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ORNL-TM-3229.txt
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,)/ | .~ =« BECEIVED BY DTIE .4} 14 197y
OAK RIDGE NATIONAL LABORATORY
operated by
UNION CARBIDE CORPORATION
for the
U.5. ATOMIC ENERGY COMMISSION
ORNL- TM- 3229
COPY NO. -
DATE - November 19, 1970
FLUID DYNAMIC STUDIES
OF THE MOLTEN-SALT REACTOR EXPERIMENT (MSRE) CORE
R. J. Kedl
5
ABSTRACT
In the MSRE reactor wvessel, fluid fuel is circulated at 1200 gpm
down through an annular region and up through 1140 passages in the
grephite core. The core design was based on preliminary tests in
a one-fifth scale model, followed by detailed measurements with
water solutions in a full-scale mockup of the reactor vessel and
internals. This report describes the models, the testing, and the
date from which velocity, pressure drop and flow patterns are deduced.
It also describes how the measurements were extrapolated to molten
salt at 1200°F in the actual reactor. The few observations possible
in the reactor were consistent with the predicted behavior.
KEYWORDS :
MOLTEN-SALT REACTORS, CORES, DESIGN, DEVELOPMENT, FLUID-FLOW, MSRE,
REACTOR VESSEL, FLOW MEASUREMENT, MODELS
NOTICE This document contains information of a preliminary nature
ond was prepared primarily for internal use at the Ouk Ridge National
Laboratory. It is subject to revision or correction and therefore does
not represent a final report.
DISTRIBUTION OF THIS DOCITMENT 1S UNLIMITED
This report was prepared as an account of work sponsored by the United
States Government. Neither the United States nor the United States Atomic
Energy Commission, nor any of their employees, nor any of their contractors,
subcontractors, or their employees, makes any warranty, express or implied, or
assumes any legal liability or responsibility for the accuracy, completeness or
usefulness of any information, apparatus, product or process disclosed, or
represents that its use would not infringe privately owned rights.
iii
i CONTENTS
o | _ ' Page No.
3 ABSTRACT o |
INTRODUCTION - . | | | 1
DESCRIPTION OF MSRE CORE AND TEST PROGRAM 1
One-Fifth Scale Model y
Full Scale Model T
DESCRIPTION AND ANALYSIS OF TEST RESULTS 9
Volute and Core Wall Cooling Annulus 9
Reactor Vessel Lower Head | ' 14
Graphit.é Moderator Assembly ' | 20
- Reactor Vessel Upper Head ' : ' . 25
o Miscellaneous Measurements | 26
EXPERIENCE WITH THE MSRE | o | 31
REFERENCES | | | 32
_LEGAL NOTICE-
This report was prepared as an account of work
© | sponsored by the United States Government, Neither
| the United States nor the United States Atomic Energy
Commission, nor any of their employees, nor any of
their contractors, subcontractors, or their employees,
makes any warranty, express or implied, or assumes any
: legal liability or responsibility for the accuracy, com-
1 pleteness or usefulness of any information, apparatus,
product or process disclosed, or represents that its use | .
would not infringe privately owned rights, :
" ‘-Q;,_\
. N ~ T e
ms'fBIBUT‘lON OF 'l"Hj_lS DOCUMENT 13 UNL‘I-M’]ED
"
- INTRODUCTION
The MSRE (Molten-Salt Reactor Experiment) is a 7.3 MV fluid-fueled,
graphite-moderated, single region nuclear resctor. The fuel consists of
uranium fluoride dissolved.in a mixture of lithium, beryllium end zir-
conium fluorides. A unique feature of this reactor concefitris that the
power is generated in circulating fluid fuel rather than stationary solid
fuel elements. The nominal operating temperature is 1200°F. A detailed
description of the reactor_concept and its components is available in many
sources, for instance References 'l, 2 and 3. A program was undertaken to
determine the fluid dynamic and heat transfer characteristics of the core.
This report presents the results of that effort. Most of the experimental
results preséfited here were obtained in the early 1960's. This report was not
_ N
written, however, until after the MSRE:nuclear operations were terminated
in December of 1969.
DESCRIPTION OF MSRE CORE AND TEST PROGRAM
Figure'l shows an isometrié view. of tfie MSRE core. 'The-fuel enters
the reactor vessel at 1200_gpm through acénstant,flowarea volute near
the top of the cylindrical section. Becausé of the varisble pressure
gradient in evolute of this'type, orifices are used to obtain a uniform
angular flcw'distribution tb the core wall cooling annulus. The fuel then
swirls down the core wall cooling annulus and into the reactor vessel lower
- head. Radial vanes are placed in the lower head to destroy the swirl gen-
erated by the volute. The lower{head,then serves &s & plenum to direct the
fuel uniformly to the_mbderatbf'région. The moderator region is composed
of long graphite'core b1ocks, squéré-in cfossisection; and with grooves.
cut longitudinally in the'h'faces; ‘When these stringers are assembled
veftically together,'the_grooves_formgthe fuel passages. Figure 2 shows
en ‘isometric and a planVViév ofra*small_clustef or core blocks. After
u-paésifig through the mpdératbr,,the-fuellthen goes into the vessel upper.
head vhich serves as a collection plenum end directs the fuel to the outlet
pipe. Each of these various regions of the core will be described in more
detail in the'appropriaté section of this report.
GRAPHITE SAMPLE ACCESS PORT
“
FUEL OUTLET =~ _
- CORE ROD THIMBLES - =
" e
LARGE GRAPHITE SAMPLES =
CORE CENTERING GRID
CORE SUPPORT
FLANGE
GRAPHITE ~MODERATOR Al
CORE BLOCKS '
5
=
-
i
!
iz
i
F
i
3 i,
* N
ll
i
i
1
-
i
FUEL INLET -/
" REACTOR CORE CAN —~
REACTOR VESSEL -
ANTI-SWIRL VANES
VESSEL DRAIN LINE
FIGURE 1.
1668
ORNL-LR-DWG G1097RIA
FLEXIBLE CONDUIT TO
CONTROL ROD DRIVES
COOLING AR LINES
ACCESS PORT COOLING JACKETS
REACTOR ACCESS PORT
SMALL GRAPHITE SAMPLES
HOLD-DOWN ROD
OUTLET STRAINER
FLOW DISTRIBUTOR
VOLUTE
~\—_FLOW DISTRIBUTION
ORIFICES
T~ CORE WALL COOLING ANNULUS
f 2 MODERATOR
_ SUPPORT GRID
MSRE REACTOR VESSEL
3
- ORNL-LR~-DWG 56874R
PLAN VIEW
NS | TYPICAL MODERATOR STRINGERS
SAMPLE PIECE
r
NOTE: NOT TO SCALE
»
FIGURE 2. TYPICAL GRAPHITE CORE BLOCK ARRANGEMENT
L
The MSRE core development program was divided into two phases. The o (;;
first phase consisted of building & 1/5 linearly scaled plastic model and |
testing with water. This was considered to be a rough and preliminary -
design checking device. The second phase consisted of bfiilding a full
scale carbon steel and aluminum model and testing with water. The only
data,pfesented in this report will be from the full scale model, however,
g brief description of the 1/5 scale model and the way it was used is
given in the next section.
Early concepts of the MSRE called for a'variablé speéd pump. It was
planned to operate the reactor at flow rates below the design flow of
1200 gpm. The lowest flow rate was undefined but could have been as low
as 25% of design flow. Later in the design stage, this reduced flow spec-
ification was dropped and design flow rate was fixed at 1200 gpm. This
change occurred during'the\testing'of‘the full scale core model. 4s a
result, data were taken at flow rates ranging from 1200 gp;n to 300 gpm,
but the emphasis in this report is on the 1200 gpm data. Late in the
operating history of the MSRE, the fuel pump was connected to & veriable
frequency unit, and the reactor was operated at reduced flow rates. The
purpose of these specisl runs was to study Xe-135 behavior. The "worst
case" as far as lateral temperature gradients in the core is concerned,
would be when it was operated at 5.5 MW (thermal) at half the design flow
rate for a period of about 3 1/2 days.
Figure 3 is a list of reactor parameters and physical properties of
interest in this study.
One-Fifth Scale Model
A small transparent plastic model of the MSRE core, linearly scaled
down by a factor of 1/5, was built and tested. The particular core com-
ponents simulated in this model were the inlet volute, flow distribution
orifices, core wall cooling annulus, lower vessel head with swirl killing
venes, moderator support and the moderator fuel channels which were simu-
lated with a tube bundle. A photograph of the model is shown in Figure L.
The particular scale factor of 1/5 was chosen because a geometrically
similar model of that size tested with water st sbout 95°F, and at a flow
rate such that its fluid velocities are equal to those of the reactor, -
will have the same Reynolds Number as that in the actusl reactor core when
w
"
$#
DESIGN CONDITIONS
FUEL SALT FLOW RATE
REACTOR POWER
FUEL INLET TEMPERATURE TO CORE
FUEL OUTLET TEMPERATURE FROM CORE
REACTOR OPERATING POWER f
FUEL SALT o
CGMPOSITION LiF
BEFz
'ZrFu
UF,,
LIQUIDUS TEMPERATURE
PROPERTIES AT 1200°F
DENSITY
SPECIFIC HEAT
THERMAL CONDUCTIVITY
- VISCOSITY .
PRANDTL NUMBER = (0 47)(19)/(0 83)
HASTELLOY N
- SPECIFIC GRAVITY
_THERMAL CONDUCTIVITY AT 1200°F -
. SPECIFIC HEAT AT 1200°F
GRAPHITE
“GRADE
" POROSITY (ACCESSIBLE T0 KEROSENE)
- WETTABILITY
MEAN COEFFICIENT OF THERMAL EXPANSION (70-1200°F)
FUEL SALT ABSORFTION AT 150 ps1 (CONFINED T0 SURFACE)
DENSITY
~ SPECIFIC HEAT (1200°F)
THERMAL CONDUCTIVITY
WITH GRAIN AT 68°F
NORMAL TO GRAIN AT 68°F
WITH GRAIN AT 1200°F
- NORMAL TO GRAIN AT 1200°F.
COEFFICIENT OF THERMAL EXPANSION
WITH GRAIN AT 68°F ~
NORMAL TO GRAIN AT 68°F -
= ~ *ESTIMATED
UNIRRADIATED
117 1bs/Ft3
1 0.42 Btu/1b °F
80-Btu/hr ft °F
45 Btu/hr ft °F
- 0.56 x 10-6/°F
1.7 x 10°6/°F
— **GRAPHITE NOT WET BY ‘FUEL SALT AT REACTOR CONDITIONS
FIGURE 3.
1200 gpm
10 Mw?t)
1175°F
1225°F
7.3 Mw(t)
65.0 mole %
29.1 mole %
5.0 mole %
0.9 mole %
813°F
141 1bs/ft3
0.47 Btu/1b °F
0.83 Btu/hr ft °F
19 1bs/ft hr
10.7
8.79
“11.71 Btu/hr ft °F
0.139 Btu/1b °F -
7.81 x 10-8/°F
CGB
6.2%
*%
0.2%
~ IRRADIATED
117 1bs/ft3
35 Btu/hr ft °F
20 Btu/hr ft °F
23 Btu/hr ft °F*
13 Btu/hr ft °F*
REACTOR PARAMETERS AND PHYSICAL PROPERTIES
ONE-FIFTH SCALE CORE MODEL
FIGURE k.
"
)
T
circulating fuel. Measurable varlables of the model are then related to
those of the reactor by the fOIIOW1ng proportlonalltles.
(1inear dlmensions) '—'5 (llnear dimensions)
MSRE Model
(fluid veloc:.ty)MSRE = (fluid veloc1ty)M del
_(Reynolds Number) —-(Reynolds Nuniber)Model
(fluid age)MSRE (fluld age )y de1
. (relatlve fluid pressure gradlents in ft- fluld)MSRE
_ (relatlve flu:.d pressure gradients in ft-fluid)
p;(turbulent heat transfer coefflcients)MSRE
= 0, 63 x (turbulent ‘Theat transfer coeffic:Lents)Mdel
Model
'Since the model'was'so small not every surface andpchannelrof the
reactor core exposed to salt was simulated As a8 result' the ‘model did not
give exact comparlsons, and was used only as a rough design check1ng device
to- establlsh early in the program the acceptability of major core concepts.
For example it was used for studies of the volute de51gn ‘end Spaclng of
flow dlstrlbutlon orlflces, design of swirl killing venes in lower head and
prellmlnary measurements of solids settling characterlstics of the 1ower
head. ' ' '
Full Scale Model
_ The full scale MSRE core model is almost an exact dnpllcate of the
actual reactor. Flgure 5 is 8 photograph of this model The model is con-
structed of carbon steel with' the exception of the core blocks and part
of the moderator support grld.whlch are of alumlnum The core blocks were
' ;made by extrudlng alumlnum approximately to shape 1ncluding the ‘longitudinal
grooves ‘and then taklng only 8 finish cut on the b side surfaces. Most of
- the tolerances of the reactor were 1ncreased (normally doubled) in the model
q';for economic reasons. In addltlon other simpllflcatlons were made to
reduce the cost if they were presumed to have a small effect on the fluid
'dynamlcs. The vessel was construeted‘w1th & large glrth flange just over
. the volute so that the~internals could be removed with relative ease,
Several transparent plastic windows wererplaced'in.the1VESSel heads, core
' wall cooling annulus and volute for viewing. Numerous holes were drilled
into the vessel walls at various plaeces for fluid measuring probes. A
carbon steel loop was built to operate this model and consisted of a pump,
i
FIGURE 5.
s
E3
-
1
Fs
&
FULL SCALE CORE MODEL
&
"
»y
*)
9
gate valve to control the flow orlflce flcwmeter loop cooler, 5400 gal
'surge tank and an 1on-exehange system for remov1ng salt 1njected durlng
fluid age measurements., e
All the initial data from the full scale model was taken Witn,the loop
filled with water and operated between T5°F and 80°F. This results in
a_Reyneids Number fer the model Ebeut'four times that of the reacter. Later
in the progrem.a thickening-agent (Jaguar-508 by Stein, Hall & Co.) was
added to the system in order to simulate Beynolds'Numbersg'end the measure-
ments uhich were strong functions of the Reynolds Number, were repeated.
AlthOugh7Jaguar—508 imparts-non;Newtonian characteristic to the water, in
the low concentratlons that were used in these tests, this was a negligible
con51deration. As data is presented in this report, it will be noted
whether or not exact Reynolds Number similarity existed. Items to simulate
the three eontrol rods and thelsurveiliance specimen holder were not
included in the core model because their design was not sufficiently well
known when the model was built. Rather, the regular graphite matrix was
continued throughout this regions.
| DESCRIPTION AND ANALYSIS OF TEST RESULTS
Volute and Core Wall Coollng Annulus
The main fuel loop piping'in the MSRE is 5 in. Schedule 4%0. Just prior
to.entering the core vessel volute the pipe size is increased to 6 in. The
cross-secfional flow area of the 6 in. pipe is approximately;equsl to that
of the vblute 28.8 in.? and 26. 0 in.z, reSpectively. ‘The'uolute is a con-
stant flow ares type and the tail end is hydraulically connected.to the head
end 50 there is rec1rculat10n. One characteristlc of this type of volute
is the varlsble static pressure around it therefore, in order to obtain
”a unlform angulaer flow dlstrlbution it 1is necessary to use oriflces between
~ the volute and core wall coollng annulus The orifices are 3/h 1n. and. occur
-in stacks of 3. At the head end of the volute the orifice stacks are 5 deg
apart. At the tail end of the volute because of the lower fuel veloc1ty
-and resultlng higher statlc pressure the orifice stack spac1ng is increased
to 22 1/2 deg. This orifice distribution was determined from the 1/5 scale
o
10
model. The orifice holes are drilled at an angle of 30 deg with the tangent
in order to maintain a tangential velocity component in the annulus. The
resulting high heat transfer coefficients cool the core vessel wall and
the reactor core can. | h
Figure 6 is a plot of the exéerimentally measured centérline velocities
in the volute as a function of angular position and at various flow rates.
At 1200 gpm water approaches the core through the 5 in. pipe et a meen
velocity of 19.2 ft/sec. Immediately inside the volute the velocity Jumps -
to about 23 ft/seé because of recirculation around the volute. At the
tail end of the volute the fielocity is about 10 ft/sec. The centerline
velocities cannot be taken as absolute representations of flow rate, par-
ticularly at the inlet where two fluid streams of different velocities
merge. Nevertheless, the linear decrease in velocify is a good indication
thét the wafier'is distributed uniformly to the corejwall cooiing annulus.
At the head end of the volute the mean velocity through‘tpe'orifices is
- about 4 ft/sec and at the tail end of the volute the mean velocity through
the orifices is sbout 18 ft/sec. Figure T is & plot of the centerline
velocity in the core wall cooling annulus as a function of elevation.
Note that the velocity decreases as the water moves‘down.the ennulus,
because the tangential component is attenusted. Figure 8 is a plot of the
centerline velocity at the bottom of the core wall cooling annulus as a
function of angular position around the core. Note that it is quite flat,
indicating uniform flow to the reactor vessel lower head. Data for Figures
6, T and 8 was teken with water in the loop. The Reynolds Numbers involved
in the volute and core wall cooling annulus are so high (over,lOh in all
ceses at 1200 gpm) that exact Reynolds similarity is-notrimpbrtant, énd
the reactor vessel containing fuel salt will have the same velocity pro-
files. |
At this point it would be informative to compute the tempersture dif-
ference between the bulk selt in the core wall cooling ennulus and'the.vessel
wall (Hastelloy N). At the midplane of the core (sbout 30 in. up in
the annulus) and at 1200 gpm, the fluid veiocity in the annulus is 7.2 ft/sec
(Figure 7). Now, molten salt behaves as a conventional Newtonian fluid so that
standard. heat transfer relationships may be used. From the Dittus-Boelter
equation and with physical properties from Figure 3 we can compute a heat
n
11
ORNL-DWG 64-6T721Al
24
,/'.\.‘ /
/ o /
7 o~ /
20 |4 %
o’ N /
% | T~ MEAN INLET '"?\\\\\ . \ /
= PIPE VELOCITY !
< 46 '\o- / _
e - ' .\ \ /
3 * ol /
S ' | ' .wo gplm II
= 12 * ¥
q ~ .
T ”,4-0..._.\ o~ e o Il )
- ~
S - | |
g 8 * ] | 7
5 - | egogn |/
3 . | L )
L e —— . o CTmees )/ /
4 .-—-—.'._“___—— -~
——lg 300 gpm 7~
o o..__,___.____.___. -
0
0 45 90 . 135 180 225 270 315 360
- 8, ANGLE FROM INLET TANGENT (deg)
FIGURE 6. ANGULAR DISTRIBUTION OF FLUID VELOCITY AT CENTER LINE OF VOLUTE
e
VERTICAL DISTANCE UP CORE WALL COOLING ANNULUS (in.)
12
ORNL-DWG 64-6723A1
70
./ | ELEVATION OF VOLUTE
7 . fi f
® @ .;’,—O
. 3009p'm/ | / /./ o
- y | './600gpm ./
o [ / - / 1200 gpm
IV
20 i — /l //
| o | o ¢
10 ' ’ |
@ o ®
oL 1] [
0" 2 4 6 8 10
FLUID VELOCITY AT ANNULUS ¢ (fps)
FIGURE T.
AT CENTER OF CORE WALL COOLING ANNULUS .
VERTICAL DISTRIBUTION OF FLUID VELOCITY
12
N
»
4
FLUID VELOCITY IN ANNULUS ¢ (ft/sec)
13
ORNL-DWG 70-11789
O O
¢ 1200 gpm o v
5
4
3
d'\ : ) O ‘ A)
i O 600 gpm O
2
| I ¢
O | O 300 gpm -
1 '
0
"0 45 9 135 180 225 270 315 360
~ ANGLE AROUND CORE (deg)
FIGURE 8. ANGULAR DISTRIBUTION OF FLUID VELOCITY
AROUND BOTTOM OF CORE WALL COOLING ANNULUS
1k
transfer coefficient at this position in the core wall cooling anfiulus
(1 in. thick) of 1370 Btufhr—ft2-°F. The heat generation rate in the
vessel wall at.this point has been estimated to be about 0.2 watts/cm3.
The vessel wall is 9/16 in. thick so the heat flux to the salt, assuming
the outside surface is insulated, will be 905 Btu/hr-ftz. The tempersture
drop across the fluid boundary layer will be only 0.66°F. Now the tempera-
turé drop in the vessel wall with an internal heat source, and assuming -
again that the outside surface is insulated, is represented by
: 2
-9t
AT = 2%
where: t = wall thickness = 9/16 in.
= internsl heat source = 0.2 w/cm3
k = thermal conductivity - 11.71 Btu/hr-ft-°F
Evalueting gives a temperature drop in the metal wall of 1.81°F. Therefore
the overall temperature drop from the outside surface of the veséel wall
to the salt in the core wall cooling annulus is the sum of the above or
" only 2.47°F. It is beyond the'scope of this report to include many detailed
thermal analyses such as sbove. These analyses have been made and many are
reported in References 8 and 9. It was felt however that one such computation
would be worthwhile to give the reader an idea of the order of magnitude of
these effects. Because of its rather lo# power density, lateral temperature
gredients are quite low in the MSRE.
Reactor Vessel Lower Head
The lower plenum of the core vessél ié formed by a‘standard 60 in. OD.
ASME flenged and dished head, containing anti-swirl veanes and a diain line
configuration. The anti-swirl venes consist of 48 plates starting about
2 in. up in the core wall cooling annulus and extending along radial lines
into the lower head for about 38% of the radial distance to the core center-
line. They are slightly elevated off the core vessel wall, fihfis eliminating
as much corner area as possible where settled solids could accumulate. The
vessel drain consist of e short section of 1 1/2 in. pipe extending slightly
| up into the vessel head at the centerline, and having a éonical umbrella over
it. In addition it incorporates a secondary drain which is a 1/2 in. con-
centric tube coming up the middle of the primary drain, penetrating through
4)
o)
41
»
15
‘the drain pipe wall just inside the vessel and wrapping around the drain
pipe horizontally ebout 90°. The conicel umbrella will prevent gross
settling of solid particles (should they exist) into the primary drain line,
however, fuel containlng solids mey still drift in and out of the unbrellea
and over a long period of time, solids could still plug this drain. The
1/2 in. line serves &s a safety drain since it is designed to prevent slow
migration of fuel in and out. Because of its size, it would drain the
‘reactor too slow under normsl conditions. The secondary drain terminates
inside the primary drain just below the freeze valve.
The- object of the anti-swirl vanes is to prevent the swirl generated
in the volute from penetrating 1nto the lower head end creating an excessive
radial pressure gradient. The unlformlty of fuel flow through the graphite
moderator region is a direct function of thls pressure gradient. Figure 9
is a plot of the experimentally observed radial pressure gradient as
measured by wall pressure taps. Since the flow in the lower head is 3-
dimensional, the static pressure at the wall is not an ebsolute measure
of the pressure influencing flow through the moderator region, nevertheless
it is & good indication. Note that the pressure is slightly higher at the
center, therefore, one would expect a slightly higher flow tfirough the moder-
ator near the center. This was measured to be the case as will be pointed
out in the sectlon on the moderator. &
As the water goes through the anti-swirl vanes and heads toward the
vessel centerline, it is turned by the lower head and produces & high velocity
Jet adjacent to the wallaerigure‘lo,is arprofile of this jet measured at
& radius of 17 inches and at b poeitions‘90° apart The flow rate was