Rosatom has successfully manufactured full-sized structural components for a HTGR using advanced carbon-carbon composites.
Engineers at the machine-building division of Rosatom have manufactured full-sized structural components for a high-temperature gas-cooled reactor using carbon-carbon composite materials.“This will allow in the future to apply the obtained experience not only for the manufacture of other structural elements of the HTGR reactor, but also to use the technology in other innovative projects of the Russian nuclear industry,” said Fedor Grigoryev, project curator at JSC “Concern Rosenergoatom.
”These components include a 1650 mm core support element and a flexible control system assembled from 500 mm sections. These materials underwent extreme testing, confirming their physical stability at temperatures of 2372°F and their ability to maintain mechanical properties up to 2912°F .“The use of carbon-carbon composite material, characterized by stable physical-mechanical properties in a wide range of temperatures and high radiation resistance gives significant advantages – allows to increase reliability and reduce mass-dimensional characteristics of reactor plants,” highlighted Rosatom in a press release.This technology is designed for an Atomic Energy-Technological Station featuring a 200 MW thermal power reactor that utilizes helium coolant to reach an outlet temperature of 1562°F and produce superheated steam at 1382°F .Reducing mass and dimensions of reactorsSpecialists analyzed the physical-mechanical and thermophysical properties of irradiated samples, ultimately selecting a material based on standard carbon fabric produced by Rosatom’s composite division.The use of these composites allows for a reduction in the mass and dimensions of reactor plants while maintaining stability in aggressive environments.By replacing traditional metallic alloys with carbon-based structures, the design accommodates the high-potential heat required for industrial chemical processes.The manufacturing process for these structural elements—including the 1650 mm support set and the modular control system—was refined using existing industrial equipment. This approach demonstrates that large-scale production can be integrated into current industrial lines, rather than requiring entirely new facilities.“It is important to emphasize that the working out of the technology for manufacturing structural elements of the HTGR reactor was carried out using industrial equipment available at the site of the technological partner,” added Grigoryev.The HTGR is a central component of the AETS, which integrates a nuclear heat source with a chemical-technological part . This configuration is specifically designed for the production of hydrogen and ammonia.Integration with hydrogen energy systemsThe high-temperature steam generated by the reactor is transferred to the CTC, providing the thermal energy necessary for chemical synthesis.Rosatom’s strategic program includes the development of domestic competencies across the supply chain for hydrogen-containing products. This includes the implementation of electrolysis systems and the infrastructure for the storage and transportation of these products to consumers.“Working out the technology for creating structural elements of the HTGR reactor from carbon composite – is not only the next significant stage of the implementation of the project for the development of technological solutions for the creation of AETS with HTGR and CTC, but also an important step forward in the field of modern and effective materials for the nuclear power of the future,” concluded the press release.
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