The performance test and analysis of ITER Main and Correction Busbar conductor

The first ITER Main Busbar (MBCN1) and Correction Busbar (CBCN1) conductor samples were manufactured in ASIPP and tested in the SULTAN facility. This paper introduces the sample manufacture, including strand, cabling, jacketing and sample preparation, and discusses the performance of MBCN1 and CBCN1 conductors. The testing results show that both samples have high T_cs, and meet the ITER requirement.Due to the ITER acceptance standard T_cs of MB conductor was changed to 6.7 K at 45.5 kA/3.9 T. The performance of MBCN1 conductor after cyclic load fits the ITER requirement, but the sample was only tested at 57 kA/2.75 T before cycling test. Using some hypothesis and equation to extrapolate the T_cs performance of MBCN1 conductor before cycling test, the result also fits the ITER requirement.For CBCN1 conductor, the central line of the central cooling spiral shifted about 1.3 mm during the cabling. The deviation causes an increase of the max self-field by about 0.005 T, which could not influence the CBCN1 conductor real T_cs performance at peak field.     

How should we test the ITER TF coils?

The international thermonuclear experimental reactor (ITER) toroidal field (TF) magnet system consists of 18 superconducting coils using a 68 kA Nb₃Sn conductor. In order to guarantee the performances of these coils prior to their installation, the test of at least one prototype coil at liquid helium temperature and full current is required. The test of all coils in the two-coil test configuration, with successive charging of each coil to nominal current is recommended. This requires a large test facility.     

ITER operational space for full plasma current H-mode operation

Sensitivity studies performed as part of the ITER IO design review highlighted a very stiff dependence of the maximum Q attainable on the machine parameters. In particular, in the considered range, the achievable Q scales with I_p^{^}4. As a consequence, the achievement of the ITER objective of Q = 10 requires the machine to be routinely operated at a nominal current I_p of 15 MA, and at full toroidal field BT of 5.3 T. This paper analyses the capabilities of the poloidal field (PF) system (including the central solenoid) of ITER against realistic full current plasma scenarios. An exploration of the ITER operational space for the 15 and 17 MA inductive scenario is carried out. An extensive analysis includes the evaluation of margins for the closed loop shape control action. The overall results of this analysis indicate that the control of a 15 MA plasma in ITER is likely to be adequate in the range of li 0.7–0.9 whereas, for a 17 MA plasma, control capabilities are strongly reduced. The ITER operational space, provided by the reference pre-2008 PF system, was rather limited if compared to the range of parameters normally observed in present experiment. Proposals for increasing the current and field limits on PF2, PF5 and PF6, adjustment on the number of turns in some of the PF coils, changes to the divertor dome geometry, to the conductor of PF6 to Nb3Sn, moving PF6 radially and/or vertically are described and evaluated in the paper. Some of them have been included in 2008 ITER revised configuration.     

Qualification tests for ITER TF conductors in SULTAN

From February 2007 to May 2008, 18 short length conductor sections have been tested in SULTAN for design verification and manufacturer qualification of the ITER Toroidal Field (TF) conductor. The test program is focussed on the current sharing temperature, T_cs, at the nominal operating conditions, 68 kA current and 11.15 T effective field, which can be fully reproduced in the SULTAN test facility. A broad range of results was observed, with over 2 K difference among the T_cs of the conductors. In average, the results are poorer compared to the potential performance estimated from the strand scaling law. The key parameters to mitigate the degradation are not yet clearly identified. The experimental challenges to test conductors with performance degradation are highlighted, including enhanced instrumentation sets, the application of gas flow calorimetry to sense the current sharing power and the post-processing of voltage data to cancel the transverse potential across the cable. The updated schedule of the tests in SULTAN is presented with the short-term action plan for conductor test.     

Coil winding pack FE-analysis for a HELIAS reactor

At the Max-Planck-Institut fuer Plasmaphysik (IPP) a reference design is being created of an upgraded five-periodic HELIAS type stellarator reactor which evolves from Wendelstein 7-X (W7-X) by scaling of the coil centre line geometries by a factor of four. This reactor type was extensively investigated at IPP with regard to physical characteristics and to some extent also to engineering issues. The upgrade concerns an increase of the induction at the plasma axis and correspondingly at the superconductor.The aim is to develop the reactor concept to a stage and such detail that major engineering problems are unveiled, and relevant comparisons with other concepts, including tokamaks, can be drawn in view of upcoming decisions concerning a DEMO reactor. Even though progress in plasma physics, and in particular future results of W7-X and other machines – particularly of ITER – will probably lead to somewhat different coil shapes, no principal changes of the reference design are expected.In this paper the option of a roll-formed square coil cable jacket is investigated. Detailed structural FE analysis of the coil winding pack demonstrates the feasibility of such a conductor which appears to be the most economical option. It also allows sufficient space for a cable current density very similar to that of the ITER TF coil with a similar overall winding pack cross section of ≈0.5 m². Already existing Nb₃Sn conductors could thus be safely applied in such a HELIAS reactor. Obvious progress of superconductor technology, particularly concerning Nb₃Al, will be beneficial concerning savings of conductor material, ease of manufacture, higher operation temperature, etc.     

Prospects for the use of high-Tc superconductors in fusion magnets and options for their test in SULTAN

In the last few years, the critical current densities of long commercially available REBa₂Cu₃O_7?x (RE-123, where RE represents Y or a rare earth element) coated conductors have reached values of 250 A/cm-width at 77 K and zero applied field. Even higher values of 600 A/cm-w (77 K, B = 0) have been demonstrated in shorter lengths. The attractive features of the use of these high-T_c superconductors (HTS) are operation temperatures above 20 K and/or magnetic fields higher than those envisaged for the ITER TF coils. Possible operation conditions for HTS fusion magnets have been studied taking into consideration the possible further improvements of RE-123 coated conductors. Investigations of stability and quench behavior indicate that stability is not a problem, whereas quench detection and protection need attention. Because of the high currents necessary for fusion magnets, many tapes need to be assembled into a transposed conductor. The qualification of HTS conductors for fusion magnets would require their test at magnetic fields of 11 T and currents well above 10 kA. The possibilities to test straight HTS conductor samples in SULTAN have been considered. For a test at 4.5 K, only the development of a low resistance joint between the HTS conductor under test and the NbTi transformer of SULTAN would be necessary. Tests up to 20 K would require that the HTS sample is connected with the NbTi transformer by a conduction-cooled HTS bus bar of large thermal resistance similar to the HTS module of a current lead. HTS conductor tests at temperatures around 50 K would be possible with modified cryogenics.     

ASDEX Upgrade enhancements in view of ITER application

The aim of the ASDEX Upgrade (AUG) programme is to support the design, prepare the physics base and develop regimes beyond the baseline of ITER and for DEMO. Its ITER-like geometry, poloidal field system, versatile heating system and power fluxes make AUG particularly suited.After the transition to fully tungsten coated plasma facing components AUG could be operated without prior boronizations and a low permanent deuterium retention was found qualifying W as wall material. ITER-like baseline H-modes (H₉₈ ～ 1, β_N ～ 2) were routinely achieved up to 1.2 MA plasma currents. W concentrations could be kept at an acceptable level of <5 × 10^?5 by central wave heating (enhancing impurity outward transport) and ELM pacing with gas puffing. The compatibility of high performance improved H-modes, the ITER hybrid scenario, with an un-boronized W wall was demonstrated achieving H₉₈ ～ 1.1 and β_N up to 2.6 at modest triangularities δ ≤ 0.3. This performance is reached despite the gas puffing needed for W influx control. Increasing δ to 0.35 allowed at even higher puff rates still a H₉₈ ～ 1.1.Reliable plasma operation in support of ITER comprised the demonstration of ECRF assisted low voltage plasma start-up and current rise at toroidal electric fields below 0.3 V/m resulting in a ITER compatible range of plasma internal inductance of 0.71–0.97. Disruption mitigation is feasible using strong gas puffs, and the achieved electron densities approach values needed for runaway suppression.Present hardware extensions in support of ITER include the upgrading of ECRH by a 4 MW/10 s system with large deposition variability (tuneable frequency between 105 and 140 GHz, real-time steerable mirrors) for central heating and MHD mode control. A powerful system of 24 in-vessel coils produces error fields up to toroidal mode number n = 4 for ELM suppression and mode rotation control. In connection with a close conducting wall they will open up the road for RWM stabilization in advanced scenarios. For those we are considering LHCD for current drive and profile control with up to 500 kA driven current. The tungsten sources are dominated by sputtering from intrinsic light impurities, and the W influx from the outboard limiters are the main source for the core plasma. ICRH induced electric fields accelerate light impurities, restricting the use of ICRH to just after boronization. 4-strap antennas imbedded in extended wall structures might solve this problem. Finally, doubling the plasma volume with plasma currents above 2 MA in AUG could be the solution for a needed ITER satellite.     

Characterization and qualification of advanced insulators for fusion magnets

Intensive research over the past decades demonstrated that the mechanical material performance of epoxy based glass fiber reinforced plastics, which are normally used by industry as insulating materials in magnet technology, degrades dramatically upon irradiation to fast neutron fluences above 1 × 10²² m^?2 (E > 0.1 MeV). which have to be expected in large fusion devices like ITER. This triggered an insulation development program based on cyanate ester (CE) and blends of CE and epoxies, which are not affected up to twice this fluence level, and therefore appropriate for large fusion magnets like the ITER TF coils. Together with several suppliers resin mixtures with very low viscosity over many hours were developed, which renders them suitable for the impregnation of very large volumes. This paper reports on a qualification program carried out during the past few years to characterize suitable materials, i.e. various boron-free R-glass fiber reinforcements interleaved with polyimide foils embedded in CE/epoxy blends containing 40% of CE, a repair resin, a conductor insulation, and various polyimide/glass fiber bonded tapes. The mechanical properties were assessed at 77 K in tension and in the interlaminar shear mode under static and dynamic load conditions prior to and after reactor irradiation at ~340 K to neutron fluences of up to 2 × 10²² m^?2 (E > 0.1 MeV). i.e. twice the ITER design fluence. The results confirmed that a sustainable solution has become available for this critical magnet component of ITER.     

Status of European manufacture of Toroidal Field conductor and strand for JT-60SA project

In the framework of the JT-60SA project, part of the Broader Approach (BA) agreement, EURATOM provides to Japan, the Toroidal Field (TF) magnet system, consisting of 18 superconducting coils. The procurement of the conductor for the TF coils is managed by Fusion for Energy, acting as EU representative in the BA agreement. The TF conductor procurement is split into two contracts, one dedicated to the production of Niobium Titanium (NbTi) and Cu strand and the other to TF conductor production through strand cabling and cable jacketing operations.The TF conductor is a rectangular-shaped cable-in-conduit conductor formed by 486 (0.81 mm diameter) strands (2/3 NbTi–1/3 Cu) wrapped in a stainless steel foil and embedded into a stainless steel jacket.The 18 TF coils require (including spares) 115 ‘Unit Lengths’ (UL) of such conductor, each 240 m long for a total of about 28 km. Correspondingly about 10,000 km for NbTi and 5000 km for Cu strand are produced.The Japanese company Furukawa Electric Co. (FEC) is in charge of TF strand manufacture while the Italian company Italian Consortium for Applied Superconductivity (ICAS) is in charge of cabling and jacketing of TF conductor ULs. In the paper, we provide information on the production stages presently achieved in TF strand and conductor contracts.     

Russian development of enhanced heat flux technologies for ITER first wall

Recently the ITER first wall (FW) design has been significantly upgraded to improve resistance to electromagnetic loads, to facilitate FW panel replacement and to increase FW ability to withstand higher (up to 5 MW/m²) surface heat loads. The latter has made it necessary to re-employ technologies previously developed for the now-abandoned port limiters. These solutions are related to the cooling channel with CuCrZr–SS bimetallic walls and hypervapotron type cooling regime, optimization of Be-tiles dimensions and Be to CuCrZr joining technique. A number of representative mockups were tested at high heat flux (HHF) at the Tsefey electron-beam facility to verify the thermo-hydraulic characteristics of the reference cooling channel design at moderate water flow velocities (V = 1–3 m/s, P = 2–3 MPa, T = 110–170 °C). The heat flux was gradually varied in the range of 1–10 MW/m² until the critical heat flux was registered. The mockups of hypervapotron structure demonstrated the required cooling efficiency and critical heat flux margin (1.4) at a water velocity of ≥2 m/s. Dimensions of Be armor tiles strongly affect the thermo-mechanical stresses both in the CuCrZr cooling wall and at the Be–CuCrZr interface. Results of tile dimensions optimization (variable in the range 12 mm × 12 mm × 6 to 50 mm × 50 mm × 8 mm) obtained by the HHF (variable in the range of 3–8 MW/m²) experiments are presented and compared with analysis. It is shown that optimization of the tile geometry and joining technology provides the required cyclic fatigue lifetime of the reference FW design.     

Overview of recent developments in pellet injection for ITER

Pellet injection is the primary fueling technique planned for core fueling of ITER burning plasmas. Also, the injection of relatively small pellets to purposely trigger rapid small edge localized modes (ELMs) has been proposed as a possible solution to the heat flux damage from larger natural ELMs likely to be an issue on the ITER divertor surfaces. The ITER pellet injection system is designed to inject pellets into the plasma through both inner and outer wall guide tubes. The inner wall guide tubes will provide high throughput pellet fueling while the outer wall guide tubes will be used primarily to trigger ELMs at a high frequency (>15 Hz). The pellet fueling rate of each injector is to be up to 120 Pa m³/s, which will require the formation of solid D–T at a volumetric rate of ～1500 mm³/s. Two injectors are to be provided for ITER at the startup with a provision for up to six injectors during the D–T phase. The required throughput of each injector is greater than that of any injector built to date, and a novel twin-screw continuous extrusion system is being developed to meet the challenging design parameters. Status of the development activities is presented, highlighting recent progress.     

The ITER full size plasma source device design

In the framework of the strategy for the development and the procurement of the NB systems for ITER, it has been decided to build in Padova a test facility, including two experimental devices: a full size plasma source with low voltage extraction and a full size NB injector at full beam power (1 MV). These two different devices will separately address the main scientific and technological issues of the 17 MW NB injector for ITER. In particular the full size plasma source of negative ions will address the ITER performance requirements in terms of current density and uniformity, limitation of the electron/ion ratio and stationary operation at full current with high reliability and constant performances for the whole operating time up to 1 h. The required negative ion current density to be extracted from the plasma source ranges from 290 A/m² in D₂ (D^?) and 350 A/m² in H₂ (H^?) and these values should be obtained at the lowest admissible neutral pressure in the plasma source volume, nominally at 0.3 Pa. The electron to ion ratio should be limited to less than 1 and the admissible ion inhomogeneity extracted from the grids should be better than 10% on the whole plasma cross-section having a surface exposed to the extraction grid of the order of 1 m².The main design choices will be presented in the paper as well as an overview of the design of the main components and systems.     

Mechanical tensile test of the full-size ITER TF conductor jacket materials at 4.2 K

316LN stainless steel is selected as a material for toroidal-field (TF) conductor jacket of International Thermonuclear Experimental Reactor (ITER). In order to evaluate the true mechanical performance of the jacket material at 4.2 K and its suitability as the ITER TF conductor jacket, the mechanical properties of the full-size TF conductor jacket tube and sub-size specimens at 4.2 K and 300 K were investigated according to ASTM standards. The measured yield strength and elongation at 4.2 K for sub-size specimens and full-size tubes are more than 950 MPa and 20%, respectively. In addition, the fractographies of all fractured specimens were observed using scanning electron microscope (SEM). These results suggest that the TF conductor jacket can satisfy ITER requirements and the result of the full-size tube at 4.2 K is more representative and important for practical applications.     

System analysis study for Korean fusion DEMO reactor

A conceptual design study for a steady-state Korean fusion DEMO reactor (K-DEMO) has been initiated. Two peculiar features need to be noted. First, the major radius is designed to be just below 6.5 m, considering practical engineering feasibilities. But still, high magnetic field at the plasma center around 8 T is expected to be achieved by using current state-of-the-art high performance Nb₃Sn strand technology. Second, a two-stage development plan is being considered. In the first stage, K-DEMO will demonstrate a net electricity generation but will also act as a component test facility. Then, after a major upgrade, K-DEMO is expected to show a net electric generation on the order of 300 MWe and the competitiveness in cost of electricity (COE). Feasibility of such a practical, near-future demonstration reactor is studied in this paper, based on a zero dimensional system analysis code study. It was shown that a net electric generation on the order of 300 MWe can be achieved below the optimistic β_N limit of 5. The elongation of K-DEMO is around 1.8 with single null configuration. Detailed optimization process and the resultant various plasma parameters are described.     

Preparation of tungsten coatings on graphite by electro-deposition via Na2WO4–WO3 molten salt system

Tungsten coating on graphite substrate is one of the most promising candidate materials as the ITER plasma facing components. In this paper, tungsten coatings on graphite substrates were fabricated by electro-deposition from Na₂WO₄–WO₃ molten salt system at 1173 K in atmosphere. Tungsten coatings with no impurities were successfully deposited on graphite substrates under various pulsed current densities in an hour. By increasing the current density from 60 mA cm⁻² to 120 mA cm⁻² an increase of the average size of tungsten grains, the thickness and the hardness of tungsten coatings occurs. The average size of tungsten grains can reach 7.13 μm, the thickness of tungsten coating was in the range of 28.8–51 μm, and the hardness of coating was higher than 400 HV. No cracks or voids were observed between tungsten coating and graphite substrate. The oxygen content of tungsten coating is about 0.022 wt%.     

High temperature superconductors for the ITER magnet system and beyond

The use of high temperature superconductor (HTS) materials in future fusion machines could increase the efficiency drastically, but strong boundary conditions exist. To outline the prospects, challenges and problems, first the benefit of using HTS materials is estimated considering the saving in cryogenic power. Next, it is demonstrated that industrial available HTS materials can be used for fusion today. For this purpose, we give a short summary of results that have been obtained from an ITER conform 70 kA HTS current lead that was designed, built and tested by the Forschungszentrum Karlsruhe and the CRPP Villigen in the frame of the European Fusion Technology Programme and in cooperation with industry. This current lead consists of an HTS part that covered the temperature range from 4.5 to 70 K and a conventional part, making the connection to room temperature. Because the HTS part had no ohmic losses and poor thermal conduction, the refrigerator power necessary for cooling the current lead was reduced drastically. The saving factor could be calculated to be 5.4 at zero current and 3.7 at 68 kA. The current lead could even be operated at 80 kA and with respect to safety criteria of ITER, a complete loss of He flow was simulated showing that the HTS current lead could hold a current of 68 kA for 6 min without active cooling. These results demonstrate that today existing HTS materials can be used in ITER for current leads or bus bar systems.For fusion machines beyond ITER, the development of an HTS fusion conductor would be the key to operate the complete magnet system at higher temperatures. The option of developing fusion conductors based on Bi-2223 and YBCO are briefly discussed. For a success of such conductors, the AC loss optimisation is crucial.     

Implementation and analysis of ITER strand test of CNDA for world-wide benchmarking

According to the International Thermonuclear Experimental Reactor (ITER) Procurement Arrangement (PA) of Cable-In-Conduit Conductor unit lengths for the magnet systems, at the start of process qualification, the Domestic Agency (DA) shall be required to conduct a benchmarking of the room and low temperature acceptance tests carried out at the strand suppliers and/or at its reference laboratories designated by the ITER Organization (IO). The first benchmarking was carried out successfully in 2009 and the second round in 2010. Bronze-Route (BR) Nb₃Sn strand and samples prepared by CERN were sent out to each participant in the first round. The second round was referred to the Internal-Tin(IT) Nb₃Sn and NbTi strand. The two rounds of benchmarking included tests for critical current, hysteresis loss, residual resistance ratio, strand diameter, Cu fraction, twist pitch, and plating thickness. As the referenced lab of Chinese DA (CNDA), the superconducting strand test lab from Institute of Plasma Physics, Chinese Academy of Sciences (ASIPP) participated in the Benchmarking. The feedback from IO showed good results and high coherence. The test facility and test results for benchmarking of CNDA were presented in this paper.     

Commissioning and initial operation of KSTAR superconducting tokamak

The commissioning and the initial operation for the first plasma in the KSTAR device have been accomplished successfully without any severe failure preventing the device operation and plasma experiments. The commissioning is classified into four steps: vacuum commissioning, cryogenic cool-down commissioning, magnet system commissioning, and plasma discharge.Vacuum commissioning commenced after completion of the tokamak and basic ancillary systems construction. Base pressure of the vacuum vessel was about 3 × 10^?6 Pa and that of the cryostat about 2.7 × 10^?4 Pa, and both levels meet the KSTAR requirements to start the cool-down operation. All the SC magnets were cooled down by a 9 kW rated cryogenic helium facility and reached the base temperature of 4.5 K in a month. The performance test of the superconducting magnet showed that the joint resistances were below 3 nΩ and the resistance to ground after cool-down was over 1 GΩ. An ac loss test of each PF coil made by applying a dc biased sinusoidal current showed that the coupling loss was within the KSTAR requirement with the coupling loss time constant less than 35 ms for both Nb₃Sn and NbTi magnets. All the superconducting magnets operated in stable without quench for long-time dc operation and with synchronized pulse operation by the plasma control system (PCS). By using an 84 GHz ECH system, second harmonic ECH assisted plasma discharges were produced successfully with loop voltage of less than 3 V. By the real-time feedback control, operation of 100 kA plasma current with pulse length up to 865 ms was achieved, which also meet the first plasma target of 100 kA and 100 ms. The KSTAR device will be operated to meet the missions of steady-state and high-beta achievement by system upgrades and collaborative researches.     

Manufacturing of small-scale mock-ups and of a semi-prototype of the ITER Normal Heat Flux First Wall

This paper describes the manufacturing development and fabrication of reduced scale ITER First Wall (FW) mock-ups of the Normal Heat Flux (NHF) design, including a “semi-prototype” with a dimension of 305 mm × 660 mm, corresponding to about 1/6 of a full-scale panel. The activity was carried out in the framework of the pre-qualification of the European Domestic Agency (EU-DA or F4E) for the supply of the European share of the ITER First Wall. The hardware consists of three Upgraded (2 MW/m²) Normal Heat Flux (U-NHF) small-scale mock-ups, bearing 3 beryllium tiles each, and of one Semi-Prototype, representing six full-scale fingers and bearing a total of 84 beryllium tiles.The manufacturing process makes extensive use of Hot Isostatic Pressing, which was developed over more than a decade during ITER Engineering Design Activity phase. The main manufacturing steps for the semi-prototype are described, with special reference to the lessons learned and the implications impacting the future fabrication of the full-scale prototype and the series which consists of 218 panels plus spares.In addition, a “tile-size” mock-up was manufactured in order to assess the performance of larger tiles. The use of larger tiles would be highly beneficial since it would allow a significant reduction of the panel assembly time.