FCI experiments in the corium/water system

The KROTOS fuel coolant interaction (FCI) tests are aimed at providing benchmark data to examine the effect of fuel/coolant initial conditions and mixing on explosion energetics. Experiments, fundamental in nature, are performed in well-controlled geometries and are complementary to the FARO large scale tests. Recently, a test series was performed using 3 kg of prototypical corium (80 w/o UO₂, 20 w/o ZrO₂) which was poured into a water column of ≤1.25 m in height (95 and 200 mm in diameter) under 0.1 MPa ambient pressure. Four tests were performed in the test section of 95 mm in diameter (ID) with different subcooling levels (10–80 K) and with and without an external trigger. Additionally, one test has been performed with a test section of 200 mm in diameter (ID) and with an external trigger. No spontaneous or triggered energetic FCIs (steam explosions) were observed in these corium tests. This is in sharp contrast with the steam explosions observed in the previously reported alumina (Al₂O₃) test series which had the same initial conditions of ambient pressure and subcooling. The post-test analysis of the corium experiments indicated that strong vaporisation at the melt/water contact led to a partial expulsion of the melt from the test section into the pressure vessel. In order to avoid this and to obtain a good penetration and premixing of the corium melt, an additional test was performed with a larger diameter test section. In all the corium tests an efficient quenching process (0.8–1.0 MW kg-melt⁻¹) with total fuel fragmentation (mass mean diameter 1.4–2.5 mm) was observed. Results from alumina tests under the same initial conditions are also given to highlight the differences in behaviour between corium and alumina melts during the melt/water mixing.     

Insight into steam explosions with corium melts in KROTOS

This paper describes two KROTOS tests in which 4 kg of corium melt was injected into a 1-m deep subcooled water pool. These tests were performed in a test vessel that allowed direct visual observations of melt injection and mixing conditions. Visual observations showed that the corium jet penetrated deep into the water while maintaining its shape. The tests did not produce spontaneous explosions. However, the second test with an external trigger produced an explosion with a relatively low efficiency of 0.15%. This is different from the behaviour of alumina melts, which exhibit one order of magnitude higher explosion efficiencies. This paper describes possible mechanisms that could have contributed to the reduced efficiency with corium melt.     

FCI experiments in the aluminum oxide/water system

The KROTOS facility at JRC Ispra was recently used to study experimentally melt-coolant premixing and steam explosion phenomena in Al₂O₃/water mixtures with approximately 1.5 kg melt at 2300–2400 °C. In the five tests performed the main parameter was the water subcooling, 10, 40 and 80 X, respectively. In the nearly saturated system, steam explosions could be externally triggered, which resulted in high (supercritical) explosion pressures in the test tube: KROTOS 26, 28. Without triggering, melt penetration in water and melt agglomeration on the bottom plate of the test tube could be observed, which gave rise to strong steaming during the melt cooling-down process: KROTOS 27. In the two tests KROTOS 29, 30, performed with 80 K subcooled water, self-triggered steam explosions occurred with pressures of more than 100 MPa. Post-test analysis of the debris revealed that 85% of the interacting fuel mass fragmented in particles of sizes smaller than 250 μm. An energy conversion ratio of 1.25% was estimated from vessel pressurization data taking into account the energy content in the fuel mass which fragmented to particle diameters of less than 250 μm. The test section was damaged in the test KROTOS 30.     

The effect of corium composition and interaction vessel geometry on the prototypic steam explosion

This paper discusses the results of steam explosion experiments using molten material consisting of UO₂ and ZrO₂ mixture, which is called corium, to simulate a prototypic steam explosion in a nuclear reactor during a postulated severe accident. About 5–10 kg of molten material with enough superheat was poured into a pool of water in a test section at room temperature to simulate ex-vessel steam explosion in the reactor situation. Most of the experiments were externally triggered. The purpose of the experiments was to investigate the effect of material composition and average void fraction on the strength of a prototypic steam explosion, which were highlighted as major unresolved issues.The experiments were performed using two kinds of mixtures, one, corium A, at 70:30 weight percent composition of UO₂ and ZrO₂, close to eutectic composition, and the other, corium B, at 80:20 weight percent. Also, two kinds of cylindrical test sections having a different diameter were used. It turned out that corium A was likely to produce an energetic steam explosion, while corium B seldom led to an energetic steam explosion. The existence of mush phase for the non-eutectic mixture is suggested to be the reason for the difference. Comparative cross sectional views of the corium particles by scanning electron microscope supported the proposed argument. The tests performed with a narrow test section seldom led to an energetic steam explosion for both materials. An increase in average void is suggested to be the reason for the non-explosive behavior, which is consistent with the physical models employed in the current steam explosion computer codes.     

Fuel coolant interaction experiments in TROI using a UO2/ZrO2 mixture

This paper discusses the results of steam explosion experiments using reactor material carried out under “Test for Real cOrium Interaction with water (TROI)” program. About 4–9 kg of corium melt jet is delivered into a sub-cooled water pool at atmospheric pressure. Spontaneous steam explosions are observed in four tests among six tests. The dynamic pressure, dynamic load, and morphology of debris clearly indicate the cases with steam explosion. The initial conditions and results of the experiments are discussed.     

Experiments on the interactions of molten ZrO2 with water using TROI facility

Korea Atomic Energy Research Institute (KAERI) launched an intermediate scale steam explosion experiment named ‘Test for Real cOrium Interaction with water (TROI)’ using reactor material. The objective of the program is to investigate whether the corium would lead to energetic steam explosion when interacted with cold water at a low pressure. The melt/water interaction is made in a multi-dimensional test section located in a pressure vessel. The inductive skull melting, which is basically a direct inductive heating of an electrically conducting melt, is implemented for the melting and delivery of corium. In the first series of tests using several kg of ZrO₂ where the melt/water interaction is made in a heated water pool at 30–95 °C, either a quenching or a spontaneous steam explosion was observed. The spontaneous explosion observed in the present ZrO₂ melt/water experiments clearly indicates that the physical properties of the UO₂/ZrO₂ mixture have a strong effect on the energetics of steam explosion.     

Ex-vessel fuel-coolant interaction experiment in the DISCO facility in the LACOMECO project

In the frame of the LACOMECO (large scale experiments on core degradation, melt retention and containment behavior) project of the 7th European Framework Program, a test in the DISCO (dispersion of corium) facility was performed in order to analyze the phenomena which occur during an ex-vessel fuel–coolant interaction (FCI). The test is focused on the premixing phase of the FCI with no trigger used for explosion phase. The objectives of the test were to provide data concerning the dispersion of water and melt out of the pit, characterization of the debris and pressurization of the reactor compartments for scenarios, where the melt is ejected from the reactor pressure vessel (RPV) under pressure. The experiment was performed for a reactor pit geometry close to a French 900 MWe reactor configuration at a scale of 1:10. The corium melt was simulated by a melt of iron–alumina with a temperature of 2400 K. A containment pressure increase of 0.04 MPa was measured, the total pressure reached about 0.24 MPa. No spontaneous steam explosion was observed. About 16% of the initial melt (11.62 kg) remained in the RPV vessel, 60% remained in the cavity mainly as a compact crust. The fraction of the melt transported out of the pit was about 24%.     

Effect of melt water interaction configuration on the process of steam explosion

Steam explosion experiments are performed at various modes of melt water interaction configuration using prototypic corium melt. The tests are performed to simulate both melt water interaction in a partially flooded cavity and melt water interaction in a cavity with submerged reactor. The tests are performed using zirconia and corium melts. The behavior of melt jet fragmentation during the flight in the air and fragmentation and mixing of melt jet in water is investigated by a high-speed video visualization and by comparison of debris size distribution and morphology of debris. Strength of steam explosion is estimated by measuring dynamic pressure and dynamic force.     

Unit Sphere Concept for Macroscopic Triggering of Large-scale Vapor Explosions

The unit sphere concept was developed to predict the triggering stage of vapor explosions for coarse mixtures composed of hot liquid droplets, cold liquid and its vapor. With an assumption that hot liquid droplets are arranged with a uniform spatial interval to construct a hexagonal cell structure, a unit sphere with thirteen droplets is formed in the coarse mixture. A droplet and adjacent twelve droplets were placed at the center and on the surface of the unit sphere, respectively. Two indices for triggering were introduced in the unit sphere concept. The first index is the ratio of mechanical energy generated at the center droplet to one required for the mechanical collapse of vapor film on an adjacent droplet. Another shows the probability that the mechanical energy at the center droplet impacts onto the minimum number of molten adjacent droplets. The present concept predicted that the triggering could occur at smaller water subcooling for a coarse mixture with alumina droplets and water than corium droplet case, and that vapor explosions were suppressed when the ambient pressure was elevated up to approximately 0.5 MPa in both cases. The evaluation of KROTOS experiments indicated that the latter triggering index was smaller for corium droplets than alumina case due to the increase in the fraction of solidified droplets in the coarse mixture, implying less triggerability for corium droplets. Those findings showed a consistency with the results of vapor explosion experiments using corium and alumina. It was qualitatively confirmed in the experiments where a molten tin jet penetrated into a water pool that the latter index is applicable to the evaluation of the triggerability.     

熔融物液柱碎化模型对先进压水堆堆外蒸汽爆炸计算的影响分析

在堆外蒸汽爆炸计算中,液柱碎化模型影响着熔融物液滴生成速率、液滴直径、液滴分布、液滴凝固和气泡比例等粗混合参数和现象,从而影响了蒸汽爆炸的冲击载荷。本文基于MC3D V3.8程序,采用不同的液柱碎化模型（CONST模型和KHF模型）对先进压水堆堆外蒸汽爆炸进行计算分析,探讨了CONST和KHF模型对蒸汽爆炸计算的影响。结果表明,两种模型计算的粗混合状态类似;在熔融物触底时刻,爆炸性准则几乎相同,此时触发爆炸得到的冲击载荷差别很小,表明该时刻触发爆炸时不同液柱碎化模型对爆炸冲击计算的影响较小;在本文所定义的工况下,先进压水堆堆坑墙体承受的最高压力约为20 MPa,最大冲量小于0.2 MPa•s。     

A use of prototypic material for the investigation of severe accident progression

An experimental research platform using corium melts is established for the understanding of safety related important phenomena during a severe accident progression. The research platform includes TROI facility for corium water interaction experiments and VESTA facility for corium-structural material interaction experiments. A cold crucible technology is adapted and improved for a generation of 5–100 kg of corium melts at various compositions. TROI facility is used for experiments to investigate premixing and explosion behaviors during a fuel coolant interaction process. More than 70 experiments using corium at various compositions were performed to simulate steam explosion phenomena in a reactor situation. The results indicate that the conversion efficiency of steam explosion for corium is less than 1%. VESTA facility is used to investigate molten corium-structural material interaction phenomena. VESTA facility consists of two cold crucibles. One crucible is used for the melting of charged material and pouring of corium melt. The other crucible is used for the corium-structural material interaction while providing an induction heating to simulate the decay heat. The results of an experiment on the interaction between corium melt and a specimen made of Inconel performed in the VESTA facility is reported.     

High pressure corium melt quenching tests in FARO

First-of-a-kind experimental data on the quenching of large masses of corium melt of realistic composition when poured into pressurised water at reactor scale depths are presented and discussed. The tests involved 18 and 44 kg of a molten mixture 80 w% UO₂-20 w% ZrO₂, which were delivered by gravity through a nozzle of diameter 0.1 m to 1 m depth nearly saturated water at 5.0 MPa. The objective was to gain early information on the melt/water quench process previous to tests that will involve larger masses of melt (1.50 kg of mixtures UO₂---ZrO₂---Zr). Particularly, pressures and temperatures were measured both in the gas phase and in the water. The results show that significant quenching occurred during the melt fall stage with 30% to 42% of the melt energy transferred to the water. About two-thirds of the melt broke up into particles of mean size of the order of 4.0 mm. The remaining one-third collected still molten in the debris catcher but did not produce any damage to the bottom plate. The maximum downward heat flux was 0.8 MW m². The maximum vessel overpressurisation, i.e. 1.8 MPa, was recorded with 44 kg of melt poured into 255 kg of water and a gas phase volume of 0.875 m³. No steam explosions occurred.     

Estimation of ex-vessel steam explosion pressure loads

An ex-vessel steam explosion may occur when, during a severe reactor accident, the reactor vessel fails and the molten core pours into the water in the reactor cavity. A steam explosion is a fuel coolant interaction process where the heat transfer from the melt to water is so intense and rapid that the timescale for heat transfer is shorter than the timescale for pressure relief. This can lead to the formation of shock waves and production of missiles that may endanger surrounding structures. A strong enough steam explosion in a nuclear power plant could jeopardize the containment integrity and so lead to a direct release of radioactive material to the environment.In this article, different scenarios of ex-vessel steam explosions in a typical pressurized water reactor cavity are analyzed with the code MC3D, which is being developed for the simulation of fuel–coolant interactions. A parametric study was performed varying the location of the melt release (central, right and left side melt pour), the cavity water subcooling, the primary system overpressure at vessel failure and the triggering time for explosion calculations. The main purpose of the study was to establish the influence of the varied parameters on the fuel–coolant interaction behaviour, to determine the most challenging cases and to estimate the expected pressure loadings on the cavity walls. For the most explosive central, right side and left side melt pour scenarios a detailed analysis of the explosion simulation results was performed. The study shows that for some ex-vessel steam explosion scenarios higher pressure loads are predicted than obtained in the OECD programme SERENA phase 1.     

Simulation of melt jet breakup and debris bed formation in water pools with IKEJET/IKEMIX

The objective of the development of the code system KESS is simulating the processes of core melting, relocation of core material to the lower head of the reactor pressure vessel (RPV) and its further heatup, modelling of fission product release and coolability of the core material. In the scope of the code development, IKEJET and IKEMIX were designed as key models for the breakup of a molten jet falling into a water pool, cooling of fragments and the formation of particulate debris beds. Calculations were performed with these codes, simulating FARO corium quenching experiments at saturated (L-28) and subcooled (L-31) conditions, as well as PREMIX experiments, e.g. PM-16. With the assumption of a reduced interfacial friction between water and steam as compared to usually applied laws, the melt breakup, energy release from the melt and pressurisation of the vessel observed in the experiments are reproduced with a reasonable accuracy. The model is further applied to reactor conditions, calculating the relocation of a mass of corium of 30 t into the lower plenum, its fragmentation and the formation of a particle bed.     

Vapor explosion studies for nuclear and non-nuclear industries

Energetic melt-water explosions are a well-established contributor to risk for nuclear reactors, and even more so for the metal casting industry. In-depth studies were undertaken in an industry-national laboratory collaborative effort to understand the root causes of explosion triggering and to evaluate methods for prevention. The steam explosion triggering studies (SETS) facility was devised and implemented for deriving key insights into explosion prevention. Data obtained indicated that onset of base surface-entrapment induced explosive boiling-caused trigger shocks is a result of complex combination of surface wettability, type of coating (organic versus inorganic), degree of coating wearoff, existence of bypass pathways for pressure relief, charring and non-condensable gas (NCG) release potential. Of these parameters NCGs were found to play a preeminent role on explosion prevention by stabilizing the melt-water steam interface and acting as a shock absorber. The role of NCGs was experimentally confirmed using SETS for their effect on stable film boiling using a downward facing heated body through which gases were injected. The presence of NCGs in the steam film layer caused a significant delay in the transitioning of film-to-nucleate boiling. The role of NCGs on explosion prevention was thereafter demonstrated more directly by introducing molten metal drops into water pools with and without NCG bubbling. Whereas spontaneous and energetic explosions took place without NCG injection, only benign quenching occurred in the presence of NCGs. Gravimetric analyses of organic coatings which are known to prevent explosion onset were also found to release significant NCGs during thermal attack by melt in the presence of water. These findings offer a novel, simple, cost-effective technique for deriving fundamental insights into melt-water explosions as well as for explosion prevention under most conditions of interest to metal casting, and possibly for nuclear reactor systems during severe accident conditions. Energetics of entrapment boiling induced shocks for explosive and non-explosive conditions were quantified using a modified zero-crossing technique. In honor of Professor R.T. Lahey Jr. the non-dimensional parameter “L_T” was proposed to delineate the explosion-onset boundary. Experimental evidence suggests that a system with L_T above a threshold value of ∼65 leads to the growth of perturbations and onset of propagating melt-water explosions. The data appear to offer valuable insights into explosion prevention in nuclear reactors during beyond-design basis accident conditions. An unresolved issue concerns the potential for trigger shocks from chemical ignition reactions between reactive metals in contact with oxide coatings such as rust.     

On the prediction of the reactor vessel integrity under severe accident loadings (RPVSA)

In order to allow more reliable predictions on the lower head response under core melt-down conditions, the temperature distribution has been analysed including the natural convection in the corium pool. Furthermore, the mechanical models and the failure criteria have been improved based on the RUPTHER and FASTHER experiments where typical temperature gradients are simulated. Lower head local melting as well as corium crust development has been addressed in the CORVIS experiments studying the contact between an alumina/iron thermite and a thick steel plate. The upper head loading by corium impact due to a postulated in-vessel steam explosion has been investigated by the BERDA experiments. Similarity rules were considered such that the results can be directly converted to reactor conditions. Based on these investigations admissible steam explosion energy releases are determined which the upper head can carry. If these limits are not exceeded the reactor containment cannot be endangered by broken head fragments. To provide the necessary basic data, mechanical material tests have been performed.     

Vulnerability of a partially flooded PWR reactor cavity to a steam explosion

When the hot molten core comes into contact with the water in the reactor cavity a steam explosion may occur. A steam explosion is a fuel coolant interaction process where the heat transfer from the melt to water is so intense and rapid that the timescale for heat transfer is shorter than the timescale for pressure relief. This can lead to the formation of shock waves and later, during the expansion of the water vapour, to production of missiles that may endanger surrounding structures.The purpose of the performed analysis is to provide an estimation of the expected pressure loadings on the typical PWR cavity structures during a steam explosion, and to make an assessment of the vulnerabilities of the typical PWR cavity structures to steam explosions. To achieve this, the fit-for-purpose steam explosion model is proposed, followed by comprehensive and reasonably conservative analyses of two typical ex-vessel steam explosion cases differing in the steam explosion energy conversion ratio. In particular, the vulnerability of the surrounding reinforced concrete walls to damage has been sought in both cases.     

Direct containment heating integral effects tests in geometries of European nuclear power plants

The DISCO test facility at Forschungszentrum Karlsruhe (FZK) has been used to perform experiments to investigate direct containment heating (DCH) effects during a severe accident in European nuclear power plants, comprising the EPR, the French 1300 MWe plant P’4, the VVER-1000 and the German Konvoi plant. A high-temperature iron–alumina melt is ejected by steam into scaled models of the respective reactor cavities and the containment vessel. Both heat transfer from dispersed melt and combustion of hydrogen lead to containment pressurization. The main experimental findings are presented and critical parameters are identified.The consequences of DCH are limited in reactors with no direct pathway between the cavity and the containment dome (closed pit). The situation is more severe for reactors which do have a direct pathway between the cavity and the containment (open pit). The experiments showed that substantial fractions of corium may be dispersed into the containment in such cases, if the pressure in the reactor coolant system is elevated at the time of RPV failure. Primary system pressures of 1 or 2 MPa are sufficient to lead to full scale DCH effects. Combustion of the hydrogen produced by oxidation as well as the hydrogen initially present appears to be the crucial phenomenon for containment pressurization.     

Corium crust strength measurements

Corium strength is of interest in the context of a severe reactor accident in which molten core material melts through the reactor vessel and collects on the containment basemat. Some accident management strategies involve pouring water over the melt to solidify it and halt corium/concrete interactions. The effectiveness of this method could be influenced by the strength of the corium crust at the interface between the melt and coolant. A strong, coherent crust anchored to the containment walls could allow the yet-molten corium to fall away from the crust as it erodes the basemat, thereby thermally decoupling the melt from the coolant and sharply reducing the cooling rate. This paper presents a diverse collection of measurements of the mechanical strength of corium. The data is based on load tests of corium samples in three different contexts: (1) small blocks cut from the debris of the large-scale MACE experiments, (2) 30 cm-diameter, 75 kg ingots produced by SSWICS quench tests, and (3) high temperature crusts loaded during large-scale corium/concrete interaction (CCI) tests. In every case the corium consisted of varying proportions of UO₂, ZrO₂, and the constituents of concrete to represent a LWR melt at different stages of a molten core/concrete interaction. The collection of data was used to assess the strength and stability of an anchored, plant-scale crust. The results indicate that such a crust is likely to be too weak to support itself above the melt. It is therefore improbable that an anchored crust configuration could persist and the melt become thermally decoupled from the water layer to restrict cooling and prolong an attack of the reactor cavity concrete.     

Experimental evaluation of the water ingression mechanism for corium cooling

Experiments were performed to assess the significance of water ingression cooling in the quenching of molten corium. Water ingression is a mechanism by which water penetrates into cracks and pores of solidified corium to enhance cooling that would otherwise be severely limited by the low thermal conductivity of the material. Quench tests were conducted with 2100 °C melts weighing 75 kg composed of UO₂, ZrO₂ and chemical constituents of concrete. The amount of concrete in the melts was varied between 4% and 23%. The melts were quenched with an overlying water layer; three tests were conducted at a system pressure of 1 bar and four tests at 4 bar. The measured cooling rates were found to decrease with increasing concrete content and, contrary to expectations, are essentially independent of system pressure. For the lower concrete content melts, cooling rates exceeded the conduction-limited rate with the difference being attributed to the water ingression mechanism. Measurements of the permeability of the corium “ingots” produced by the quench tests were used to obtain a second, independent set of dryout heat flux data, which exhibits the same trend as the quench test data. The data was used to validate an existing dryout heat flux model based on corium permeability associated with thermally induced cracking. The model uses the thermal and mechanical properties of the corium and coolant, and it reproduces the very particular data trend found for the dryout heat flux as a function of concrete content. The model predicts that water ingression cooling would be most effective for concrete-free corium mixtures such as in-vessel type melts. For such a melt the model predicts a dryout heat flux of 400 kW/m² at a pressure of 1 bar. The results of this study provide an experimental basis for a water ingression model that can be incorporated into computer codes used to assess accident management strategies.