

The Uranium-238 "blanket" surrounding the fuel core will undergo nuclear transmutation to produce more fuel, thus earning the name 'Breeder', it said, adding the use of Throium-232, which in itself is not a fissile material, as a blanket is also envisaged in this stage.

By transmutation, Thorium will create fissile Uranium-233 which will be used as fuel in the third stage.

PFBR is thus a stepping stone for the third stage of the programme, paving the way for the eventual full utilization of India’s abundant thorium reserves.

In terms of safety, PFBR is an advanced third-generation reactor with inherent passive safety features ensuring a prompt and safe shutdown of the plant in the event of an emergency.

Since it uses the spent fuel from the first stage, PFBR also offers a great advantage in terms of a significant reduction in nuclear waste generated, thereby avoiding the need for large geological disposal facilities.

Notably, despite the advanced technology involved, both the capital cost and the per unit electricity cost are comparable to other nuclear and conventional power plants.

Many countries, including the US, Japan and France, have tried developing fast breeder reactors and have given up due to repeated failure to safely handle liquid sodium. Russia commissioned the BN-800 Fast Breeder Reactor in 2016.


(This story has not been edited by THE WEEK and is auto-generated from PTI)
 

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Indian engineering company Larsen & Toubro (L&T) has shipped the second steam generator destined for the units 5 and 6 of the Kaiga nuclear power plant in Karnataka State.

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The steam generator prepares to leave the factory (Image: L&T)


A "flagging off" ceremony was held on 12 July by L&T to mark the shipment of the steam generator from its Hazira complex in Gujarat.


Speaking at the ceremony, Anil Parab, whole-time director and senior executive vice president - L&T Heavy Engineering & L&T Valves, said: "L&T Heavy Engineering, as an industry trendsetter, continues to create global benchmarks in delivery of critical nuclear equipment. Eleven-month early delivery of this second steam generator is another example of consistency and resilience even during pandemic and supply chain disruptions. We are fully geared up as the trusted and dedicated partner of the Department of Atomic Energy and Nuclear Power Corporation of India Limited (NPCIL) to triple the current installed nuclear power capacity to 100 GWe by 2047."


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Workers "flag off" the steam generator (Imagwe: L&T)


In March 2018, L&T Special Steels and Heavy Forgings Private Limited - a joint venture between L&T and NPCIL - received an order worth INR4.42 billion (USD52.9 million) from NPCIL to supply forgings for steam generators. These forgings will be used in the manufacture of the critical equipment for six new indigenous 700 MWe pressurised heavy water reactors (PHWRs), part of the Indian government's plan to construct ten PHWR units.


The Indian cabinet in 2017 approved the construction of ten domestically designed 700 MWe PHWR units using a fleet mode of construction to bring economies of scale as well as maximising efficiency. The first two of these units are Kaiga 5 and 6.


L&T delivered the first steam generator for Kaiga units 5 and 6 in March this year, 12 months ahead of contractual delivery.


Steam generators are heat exchangers used to convert water into steam from heat produced in a nuclear reactor core. In PHWRs, the coolant is pumped, at high pressure to prevent boiling, from the reactor coolant pump, through the nuclear reactor core, and through the tube side of the steam generators before returning to the pump.


L&T says it has "a proven track record of manufacturing more than 42 steam generators for major nuclear power plants across the nation".


Researched and written by World Nuclear News
 

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Kakrapar_Atomic_Power_Plant.jpg

Kakrapar Atomic Power Station

India's first indigenously developed 700 MW nuclear power reactor at the Kakrapar Atomic Power Project (KAPP) in Gujarat started commercial operations on Friday, a senior official said. "With great pleasure, this is to inform that our first indigenous 700 MWe Unit, KAPP-3, has become commercial on 30th June 2023 at 1000 Hrs," a senior KAPP official said.

Presently, the unit is operating at 90 per cent of its total power, he said.

The Nuclear Power Corporation of India Limited (NPCIL) is building two 700 MW pressurised heavy water reactors (PHWRs) at Kakrapar, which is also home to two 220 MW power plants.

Various commissioning activities were underway at KAPP 4, which had achieved 96.92 per cent progress by May end, according to officials.

PHWR_under_Construction_at_Kakrapar_Gujarat_India.jpg

KAPP 3 & 4 during construction phase, 2016

The NPCIL plans to build sixteen 700 MW PHWRs across the country and has granted financial and administrative sanction for the same.

Construction of 700 MW nuclear power plants is underway at Rawatbhata in Rajasthan (RAPS 7 and 8) and at Gorakhpur in Haryana (GHAVP 1 and 2).

The government has sanctioned building of 10 indigenously developed PHWRs in fleet mode at four locations -- Gorakhpur in Haryana, Chutka in Madhya Pradesh, Mahi Banswara in Rajasthan and Kaiga in Karnataka.


The IPHWR-700 builds on the previous IPHWR-220 & 540 MWe models - of which 14 and 2 are in operation respectively.


The new series of this PHWR is making more progress:

 
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