Sistema de simulación de escenarios de ciclos avanzados de combustible nuclear en transición = Simulation system for advanced fuel cycle transition scenarios

El estudio de los ciclos del combustible nuclear requieren de herramientas computacionales o "códigos" versátiles para dar respuestas al problema multicriterio de evaluar los actuales ciclos o las capacidades de las diferentes estrategias y escenarios con potencial de desarrollo en a nivel nacional, regional o mundial. Por otra parte, la introducción de nuevas tecnologías para reactores y procesos industriales hace que los códigos existentes requieran nuevas capacidades para evaluar la transición del estado actual del ciclo del combustible hacia otros más avanzados y sostenibles. Brevemente, esta tesis se centra en dar respuesta a las principales preguntas, en términos económicos y de recursos, al análisis de escenarios de ciclos de combustible, en particular, para el análisis de los diferentes escenarios del ciclo del combustible de relativa importancia para España y Europa. Para alcanzar este objetivo ha sido necesaria la actualización y el desarrollo de nuevas capacidades del código TR_EVOL (Transition Evolution code). Este trabajo ha sido desarrollado en el Programa de Innovación Nuclear del CIEMAT desde el año 2010. Esta tesis se divide en 6 capítulos. El primer capítulo ofrece una visión general del ciclo de combustible nuclear, sus principales etapas y los diferentes tipos utilizados en la actualidad o en desarrollo para el futuro. Además, se describen las fuentes de material nuclear que podrían ser utilizadas como combustible (uranio y otros). También se puntualizan brevemente una serie de herramientas desarrolladas para el estudio de estos ciclos de combustible nuclear. El capítulo 2 está dirigido a dar una idea básica acerca de los costes involucrados en la generación de electricidad mediante energía nuclear. Aquí se presentan una clasificación de estos costos y sus estimaciones, obtenidas en la bibliografía, y que han sido evaluadas y utilizadas en esta tesis. Se ha incluido también una breve descripción del principal indicador económico utilizado en esta tesis, el “coste nivelado de la electricidad”. El capítulo 3 se centra en la descripción del código de simulación desarrollado para el estudio del ciclo del combustible nuclear, TR_EVOL, que ha sido diseñado para evaluar diferentes opciones de ciclos de combustibles. En particular, pueden ser evaluados las diversos reactores con, posiblemente, diferentes tipos de combustibles y sus instalaciones del ciclo asociadas. El módulo de evaluaciones económica de TR_EVOL ofrece el coste nivelado de la electricidad haciendo uso de las cuatro fuentes principales de información económica y de la salida del balance de masas obtenido de la simulación del ciclo en TR_EVOL. Por otra parte, la estimación de las incertidumbres en los costes también puede ser efectuada por el código. Se ha efectuado un proceso de comprobación cruzada de las funcionalidades del código y se descrine en el Capítulo 4. El proceso se ha aplicado en cuatro etapas de acuerdo con las características más importantes de TR_EVOL, balance de masas, composición isotópica y análisis económico. Así, la primera etapa ha consistido en el balance masas del ciclo de combustible nuclear actual de España. La segunda etapa se ha centrado en la comprobación de la composición isotópica del flujo de masas mediante el la simulación del ciclo del combustible definido en el proyecto CP-ESFR UE. Las dos últimas etapas han tenido como objetivo validar el módulo económico. De este modo, en la tercera etapa han sido evaluados los tres principales costes (financieros, operación y mantenimiento y de combustible) y comparados con los obtenidos por el proyecto ARCAS, omitiendo los costes del fin del ciclo o Back-end, los que han sido evaluado solo en la cuarta etapa, haciendo uso de costes unitarios y parámetros obtenidos a partir de la bibliografía. En el capítulo 5 se analizan dos grupos de opciones del ciclo del combustible nuclear de relevante importancia, en términos económicos y de recursos, para España y Europa. Para el caso español, se han simulado dos grupos de escenarios del ciclo del combustible, incluyendo estrategias de reproceso y extensión de vida de los reactores. Este análisis se ha centrado en explorar las ventajas y desventajas de reprocesado de combustible irradiado en un país con una “relativa” pequeña cantidad de reactores nucleares. Para el grupo de Europa se han tratado cuatro escenarios, incluyendo opciones de transmutación. Los escenarios incluyen los reactores actuales utilizando la tecnología reactor de agua ligera y ciclo abierto, un reemplazo total de los reactores actuales con reactores rápidos que queman combustible U-Pu MOX y dos escenarios del ciclo del combustible con transmutación de actínidos minoritarios en una parte de los reactores rápidos o en sistemas impulsados por aceleradores dedicados a transmutación. Finalmente, el capítulo 6 da las principales conclusiones obtenidas de esta tesis y los trabajos futuros previstos en el campo del análisis de ciclos de combustible nuclear. ABSTRACT The study of the nuclear fuel cycle requires versatile computational tools or “codes” to provide answers to the multicriteria problem of assessing current nuclear fuel cycles or the capabilities of different strategies and scenarios with potential development in a country, region or at world level. Moreover, the introduction of new technologies for reactors and industrial processes makes the existing codes to require new capabilities to assess the transition from current status of the fuel cycle to the more advanced and sustainable ones. Briefly, this thesis is focused in providing answers to the main questions about resources and economics in fuel cycle scenario analyses, in particular for the analysis of different fuel cycle scenarios with relative importance for Spain and Europe. The upgrade and development of new capabilities of the TR_EVOL code (Transition Evolution code) has been necessary to achieve this goal. This work has been developed in the Nuclear Innovation Program at CIEMAT since year 2010. This thesis is divided in 6 chapters. The first one gives an overview of the nuclear fuel cycle, its main stages and types currently used or in development for the future. Besides the sources of nuclear material that could be used as fuel (uranium and others) are also viewed here. A number of tools developed for the study of these nuclear fuel cycles are also briefly described in this chapter. Chapter 2 is aimed to give a basic idea about the cost involved in the electricity generation by means of the nuclear energy. The main classification of these costs and their estimations given by bibliography, which have been evaluated in this thesis, are presented. A brief description of the Levelized Cost of Electricity, the principal economic indicator used in this thesis, has been also included. Chapter 3 is focused on the description of the simulation tool TR_EVOL developed for the study of the nuclear fuel cycle. TR_EVOL has been designed to evaluate different options for the fuel cycle scenario. In particular, diverse nuclear power plants, having possibly different types of fuels and the associated fuel cycle facilities can be assessed. The TR_EVOL module for economic assessments provides the Levelized Cost of Electricity making use of the TR_EVOL mass balance output and four main sources of economic information. Furthermore, uncertainties assessment can be also carried out by the code. A cross checking process of the performance of the code has been accomplished and it is shown in Chapter 4. The process has been applied in four stages according to the most important features of TR_EVOL. Thus, the first stage has involved the mass balance of the current Spanish nuclear fuel cycle. The second stage has been focused in the isotopic composition of the mass flow using the fuel cycle defined in the EU project CP-ESFR. The last two stages have been aimed to validate the economic module. In the third stage, the main three generation costs (financial cost, O&M and fuel cost) have been assessed and compared to those obtained by ARCAS project, omitting the back-end costs. This last cost has been evaluated alone in the fourth stage, making use of some unit cost and parameters obtained from the bibliography. In Chapter 5 two groups of nuclear fuel cycle options with relevant importance for Spain and Europe are analyzed in economic and resources terms. For the Spanish case, two groups of fuel cycle scenarios have been simulated including reprocessing strategies and life extension of the current reactor fleet. This analysis has been focused on exploring the advantages and disadvantages of spent fuel reprocessing in a country with relatively small amount of nuclear power plants. For the European group, four fuel cycle scenarios involving transmutation options have been addressed. Scenarios include the current fleet using Light Water Reactor technology and open fuel cycle, a full replacement of the initial fleet with Fast Reactors burning U-Pu MOX fuel and two fuel cycle scenarios with Minor Actinide transmutation in a fraction of the FR fleet or in dedicated Accelerator Driven Systems. Finally, Chapter 6 gives the main conclusions obtained from this thesis and the future work foreseen in the field of nuclear fuel cycle analysis.

Refinery Nonconventional Feedstocks: Influence of the Coprocessing of Vacuum Gas Oil and Low Density Polyethylene in Fluid Catalytic Cracking Unit on Full Range Gasoline Composition

Gasoline coming from refinery fluid catalytic cracking (FCC) unit is a major contributor to the total commercial grade gasoline pool. The contents of the FCC gasoline are primarily paraffins, naphthenes, olefins, aromatics, and undesirables such as sulfur and sulfur containing compounds in low quantities. The proportions of these components in the FCC gasoline invariable determine its quality as well as the performance of the associated downstream units. The increasing demand for cleaner and lighter fuels significantly influences the need not only for novel processing technologies but also for alternative refinery and petrochemical feedstocks. Current and future clean gasoline requirements include increased isoparaffins contents, reduced olefin contents, reduced aromatics, reduced benzene, and reduced sulfur contents. The present study is aimed at investigating the effect of processing an unconventional refinery feedstock, composed of blend of vacuum gas oil (VGO) and low density polyethylene (LDPE) on FCC full range gasoline yields and compositional spectrum including its paraffins, isoparaffins, olefins, napthenes, and aromatics contents distribution within a range of operating variables of temperature (500–700 °C) and catalyst-feed oil ratio (CFR 5–10) using spent equilibrium FCC Y-zeolite based catalyst in a FCC pilot plant operated at the University of Alicante’s Research Institute of Chemical Process Engineering (RICPE). The coprocessing of the oil-polymer blend led to the production of gasoline with very similar yields and compositions as those obtained from the base oil, albeit, in some cases, the contribution of the feed polymer content as well as the processing variables on the gasoline compositional spectrum were appreciated. Carbon content analysis showed a higher fraction of the C9–C12 compounds at all catalyst rates employed and for both feedstocks. The gasoline’s paraffinicity, olefinicity, and degrees of branching of the paraffins and olefins were also affected in various degrees by the scale of operating severity. In the majority of the cases, the gasoline aromatics tended toward the decrease as the reactor temperature was increased. While the paraffins and iso-paraffins gasoline contents were relatively stable at around 5 % wt, the olefin contents on the other hand generally increased with increase in the FCC reactor temperature.

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Reprocessing of irradiated fission reactor fuel and breeding material : a literature search /

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Reprocessing of irradiated fission reactor fuel and breeding material : a literature search /

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Reprocessing of irradiated fission reactor fuel and breeding materials : an annotated bibliography of selected report literature /

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Fuels from tyres by pyrolysis in molten salts

The current annual arisings of used car/van tyres in the U.K. has been found to be around 25m (188,000 tonnes). After the established reuse industries have taken their requirements this leaves 13.5m (102,000 tonnes) waste tyres; a quantity that can no longer be satisfactorily tipped. Laboratory scale experiments have shown that tyre can be pyrolised, using a molten carbonate system as the reaction medium, at rates corresponding to 14.9-42.7 g tyre/min. per litre of melt over the range 475 and 650°C. The product yields by weight of tyre input between the same temperatures are: hydrocarbon oil 23-36 wt. %, hydrocarbon gas 7- 18 wt. %, carbonaceous char 35-40 wt. %, steel 16.7 wt. % and inorganics 5.4 wt. %. The oil and gas evolve from the reactor and can easily be collected by conventional means. The steel and inorganics remain in the reactor although on the commercial scale it is proposed that they would be removed by physical and chemical methods respectively. The char was found to pose considerable handling problems and so a method was devised by which it could be gasified in the reactor. This was best achieved by passing air at a less than stoichiometric rate which gave a gaseous product rich in carbon monoxide. In addition this action provides heat for the system as a whole. The rates at 675-9000C were in the range corresponding to 5.6- 14.89 char/min. per litre of melt. A process flow chart has been proposed for a continuous operation based on these systems. Data from theoretical and experimental studies has enabled economic evaluations of several commercial scales to be carried out. These have shown that 4,000 and 10,000 t/yr operations show a DCF rate of return around 30% while a 50,000 t/yr operation shows 60% which would be attractive to an experienced scrap operator.

The pre-treatment and pyrolysis of biomass for the production of liquids for fuels and speciality chemicals

Fast pyrolysis of biomass is a significant technology for producing pyrolysis liquids [also known as bio-oil], which contain a number of chemicals. The pyrolysis liquid can be used as a fuel, can be produced solely as a source of chemicals or can have some of the chemicals extracted and the residue used as a fuel. There were two primary objectives of this work. The first was to determine the fast pyrolysis conditions required to maximise the pyrolysis liquid yield from a number of biomass feedstocks. The second objective was to selectively increase the yield of certain chemicals in the pyrolysis liquid by pre-treatment of the feedstock prior to pyrolysis. For a particular biomass feedstock the pyrolysis liquid yield is affected by the reactor process parameters. It has been found that, providing the other process parameters are restricted to the values shown below, reactor temperature is the controlling parameter. The maximum pyrolysis liquid yield and the temperature at which it occurs has been found by a series of pyrolysis experiments over the temperature range 400-600°C. high heating rates > 1000°C/s; pyrolysis vapour residence times <2 seconds; pyrolysis vapour temperatures >400 but <500°C; rapid quenching of the product vapours. Pre-treatment techniques have been devised to modify the chemical composition and/or structure of the biomass in such a way as to influence the chemical composition of the pyrolysis liquid product. The pre-treatments were divided into two groups, those that remove material from the biomass and those which add material to the biomass. Component removal techniques have selectively increased the yield of levoglucosan from 2.45 to 18.58 mf wt.% [dry feedstock basis]. Additive techniques have selectively increased the yield of hydroxyacetaldehyde from 7.26 to 11.63 mf w.% [dry feedstock basis]. Techno-economic assessment has been carried out on an integrated levoglucosan production process [incorporating pre-treatment, pyrolysis and chemical extraction stages] to assess which method of chemical production is the more cost effective. It has been found that it is better to pre-treat the biomass in order to increase the yield of specific chemicals in the pyrolysis liquid and hence improve subsequent chemicals extraction.

Improvement of bio-oil stability in wood pyrolysis process

Pyrolysis is one of several thermochemical technologies that convert solid biomass into more useful and valuable bio-fuels. Pyrolysis is thermal degradation in the complete or partial absence of oxygen. Under carefully controlled conditions, solid biomass can be converted to a liquid known as bie-oil in 75% yield on dry feed. Bio-oil can be used as a fuel but has the drawback of having a high level of oxygen due to the presence of a complex mixture of molecular fragments of cellulose, hemicellulose and lignin polymers. Also, bio-oil has a number of problems in use including high initial viscosity, instability resulting in increased viscosity or phase separation and high solids content. Much effort has been spent on upgrading bio-oil into a more usable liquid fuel, either by modifying the liquid or by major chemical and catalytic conversion to hydrocarbons. The overall primary objective was to improve oil stability by exploring different ways. The first was to detennine the effect of feed moisture content on bio-oil stability. The second method was to try to improve bio-oil stability by partially oxygenated pyrolysis. The third one was to improve stability by co-pyrolysis with methanol. The project was carried out on an existing laboratory pyrolysis reactor system, which works well with this project without redesign or modification too much. During the finishing stages of this project, it was found that the temperature of the condenser in the product collection system had a marked impact on pyrolysis liquid stability. This was discussed in this work and further recommendation given. The quantity of water coming from the feedstock and the pyrolysis reaction is important to liquid stability. In the present work the feedstock moisture content was varied and pyrolysis experiments were carried out over a range of temperatures. The quality of the bio-oil produced was measured as water content, initial viscosity and stability. The result showed that moderate (7.3-12.8 % moisture) feedstock moisture led to more stable bio-oil. One of drawbacks of bio-oil was its instability due to containing unstable oxygenated chemicals. Catalytic hydrotreatment of the oil and zeolite cracking of pyrolysis vapour were discllssed by many researchers, the processes were intended to eliminate oxygen in the bio-oil. In this work an alternative way oxygenated pyrolysis was introduced in order to reduce oil instability, which was intended to oxidise unstable oxygenated chemicals in the bio-oil. The results showed that liquid stability was improved by oxygen addition during the pyrolysis of beech wood at an optimum air factor of about 0.09-0.15. Methanol as a postproduction additive to bio-oil has been studied by many researchers and the most effective result came from adding methanol to oil just after production. Co-pyrolysis of spruce wood with methanol was undertaken in the present work and it was found that methanol improved liquid stability as a co-pyrolysis solvent but was no more effective than when used as a postproduction additive.

Studies on the deactivation and reactivation of spent hydroprocessing catalyst

A study is reported on the deactivation of hydroprocessing catalysts and their reactivation by the removal of coke and metal foulants. The literature on hydrotreating catalyst deactivation by coke and metals deposition, the environmental problems associated with spent catalyst disposal, and its reactivation/rejuvenation process were reviewed. Experimental studies on catalyst deactivation involved problem analysis in industrial hydroprocessing operations, through characterization of the spent catalyst, and laboratory coking studies. A comparison was made between the characteristics of spent catalysts from fixed bed and ebullating bed residue hydroprocessing reactor units and the catalyst deactivation pattern in both types of reactor systems was examined. In the laboratory the nature of initial coke deposited on the catalyst surface and its role on catalyst deactivation were studied. The influence of initial coke on catalyst surface area and porosity was significant. Both catalyst acidity and feedstock quality had a remarkable influence on the amount and the nature of the initial coke. The hydroenitrogenation function (HDN) of the catalyst was found to be deactivated more rapidly by the initial coke than the hydrodesulphurization function (HDS). In decoking experiments, special attention was paid to the initial conditions of coke combustion, since the early stages of contact between the coke on the spent catalyst surface and the oxygen are crucial in the decoking process. An increase in initial combustion temperature above 440oC and the oxygen content of the regeneration gas above 5% vanadium led to considerable sintering of the catalyst. At temperatures above 700oC there was a substantial loss of molybdenum from the catalyst, and phase transformations in the alumina support. The preferred leaching route (coked vs decoked form of spent catalyst) and a comparison of different reagents (i.e., oxalic acid and tartaric acid) and promoters (i.e., Hydrogen Peroxide and Ferric Nitrate) for better selectivity in removing the major foulant (vanadium), characterization and performance evaluation of the treated catalysts and modelling of the leaching process were addressed in spent catalyst rejuvenation studies. The surface area and pore volume increased substantially with increasing vanadium extraction from the spent catalyst; the HDS activity showed a parallel increase. The selectivity for leaching of vanadium deposits was better, and activity recovery was higher, for catalyst rejuvenated by metal leaching prior to decoking.

Synthesis and characterisation of pillared clay catalysts for hydro-cracking of heavy liquid fuels

A range of chromia pillared montmorillonite and tin oxide pillared laponite clay catalysts, as well as new pillared clay materials such as cerium and europium oxide pillared montmorillonites were synthesised. Methods included both conventional ion exchange techniques and microwave enhanced methods to improve performance and/or reduce preparation time. These catalytic materials were characterised in detail both before and after use in order to study the effect of the preparation parameters (starting material, preparation method, pillaring species, hydroxyl to metal ratio etc.) and the hydro cracking procedure on their properties. This led to a better understanding of the nature of their structure and catalytic operation. These catalysts were evaluated with regards to their performance in hydrocracking coal derived liquids in a conventional microbomb reactor (carried out at Imperial College). Nearly all catalysts displayed better conversions when reused. The chromia pillared montmorillonite CM3 and the tin oxide pillared laponite SL2a showed the best "conversions". The intercalation of chromium in the form of chromia (Cr203) in the interlayer clearly increased conversion. This was attributed to the redox activity of the chromia pillar. However, this increase was not proportional to the increase in chromium content or basal spacing. In the case of tin oxide pillared laponite, the catalytic activity might have been a result of better access to the acid sites due to the delaminated nature of laponite, whose activity was promoted by the presence of tin oxide. The manipulation of the structural properties of the catalysts via pillaring did not seem to have any effect on the catalysts' activity. This was probably due to the collapse of the pillars under hydrocracking conditions as indicated by the similar basal spacing of the catalysts after use. However, the type of the pillaring species had a significant effect on conversion. Whereas pillaring with chromium and tin oxides increased the conversion exhibited by the parent clays, pillaring with cerium and europium oxides appeared to have a detrimental effect. The relatively good performance of the parent clays was attributed to their acid sites, coupled with their macropores which are able to accommodate the very high molecular mass of coal derived liquids. A microwave reactor operating at moderate conditions was modified for hydro cracking coal derived liquids and tested with the conventional catalyst NiMo on alumina. It was thought that microwave irradiation could enable conversion to occur at milder conditions than those conventionally used, coupled with a more effective use of hydrogen. The latter could lead to lower operating costs making the process cost effective. However, in practice excessive coke deposition took place leading to negative total conversion. This was probably due to a very low hydrogen pressure, unable to have any hydro cracking effect even under microwave irradiation. The decomposition of bio-oil under microwave irradiation was studied, aiming to identify the extent to which the properties of bio-oil change as a function of time, temperature, mode of heating, presence of char and catalyst. This information would be helpful not only for upgrading bio-oil to transport fuels, but also for any potential fuel application. During this study the rate constants of bio-oil's decomposition were calculated assuming first order kinetics.

The intermediate pyrolysis and catalytic steam reforming of brewers spent grain

Brewers spent grain (BSG) is a widely available feedstock representing approximately 85% of the total by-products generated in the brewing industry. This is currently either disposed of to landfill or used as cattle feed due to its high protein content. BSG has received little or no attention as a potential energy resource, but increasing disposal costs and environmental constraints are now prompting the consideration of this. One possibility for the utilisation of BSG for energy is via intermediate pyrolysis to produce gases, vapours and chars. Intermediate pyrolysis is characterised by indirect heating in the absence of oxygen for short solids residence times of a few minutes, at temperatures of 350-450 °C. In the present work BSG has been characterised by chemical, proximate, ultimate and thermo-gravimetric analysis. Intermediate pyrolysis of BSG at 450 °C was carried out using a twin coaxial screw reactor known as Pyroformer to give yields of char 29%, 51% of bio-oil and 19% of permanent gases. The bio-oil liquid was found to separate in to an aqueous phase and organic phase. The organic phase contained viscous compounds that could age over time leading to solid tars that can present problems in CHP application. The quality of the pyrolysis vapour products before quenching can be upgraded to achieve much improved suitability as a fuel by downstream catalytic reforming. A Bench Scale batch pyrolysis reactor has then been used to pyrolyse small samples of BSG under a range of conditions of heating rate and temperature simulating the Pyroformer. A small catalytic reformer has been added downstream of the reactor in which the pyrolysis vapours can be further cracked and reformed. A commercial reforming nickel catalyst was used at 500, 750 and 850 °C at a space velocity about 10,000 L/h with and without the addition of steam. Results are presented for the properties of BSG, and the products of the pyrolysis process both with and without catalytic post-processing. Results indicate that catalytic reforming produced a significant increase in permanent gases mainly (H2 and CO) with H2 content exceeding 50 vol% at higher reforming temperatures. Bio-oil yield decreased significantly as reforming temperature increased with char remaining the same as pyrolysis condition remained unchanged. The process shows an increase in heating value for the product gas ranging between 10.8-25.2 MJ/m as reforming temperature increased. © 2012 Elsevier B.V. All rights reserved.