Proceedings of the 3rd Applied Science for Technology Innovation, ASTECHNOVA 2014

International Energy Conference

Yogyakarta, Indonesia, 13-14 August 2014

Modular Concept and Optimization of

PCMSR 250 MWe Turbine Module
Andang Widi Harto
Engineering Physics Department, Universitas Gadjah Mada
Jln. Grafika No.2, Yogyakarta 5528, Indonesia
andangftn@yahoo.com; andangwh@ugm.ac.id

ABSTRACT
Passive Compact Molten Salt Reactor (PCMSR) is a modular advanced nuclear reactor type. The
PCMSR uses liquid fuel (molten fluoride salt) and solid graphite moderator. The PCMSR is designed as a
thermal breeder reactor, thus the fuel consumption is very efficient and the amount of radioactive waste is
reduced significantly. Another important features of PCMSR are inherently safe, totally passive safety
system and economic. For cost reduction, PCMSR applies the concept of simplicity and modularity.
PCMSR design consists of reactor module, turbine module and fuel management module. The turbine
module is a regenerative multi stage Brayton cycle consists of four stages turbine and heater, four stages
compressor and cooler plus one stage regenerator. The maximum temperature operation is 1323 K (1150
C) and minimum temperature operation is 333 K (60 C).
The turbine system performance analysis will be performed by calculating overall turbine system
efficiency. This will be calculated using formula derived from thermodynamics multistage regenerative
Brayton cycle. For the optimum design, more detail heat transfer calculation will be performed for heat
transfer equipment, i.e. heaters, coolers and regenerator.
Overall efficiency calculation shows that the maximum efficiency is 56 % at optimum turbine
pressure ratio of 4.3 for 4 stages turbine and 4 stages compressor. The isentropic efficiency of turbines
and compressors are 93 % and 88 % respectively. The same value of heat transfer capability is designed
for all heaters and compressors.
Heat transfer calculation shoes that the active length of the heaters and the coolers are
approximately the same, i.e. 5 m. The active length of recuperator is 11.2 m. With these sizes of the
heaters, coolers and recuperators, the estimated total length of the turbine module is roughly 20 m.
With these sizes, the turbine module can be completely fabricated in a workshop, transported and
erected to power plant site.
KEYWORDS: PCMSR, modularity, turbine module optimization
1

INTRODUCTION

The worldwide human energy demand is predicted to be increase in the next decades, according to
World Energy Resources and Consumption. However the conventional energy resources (coal, oil and
natural gas) capability in supporting the next energy demand will be reduced due to diminishing of these
resources and the environmental impact related to the uses conventional energy resources, i.e. greenhouse
gas effect. For replacing the conventional energy uses, nuclear energy is the prominent alternative that has
been proven technologically and economically.
However, the recent nuclear reactors commonly use U-235 as the effective nuclear fuel. Due to the
fact that natural uranium resources contains only 0.71 % of U-235, the recent nuclear reactors use only
78

0.6 % - 0.7 % of the overall nuclear fuel resources. With the amount of the known proven natural uranium
recently is 5000 kilo tons (Energy Watch Group, 2006) and the recent worldwide nuclear reactor capacity
power is 400 GWe (http://www.nucleartourist.com/), the worldwide known proven nuclear fuel resources
will be available only for 50 until 80 years (Energy Watch Group, 2006).
The fact that the common nuclear reactor recently use only 0.6 % - 0.7 % of the overall nuclear fuel
resources means that more than 99 % of the nuclear material become waste. Estimately 12 % of the
nuclear material will become spent fuel and the rest is depleted uranium. Moreover, another potential
nuclear fuel resource, i.e. thorium, still can not be used.
Thus, it is important to develop the next generation of nuclear reactor to use the rest of natural
uranium content (U-238), reuse nuclear spent fuel or use the more abundant nuclerr fuel resource, i.e.
thorium. Because all nuclear material resources can be used in such reactor, the nuclear fuel utility factor
can increased with the factor of 150 times. It means that the recently known nuclear fuel resources will be
available for more than 1000 years. (Based on US Geological Survey, Mineral Commodity Summaries
(1997-2006) and OECD/NEA, Nuclear Energy, Trends in Nuclear Fuel Cycle, Paris, France (2001)).
2

FUNDAMENTAL THEORY

2.1

PCMSR (Passive Compact Molten Salt Reactor)

PCMSR (Passive Compact Molten Salt Reactor) is designed to use the natural nuclear fuel
resources of thorium. The thorium in non fisile fuel thus it must be converted to the fissile fuel of U-233
by the reactor itself. PCMSR use liquid fluoride salt with the composition of 39.9 % mole 232ThF4, mole
59.6 % 7LiF, 0.5 % of fissile component, ant small fraction of minor actinides and fission product
nuclides. The exact fuel composition is depend on the initial fuel composition (i.e. depend on the fuel
fabrication) and the on line fuel reprocessing during operation (Uhlir, 2009). PCMSR use graphite as
moderator and structure and euthectic flinak salt (LiF-NaK-KF) as intermediate coolant (Harto, 2012).
The use of molten salt fuel combined with graphite moderator gives some important benefits, i.e. :
a. Molten salt has high boiling point (1400 C) and graphite does not melt but will sublime at 3300
C (Benes et al., 2009). It means that the reactor can be operated at very high temperature at
atmospheric pressure. This gives potential to achieve high efficiency of energy conversion
meanwhile eliminate the probability of the pressure expansion accident.
b. The use of liquid fuel salt allows incorporating of the on line refueling and fuel reprocessing
system. The neutron poison fission product can be continually removed meanwhile the fissile and
fertile fuel can be added to the reactor as it is needed (Forsbeg et al., 2004).
c. Pa-233 can be removed from reactor to allow it to decay to become U-233. In the reactor core,
Pa-233 has probability to absorb neutron to become non valuable U-234. Thus removing Pa-233
can increase the reactor breeding capability (Forsbeg et al., 2004).
d. The fertile material Th-232 gives strong contribution to achieve relatively large negative
temperature coefficient (Forsbeg et al., 2004).
e. The points a, b, c and d give the possibility to design the reactor core which has very little fuel
excess reactivity as well as negative temperature reactivity coefficient. These mean that the
reactor has inherent safety characteristic and the incorporating the passive shutdown system is
possible (Forsbeg et al., 2004).
f. The high temperature operation makes the PCMSR can be used as high temperature heat supply
system as well as efficient electric power generation. The high temperature heat can be used as
many commercial application such as efficient hydrogen production, coal gasification and
liquefaction, metal ore reduction etc (Forsbeg et al., 2004).

79

The fuel cost of PCMSR is estimated be 1/7 of the fuel and waste cost of the recent nuclear reactor
technology (LWR) (Whatley et al., 2004). This is due to the breeding capability and the application on
line refueling and fuel reprocessing.
The capital cost of PCMSR is also estimated to be reduced due to the application of modularity
concept. The target of the overall generating cost of PCMSR design is 2 cent US$ per kWh or even lower.
The total generation cost of the recent nuclear technology is roughly 4 to 5 cent US$ per kWh.
The PCMSR design applies integral and modularity concept. PCMSR has three main modules, i.e.
reactor module, turbine module and fuel management module. This paper deals with the turbine module.
Each module consists of several related components and equipment those are arranged into integral
design.
2.2

The Turbine Module of PCMSR

PCMSR can be operated at very high temperature due to the using of graphite moderator, fuel salt
and coolant salt (Benes et al., 2009). Due to the high temperature operation, PCMSR does not use
Rankine Cycle steam turbine as common for the recent nuclear power plant technology. PCMSR uses
multi heating, multi cooling and regenerating Brayton Cycle gas turbine. The PCMSR uses multi heating,
multi cooling and regenerating Brayton Cycle gas turbine. The PCMSR turbine system consists of
multistage turbine, multistage compressor, multi stage heater, multi stage cooler and regenerator or
recuperator.
Figure 1 shows the schematic diagram of a a PCMSR system using multi stage regenerative
Brayton cycle (Harto, 2012).
3

METHOD
The calculation method involving three steps, i.e.
- General parametric optimization
- Detail calculation on heat exchanger (heater, cooler, recuperator)
- Detail calculation on blades (turbine stator, turbine rotor, compressor rotor, compressor stator).

3.1

General parametric optimization

The aim of general parametric optimization is to provide the optimum operation condition that
gives maximum energy conversion efficiency at turbine operation temperature suitable with reactor
operation condition. Using thermodynamics cycle formulation, the energy conversion efficiency of multi
heating, multi cooling and regenerating Brayton cycle can be calculated as
1
1

N E
NC

R
TC
N
1
pC
C

1
M L H N E E 1

TA pE R pE C pC

1
1

1 N E
R pC NC
TC
1
1 R 1
1 R TE
1 R E N E 1 R 1

TA
TA
C pC
pE R pE

where:

Overall efficiency of turbine system

TC
80

Maximum cycle temperature

(1)

M
L
H
E
C
pE
pC
R

Mechanical efficiency of turbine system

TA
TE

Efficiency of electrical system

Heater efficiency
Isentropic efficiency of turbine

R pE
R pC
NE
NC

Isentropic efficiency of compressor

Expansion efficiency of turbine
Expansion efficiency of compressor

Minimum cycle temperature

Bottom regenerator temperature difference
Ratio of cp to cv
Total turbine pressure ratio
Total compressor pressure ratio
Number of turbine stages
Number of compressor stages

Recuperator efficiency
10

P CMS R ENERGY
CONVERS ION S YS TEM
S CHEMATIC DIAGRAM

6
4
1

20
19

14

13

12

18

17

16

11

15

24

23

22

21

26
3

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

25

Re a ctor
P rima ry he a t e xcha nge r
Fue l circula tion pump
Inte rme dia te he a t e xcha nge r
P rima ry coola nt circula tion pump (if ne ce ssa ry)
Inte rme dia te coola nt circula tion pump
1 st sta ge he a te r (high pre sure )
2 nd sta ge he a te r (me dium high pre ssure )
3 rd sta ge he a te r (me dium low pre ssure )
4 th sta ge he a te r (low pre ssure )
1 st sta ge turbine (high pre ssure )
2 nd sta ge turbine (me dium high pre ssure )
3 rd sta ge turbine (me dium low pre ssure )

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

4 th sta ge turbine (low pre ssure )

Re cupe ra tor
1 st sta ge compre ssor (low pre ssure )
2 nd sta ge compre ssor (me dium low pre ssure )
3 rd sta ge compre ssor (me dium high pre ssure )
4 th sta ge compre ssor (high pre ssure )
Ele ctric ge ne ra tor
1 st sta ge coole r (low pre ssure )
2 nd sta ge coole r (me dium low pre ssure )
3 rd sta ge coole r (me dium high pre ssure )
4 th sta ge coole r (high pre ssure )
Cooling wa te r circula tion pump
He a t sink syste m

Figure 1: The schematic diagram of a PCMSR system using multi stage regenerative Brayton cycle
(Harto, 2012)
3.2

Detail heat exchanger calculation

PCMSR turbine system uses several heat exchangers, those are multi stage heaters, multistage
coolers and recuperators (Harto, 2012a). All of the heat exchangers are counter flow shell and tube types.
In all of the heat exchanger, heat is transferred from the hot fluid to the cold fluid. At the heaters, the hot
fluid is intermediate coolant salt and the cold fluid is helium working fluid. At the coolers, the hot fluid is
helium working fluid and the cold fluid is cooling water. At recuperators the hot fluid is low pressure
helium and the cold fluid high pressure helium.
The heat exchanger calculation is conducted by using
the formula of :

UNT Di T1 T2
dT1

dz

dc
m 1 c P1 T1 P1
dT1

and

UN T Di T1 T2 U Loss D S T2 TL
dT2

dz

dc
m 2 c P 2 T2 P 2
dT2

81

(2)

where:

Fluid temperature

Di
m

Inner tube diameter

NT
U
DS
U Loss

Fluid mass flow rate

Axial position

Number of tubes
Overall heat transfer coefficient
Overall heat exchanger inner diameter
Heat loss coefficient

The index of 1 and 2 refer to the first fluid and the to the second fluid respectively.

3.3

Detail turbine and compressor blades calculation

Detail turbine and compressor blades calculation is performed for the optimal turbine condition
only. This calculation is performed to get thermodynamics condition of the working fluid as it flows
through turbine or compressor blades. The results of the calculation are pressure difference, enthalpy
difference, velocity difference and temperature difference of the working fluid along the blades (i.e. from
blade inlet to blade outlet). The calculation also performed to get the blade power. The blade geometry is
arranged to get the overall blade power suitable with the optimum condition resulted from the previous
general parametric calculation.
The method of this calculation is the solving of one dimensional mass flow, momentum and energy
balances plus modified ideal gas equation of state along flow line of the gas fluid in the turbine or
compressor blades. The finite difference method is used to perform these calculations.
The additional calculation (i.e. velocity triangle) is also preformed to calculate pressure drop
between stator and rotor for all turbine blades or compressor blades.
4

RESULT AND DISCUSSION

4.1

General parametric optimization

The aim of this calculation is to provide optimum turbine configurations which give maximum
thermodynamics (energy conversion) efficiency. In this calculation, several parameters are assumed to
have fixed values. These parameters are: p F ,regenerator = 0,7 bar, p E ,regenerator = 0,7 bar, p C = 60 bar, T A =
333 K,

99,3 %,

= 88 %,

pC

= 99,3 %,

= 93 %,

= 99,9 %,

= 98,8 %,

= 99 %,

= 97 % ,

TE = 50 K, pE =

TC = 1373 K. The calculation is performed by varying the number of heating and

cooling stages and the turbine system pressure ratio. The calculation result is shown at Table 1.
Table 1 shows that for every number of heating and cooling, there is a maximum value of turbine
pressure ratio that gives maximum efficiencies.
Table 1: Efficiency of Regenerative Multistage Equal Heating Equal Cooling Brayton with helium
working fluid and turbine inlet temperature 1373 K
2 heating stages
and 2 cooling stages
(%)
RPE

2 heating stages
and 2 cooling stages
(%)
RPE

2 heating stages
and 2 cooling stages
(%)
RPE

1,3745
1,9645
2,6568
3,4511
4,3474

1,9285
2,4041
2,9456
4,2667
6,8966

3,0252
3,2945
4,3223
5,5715
7,9251

44,1779
51,3322
52,3724
51,9718
51,0226

52,2499
54,0122
54,5503
54,4986
53,0824

82

55,4985
55,7490
56,1342
56,1087
55,6781

P AS S IVE C OMP AC T MOLTEN S ALT

R EAC TOR (P C MS R )
TUR BINE S YS TEM
R EMAR KS :
1. 1 s t s tage turbine (high pres s ure)
2. 2 nd s tage turbine (medium high
pres s ure)
3. 3 rd s tage turbine (medium low
pres s ure)
4. 4 th s tage turbine (low pres s ure)
5. 1 s t s tage compres s or (low pres s ure)
6. 2 nd s tage compres s or
(medium low pres s ure)
7. 3 rd s tage compres s or
(medium high pres s ure)
8. 4 th s tage compres s or
(high pres s ure)

9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

15

14

1 s t s tage heater (high pres s ure)

1 s t s tage cooler (low pres s ure)
R ecuperator
Bottom bearing and flywheel
Top bearing and flywheel
Generator
Exciter
Electrical bus h
Intermediate s alt expans ion tank
intermediate s alt pump
Helium s torage tank for turbine maintenance
C ompartment for helium purification s ys tem
C ompartment for auxiliary machinery s ys tem
C ompartment for auxiliary electrical s ys tem
C ooling water circulation pump
Air cooled heat rejection s ys tem
C ooling air induced fan
22
16

13

17

25
4

20

21

2
4

3
9
2

18

19
11
5

6
10

23
7

8
12

Figure 2: The schematic diagram of the PCMSR turbine module (Harto, 2012)

83

1
5

b
4

7
2

4
8

4
8

1.
2.
3.
4.
5.
7.

TURBINE S ECTION ARRANGEMENT OF P CMS R

TURBINE S YS TEM
1 s t s tage heater (high pres s ure)
nd
2 s tage heater (medium high pres s ure)
3 rd s tage heater (medium low pres s ure)
4 th s tage heater (low pres s ure)
Recuperator
6. Turbine s haft
Turbine dis k
8. Turbine blade

1.
2.
3.
4.
5.
7.

COMP RES S OR S ECTION ARRANGEMENT OF

P CMS R TURBINE S YS TEM
1 s tage cooler (low pres s ure)
nd
2 s tage cooler (medium low pres s ure)
3 rd s tage cooler (medium high pres s ure)
4 th s tage cooler (high pres s ure)
Recuperator
6. Compres s or s haft
Compres s or dis k
8. Compres s or blade
st

.
Figure 3: Radial arrangement of PCMSR turbine
module at turbine section

Figure 4: Radial arrangement of PCMSR turbine

module at compressor section

The 4 heating and 4 cooling stages design is then chosen as reference design and will be used for the next
more detail calculation. For this reference design, the optimum turbine pressure ratio is approximately
4.3. This gives the maximum efficiency of 56 %.
4.2

Heat exchanger calculation

The results of heat exchanger calculation using Eq. (2) are shown at Table 2. The PCMSR turbine
system is designed to have equal heating values for all of the heating stages and also equal cooling values
for all of cooling stages. The consequence of this design is the length of heaters for all of heating stages
and the length of all coolers for all of cooling stages are almost the same. Table 2 shows that the active
lengths of all heaters and all coolers are approximately the same of 5 m. The recuperators has the active
length of 11.2 m. Referring to the turbine system arrangement as shown at Figure 2, the length of turbine
module vessel is approximately 15 m. With the addition of the length of generator and exciter (estimated
as 5 m), the total length becomes 20 m.
All of the heaters, coolers and recuperators have roughly the same diameters of 1.3 m. There are
totally twenty heat exchangers (8 heaters (2 parallel heaters per stage), 8 coolers (2 parallel coolers per
stages), 4 parallel recuperators) that to be arranged as shown at Figure 2 or Figure 3. With this
arrangement, the diameter of the turbine module vessel is approximated 7 m. This size (i.e. the total
length of 20 m and the total diameter of 7 m) makes the possibility to manufacture the overall turbine
module completely in a workshop. The complete turbine module is then transported to the power plant
site and erected. This design full fills the modularity concept requirement.
84

Table 2: Calculation result for heaters coolers and recuperators of PCMSR 250 MWe
Parameter

Cooler 1

Cooler 2

Cooler 3

Cooler 4

Heater 1

Pressure

Low

Medium
low

Medium
high

High

High

Tube fluid

Water

Water

Water

Water

Shell fluid
Paralel unit number
Number of tube per unit
Outer tube diameter (cm)
Tube thickness (cm)
Intertube pitch (cm)
Effective cross section per unit (m2)
Effective diameter per unit (m)
Effective length (m)
Tube fluid flow rate (kg/s)
Shell fluid flow rate (kg/s)
Tube fluid inlet temperature (K)
Tube fluid outlet temperature (K)
Shell fluid inlet temperature (K)
Shell fluid outlet temperature (K)
Tube fluid pressure drop (bar)
Shell fluid pressure drop (bar)
Heat transfer rate (MW)

Helium
2
9750
0.7
0.1
1.2
1.2159
1.2442
5.15
220
150
320.041
363.000
389.014
332.939
0.0522
0.0782
43.3760

Helium
2
9750
0.7
0.1
1.2
1.2159
1.2442
5.03
220
150
319.242
363.000
389.637
332.961
0.0511
0.0533
44.1864

Helium
2
9750
0.7
0.1
1.2
1.2159
1.2442
5.02
220
150
319.181
363.000
389.597
333.013
0.0510
0.0369
44.2501

Helium
2
9750
0.7
0.1
1.2
1.2159
1.2442
4.98
220
150
318.956
363.000
389.839
333.001
0.0506
0.0255
44.4792

4.3

Fluoride
salt
Helium
2
9000
0.7
0.1
1.25
1.2178
1.2452
5.09
427.25
150
1731.000
1233.179
1179.476
1232.000
0.1345
0.1103
112.1044

Heater 2

Heater 3

Medium
high
Fluoride
salt
Helium
2
9000
0.7
0.1
1.25
1.2178
1.2452
5.05
427.25
150
1731.000
1233.616
1179.475
1232.000
0.1334
0.1488
111.7547

Medium
low
Fluoride
salt
Helium
2
9000
0.7
0.1
1.25
1.2178
1.2452
4.93
427.25
150
1731.000
1235.415
1180.261
1232.000
0.1302
0.1976
110.2958

Heater 4
Low
Fluoride
salt
Helium
2
9000
0.7
0.1
1.25
1.2178
1.2452
4.74
427.25
150
1731.000
1237.690
1180.262
1232.000
0.1252
0.2585
108.4797

recupera
tor
High /
Low
Helium
Helium
4
18250
0.7
0.1
0.91
1.2909
1.3088
11.22
150
150
1228.064
389.014
350.661
1179.759
0.9101
0.8684
647.5381

Turbine blades calculation

The turbine and compressor blades (both stator and rotor) are optimize for the nominal rotational
speed of 3000 rpm. The thermodynamic parameter calculation result for 250 MWe PCMSR turbine
system is shown at Table 3. The all heating stages and all cooling stages are designed to operate at the
same heat transfer value and at the same temperature operation range.
As the consequence of this design, the all of turbine stages except the last turbine stage have almost
the same power. Also the all of compressor stages except the last compressor stage have almost the same
power.
The last turbine stage has lower power to get higher outlet temperature to provide adequate upper
regeneration temperature difference. The last compressor stage has lower power to get lower outlet
temperature to provide adequate lower regeneration temperature difference.
The geometry calculation results show that the average turbine blade radius is 157 cm (3.14 m of
average diameter) and the average compressor blade diameter is 102 cm (2.04 m average radius).
5

CONCLUSION

The optimization of turbine module design of PCMSR 250 MWe has been calculated. The result of
these calculation shows that it is possible to get the design that full fill modularity requirement, i,e, can be
completely manufactured in a workshop and then completely transported and erected to the power plant
site.

85

Table 3: Turbine and compressor calculation result for PCMSR 250 MWe turbine system
Parameter
Type
Working fluid
Mass flow rate (kg/s)
Pressure operation
category
Inlet temperature (K)
Outlet temperature (K)
Inlet pressure (bar)
Outlet pressure (bar)
Pressure ratio
Isentropic efficiency (%)
Power (MW)
Total Power (MW)
Overall pressure ratio
regeneration temperature
difference (K)

stage 1

High
1323,000
1179,759
60,0000
44,1177
1,3600
93,7193
111,2513

Turbine
stage 2
stage 3
Axial flow turbine
Helium
150
Medium
Medium
High
Low
1323,000 1323,000
1180,081 1180,786
44,0640
32,3648
32,4319
23,7978
1,3587
1,3600
93,8501
93,2131
111,3698 111,6715
414,4916
3,0930

stage 4

stage 1

Low

Low

1323,000
1228,064
22,5919
19,3986
1,2237
93,0503
80,1990

333,000
389,225
18,3611
26,4644
1,4413
88,0266
41,0210

48,035 (upper)

Compressor
stage 2
stage 3
Axial flow turbine
Helium
150
Medium
Medium
Low
High
333,000
333,000
389,399
389,692
26,3714
37,9729
38,0436
54,6364
1,4426
1,4388
88,0756
87,9935
41,1003
40,7634
136,3017
3,3220

stage 4

High
333,000
349,652
54,5813
60,9961
1,1175
87,8108
13,4170

39,573 (lower)

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86