4.1. Options of Coal Repowering
This study compared three options to determine how to convert selected thermal power plants to nuclear power generation with SMRs. A summary of the proposed coal repowering options is shown in
Table 7. These options were part of a comprehensive analysis that examined the feasibility and implications of converting aging CPPs to SMR power plants in the United States. The study explored the feasibility of such conversions, the economic and technical factors influencing investor decisions, and the impacts on local communities [
24]. In the report, overnight construction costs (OCC) were estimated by leveraging data from the Advanced Fuel Cycle Cost Basis [
25]. This report provides a detailed methodology for calculating OCC for various nuclear fuel cycle options. The analysis incorporates data from the EEDB Program (1979) to identify shared components between CPPs and nuclear power plants (NPPs) [
26]. By evaluating the reuse potential of components such as power transmission infrastructure, cooling systems, and civil structures, the study estimated the cost savings achievable through repurposing existing CPP infrastructure. The resulting OCC values reflect Nth-of-a-kind (NOAK) conditions and exclude financing costs, offering a baseline for understanding the potential economic benefits of repowering projects. Thus, it should be noted that the OCC values may represent underestimated figures compared to real cases.
For example, the construction cost of NuScale, a PWR-type SMR in the United States, was initially estimated at
$5.3 billion but surged to
$9.3 billion by 2023 [
27]. This increase was attributed to factors such as high interest rates and rising raw material costs. This demonstrates that first-of-a-kind SMRs with financial costs integrated can have significantly higher OCC values than those summarized in
Table 7. However, the purpose of presenting this table in our study is not to assert that repowering is economically feasible. Instead, it aims to explore various infrastructural options for repowering, assess the extent to which infrastructure can be reused, and provide an approximation of the associated cost savings.
Option 1 involves building a new nuclear power plant without any relation to the existing CPP. This approach offers a clean slate, allowing for modern design implementation without constraints from existing infrastructure. However, it fails to capitalize on potential cost savings and faces the full burden of CPP decommissioning costs.
Option 2 proposes reusing the site, electrical, and heat-sink components from the CPPs for the new nuclear power plant. This strategy leverages existing infrastructure, potentially reducing construction costs and timelines. It also maintains continuity in terms of location and some workforce. However, it still incurs significant CPP decommissioning costs and limits the design flexibility of the new nuclear power plant.
Option 3 goes beyond the others by reusing not only the site, electrical, and heat sink components but also the steam cycle components of the CPP. This is a very useful way to maximize the utilization of existing infrastructure and potentially achieve more effective carbon savings. The cost savings from such extensive reuse is not only economically sound but also environmentally attractive in that it reduces waste and makes the best use of available resources. As shown in
Table 7, Option 3 is more economical than Option 1 for HTGR-type reactors. For PWR-type reactors, the estimated price for Option 3 is not available due to the lack of projects using this option [
24].
However, this study proposes an initial repowering method based on Option 3 for both PWR and HTGR reactors. This is to further explore the possibility of using PWR-based SMRs for repowering coal and identify the technical issues for this option. The characteristics of both PWR and HTGR-based SMRs and the specific features of the target thermal power plant will be next considered for evaluating Option 3 for repowering coal with SMRs.
4.2. Evaluation Methodology
When considering the replacement of a CPP with an SMR based on Option 3, it is crucial to maintain the volumetric flow rate to ensure compatibility with the existing steam turbine system. This approach not only leverages the established infrastructure but also minimizes the need for extensive modifications, which can be both cost-effective and time-efficient for SMRs.
To efficiently reuse the currently operating thermal power plant equipment during the process of replacing the heat source of CPPs with SMRs, an integration is proposed, beginning from the inlets of the three turbines mentioned above. The work, mass, and volumetric flows for the three candidate turbines are detailed in
Table 8. To maximize the work produced by conventional turbines, this study focuses on initial research on integration starting from the IP turbine inlet, excluding steam in supercritical regions that are not realistically achievable by SMRs, as in the inlet conditions of HP turbines of CPP.
In this paper, the published conditions of currently accessible HTGR and PWR-type SMRs were used as examples to determine the number of SMR units required when repowering the selected reference CPP while utilizing the existing steam turbine. The steam conditions at the exit of the steam generator were utilized for the analysis. The list of investigated SMRs contains two HTGR references and two PWR references. The steam generator conditions were determined as follows since the publicly available information does not provide all the necessary information for the analysis.
For HTGRs, only the core information is publicly available. This core data was used to calculate the conditions for the steam that could be generated by the steam generator. To simplify the analysis, it was assumed that the product of the flow rate inside the core and the enthalpy change at the inlet and outlet is equal to the product of the flow rate and enthalpy change at the secondary side of the steam generator. To determine the enthalpy at the inlet of the steam generator, a conservative assumption was made that the quality at that point is 0 and the pinch temperature inside the steam generator is assumed to be 15 K. The pressure at the inlet and outlet of the steam generator is determined by the pressure corresponding to the saturation temperature at the specified pinch temperature. Additionally, the conditions at the outlet of the steam generator were considered to be the same as the conditions at the coupling with the thermal power plant. This approach enabled the determination of the mass flow rate on the steam generator side (Equation (9)).
After determining the mass flow rate using the aforementioned method, it is then throttled to achieve a pressure condition suitable for coupling with the secondary side of the thermal power plant. In this process, the inlet conditions of the intermediate pressure (IP) turbine of the thermal power plant are utilized. This is because the reference power plant utilizes steam from the supercritical region in the high-pressure (HP) turbine. The high pressure and high temperature impose a significant load on the steam generator. Therefore, to facilitate the integration of SMRs and thermal power plants, it is preferable to avoid operating conditions in the supercritical region as much as possible. With the inlet pressure condition of the IP turbine met through throttling, the density at that specific pressure and temperature determines the volumetric flow rate per unit of the SMR. This process was utilized to calculate the number of SMR units required to produce steam equal to the volumetric flow rate of the IP turbine of the thermal power plant.
Since SMRs of the PWR type cannot reach the inlet temperature of a conventional thermal power plant in most cases, additional thermal energy is assumed to be utilized to arrive to the target temperature. As illustrated in
Figure 16, steam is heated by an external fuel and then throttled to enter the IP turbine. In this process, the steam condition prior to heating begins at the steam generator condition of each SMR and is heated to a temperature region with the same enthalpy as the inlet condition of the IP turbine before being throttled. During this process, the number of SMR units and the amount of external heat sources required to match the volumetric flow rate of a conventional IP turbine will be evaluated.
4.3. Evaluation Results
HTGR uses helium as a coolant, and its specific operating conditions of HTGR reference #1 are detailed in
Table 9 [
28]. A temperature profile that satisfies the previously mentioned conservative pinch temperature of 15 K under these conditions is shown in
Figure 17. A pinch has formed between the core inlet (steam generator primary side outlet) and the steam generator secondary side inlet. This profile results from maximizing the flow on the secondary side while maintaining a pinch temperature of 15 K for all temperatures between the inlet and outlet of the steam generator’s primary side. Under these conditions, the mass flow rate of the steam generator’s secondary side is 53.56 kg/s.
Since the steam outlet has the same enthalpy as the IP turbine inlet condition of the reference thermal power plant, throttling will adjust the steam to match the target condition. This process is illustrated in
Figure 18, and the conditions at each point are detailed in
Table 9. Considering the density of the steam at the IP turbine inlet condition after throttling, a single unit of HTGR reference #1 can produce a volumetric flow rate of 5.44 m
3/s. Therefore, approximately 6.30 units would be required to match the volumetric flow rate at the IP turbine inlet, as indicated in
Table 10.
The same analysis was conducted on HTGR reference #2. The core operating conditions for HTGR reference #2 are provided in
Table 11 [
29]. Compared to HTGR reference #1, HTGR reference #2 shows a lower core inlet temperature, a higher core outlet temperature, and the same mass flow rate. In the case of the HTGR reference #2, the temperature profile of the primary and secondary steam generators was calculated with the condition of maximizing the mass flow rate of the steam generator. A 15K pinch was formed at the outlet of the steam generator primary and the inlet of the secondary, similar to the HTGR reference #1 case.
As shown in
Figure 19, the temperature at the inlet of the steam generator secondary is 245 °C, which is 15 K lower than the core inlet temperature of 260 °C. For HTGR reference #2, the larger temperature difference between the inlet and outlet of the core compared to HTGR reference #1 allows it to generate a higher mass flow rate of 55.17 kg/s. However, despite the relatively large temperature change, the mass flow rate did not increase significantly because helium, the coolant in the core, exists in the gas phase in this temperature range. The increased enthalpy from the higher temperature range is small compared to the latent heat of steam. The effect is minimal.
Figure 20 illustrates the T-S diagram for steam from the secondary steam generator inlet to throttling for merging with the IP turbine. The conditions at each point are detailed in
Table 12. Since the secondary inlet temperature is lower compared to the HTGR reference #1 case, the corresponding pressure in the secondary is also relatively low. After calculating the steam density post-throttling and using the previously obtained mass flow rate, the volumetric flow rate generated per HTGR reference #2 unit is 5.60 m
3/s. Therefore, approximately 6.12 units are required to meet the IP turbine’s inlet conditions.
In case of PWR reference #1, it is capable of producing steam that meets the outlet conditions specified in
Table 13. The challenge with integrating a PWR-type SMR with the power conversion system of a thermal power plant is arriving at the required high temperatures. Therefore, the steam inlet conditions are achieved by using other energy source to make the steam enthalpy as the same value of the operating IP turbine inlet. This process is depicted in
Figure 21, with the conditions at each point detailed in
Table 13. Using this process, a single unit, which has 160.8 kg/s [
30] of mass flow rate, can supply 16.33 m
3/s of steam. To match the operating conditions of a conventional thermal power plant, 2.10 units are required. Additionally, an external heat source providing 101.54 MW per unit is necessary to heat the steam from the steam generator outlet to the inlet conditions of the IP turbine.
PWR reference #2 has a relatively high steam generator outlet temperature and pressure compared to PWR reference #1, as shown in
Table 14. The same process ensures the steam meets the inlet conditions of the IP turbine, as illustrated in
Figure 22. With the mass flow rate of 70 kg/s per unit [
31], PWR reference #2 can deliver volumetric flow rate of 7.19 m
3/s. Therefore, 4.77 units are required to meet the IP turbine’s inlet conditions. Additionally, PWR reference #2 requires an external heat source of 54.13 MW per unit to achieve this.
Table 15 presents a summary of thermodynamic analysis for different reactor types in the context of repowering CPPs while reusing the part of operating steam turbines. The table compares HTGRs and PWRs, focusing on their volumetric flow rates, required units, and external thermal power needs.
HTGRs, represented by references #1 and #2, show volumetric flow rates of 5.44 m3/s and 5.60 m3/s, respectively. To meet the required volume flow rate of 34.33 m3/s, multiple HTGR units are necessary, specifically 6.30 units of reference #1 or 6.12 units of reference #2. The key advantage of HTGRs lies in their high-temperature output, eliminating the need for additional external thermal power in repowering applications. This makes HTGRs thermally efficient, despite the requirement for multiple units.
In contrast, PWRs exhibit different characteristics. PWR reference #1 has a higher volumetric flow rate of 16.33 m3/s, while reference #2 flows at 7.19 m3/s. These higher rates mean fewer reactor units are needed to achieve the 34.33 m3/s target—only 2.10 units for reference #1 or 4.77 units for reference #2. However, PWRs operate at lower temperatures than HTGRs, necessitating additional external thermal power. This is evidenced by the external thermal power requirements: 185.10 MW for reference #1 and 258.45 MW for reference #2. Fewer required number of units and the required external thermal energy are crucial when considering PWRs for repowering CPPs while reusing steam turbines.
The analysis aims to maintain the inlet conditions (temperature, pressure, and volume flow) of the IP turbine, thereby preserving its efficiency. This approach ensures seamless integration of the repowered system with existing turbine infrastructure, minimizing modifications and maintaining operational efficiency. The required volumetric flow rate of 34.33 m3/s serves as a benchmark for comparing reactor options and determining the number of units needed for each type.
The varying mass flow rates between reactor types highlight the need for careful consideration of optimal extrapolation and branching flows. Further analysis is required to determine the most effective distribution and management of steam flow throughout the system, especially when dealing with multiple reactor units or incorporating external thermal power sources. This optimization is critical for maximizing overall system efficiency and ensuring smooth integration with existing turbine systems in repowering CPPs.