1 nuclear cookies. 2 problem statement during normal operation an electro refiner produces a small...
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1
Nuclear Cookies
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Problem Statement
During normal operation an electro refiner produces a small amount of plutonium that builds up. When the plutonium concentration gets too high a portion of the salt must be removed. The scope of this project is to remove a volume of salt from the ER and parse it into appropriately sized cubes for transport to a grinder.
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Mock-up of ER
Once we have a solid lead on which route we are going down we can use this mock-up to simulate things like the bucket lowering into the ER, or the conveyor removing something like water from the tank below.
Will have metal plate over this hole with a more precisely machined hole
SpecificationsGeneral Requirements Specific Requirements Acceptable Performance Tolerance/Targeted
Performance
Evolution (1 cycle) Amount of salt removed 16,500 cm3 -500 cm3
Time 1 week 3 days (goal)
Disassembly/Assembly (maintenance)
Time for disassembly or assembly 1 day 2 hours
# Parts 10 2 parts
Consistent Fasteners Dowel pins for alignment and socket head cap screws (all same size)
N/A
Size Height 7 ft maximum
Fit in 84 in by 60 in airlock 2 pieces 1 piece (goal)
Footprint when resting 3 ft by 3 ft maximum
Fit electrorefiner ports 10.75 in, 4in, or 8.875 in N/A
Materials Survive dry and radioactive environment
steel, aluminum, high altitude brushes
N/A
Withstand high temperatures 650 oC melting point for all materials in ER, 1000 oC for all structural components
minimum
Withstand beating ¼ in thick minimum
Handling (set up/take down)
Fit with cranes and manipulators Hooks and Handles N/A
Set up and take down Only assembly/disassembly is trays N/A
Vertical Motion for entry/exit with ER
40 in 2 in
Specifications
General Requirements Specific Requirements Acceptable Performance Tolerance/Targeted Performance
Life Expectancy Time 10 years minimum
Number of cycles 100 minimum
Parts replaced during lifetime 0 maximum
Time spent tweaking mechanism
1 hour per cycle average over lifetime
maximum
Electrical Power Available Power Source 110 Volts Volts
Salt Cubes Size 2 in by 2in by 2 in maximum
Interaction with ER vessel
Gap between bottom of vessel and bottom of our device
4 in minimum
Salt level range device is designed for
16 in to 20 in from bottom 0 in (but may work outside that range)
Relative Importance of Specs
General Requirement Weighting ReasonEvolution 5 The essence of what we are trying to do
Disassembly/Assembly 2 If the other specs are met, this one becomes a non-issue
Size 4 For our device to work, it must fit these specs
Materials 3 For some designs, basically a non-issue, for others an definite problem
Handling 4 For our device to work, it must fit these specs
Life Expectancy 1 We don’t foresee this being an much of an issue
Electrical Power 3 For some designs, basically a non-issue, for others an definite problem
Salt Cubes 5 Has to be done for the grinder to work
Interaction with Vessel 2 Not an issue with all designs, only a small issue with others
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Pulley System
Function Options
Removal Method
Dipping Tray
Pressure Differential
Buckets Archimedes Screw
Removal Tool Elevator Crane Trays Motorized Pipe Suction
Freezing to Size Required
Venturi Atomizing Salt
Trays Breaking Icemaker
Transport to Container
Funnel Weir/Trough Flexible Metal Tubing
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Pulley/Conveyor Concept
1. Individual cube containers scoop out salt
2. Cubes are transported using a conveyor system
3. Salt freezes on the way up
4. Cubes fall out on the way down
5. Cubes slide down on ramp to storage container
FreezingRange
Disadvantages• Heat can escape from the
electrorefiner• Complexity—many places for device
to fail• Unsure if 110 Volt electric motor can
produce enough power• Long set-up time (2 separate pieces
that must be put together, conveyer and ramp)
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Pulley System Analysis
Advantages• High Upside: 9 hours to
remove and freeze 16,500 cm3 into cubes
• Run continuously without a need to stop
• Can remove salt with salt level as low as 6 in from bottom
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Evaluation of Pulley System Concept
General Requirement Weighting Performance Rating Total
Evolution 5 3 15
Assembly 2 0 0
Size 4 2 8
Materials 3 3 9
Handling 4 0 0
Life Expectancy 1 1 1
Electrical Power 3 1 3
Salt Cubes 5 3 15
Interaction with vessel 2 3 6
Total 57
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Venturi Tube
Function Options
Removal Method
Dipping Tray
Pressure Differential
Buckets Archimedes Screw
Removal Tool Elevator Crane Trays Motorized Pipe Suction
Freezing to Size Required
Venturi Atomizing Salt
Trays Breaking Icemaker
Transport to Container
Funnel Weir/Trough Flexible Metal Tubing
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Venturi Tube Analysis
Pressure differential from argon flow pulls salt from the ER and flash freezes it through atomization upon exit.
Disadvantages•High volume flow rate input required to drive suction.
•Unknown reliability and functionality.
•Potential draw tube freezing problems.
Advantages•Completes the extraction and freezing in one step.
•Small.
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Evaluation of Venturi System Concept
Specification Weighting Performance Rating Total
Evolution 5 1 5
Assembly 2 3 6
Size 4 3 12
Materials 3 3 9
Handling 4 3 12
Life Expectancy 1 1 1
Electrical Power 3 3 9
Salt Cubes 5 2 10
Interaction w/ER 3 3 9
Net total 73
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Bucket-Tray Systems
Function Options
Removal Method
Dipping Tray
Pressure Differential
Buckets Archimedes Screw
Removal Tool Elevator Crane Trays Motorized Pipe Suction
Freezing to Size Required
Venturi Atomizing Salt
Trays Breaking Icemaker
Transport to Container
Funnel Weir/Trough Flexible Metal Tubing
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Bucket Tray Concept 1(double-click on photo to see video)
Basic Function:
Bucket system supplies salt to the tray system.
Then after a set freezing time the operator places the trays into a flipping mechanism that
places all the cubes into the container used to transport the salt to the grinder in HFEF
Will be designed
for crane
All metal high temperature valve
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Mr. BucketProposed Bucket Size (8in ID, 11½ in tall)
Removes ~9400 cm3 with each bucket cycle.
Acme Screw to tighten down a lid for transport
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Tray Ideas Designs Center Around:• Use on the table top in the hot cell where the existing design is emptied• Handling the amount of salt provided by the bucket from either one or
multiple dumps • Reducing the handling for getting cubes into the container • Getting salt to freeze into the required shape• Safe against Spilling
When the salt is dry the tray will be removed and replaced with the container that carries the salt to the grinder
Any spills are contained and go into the tray beneath
Enough capacity for one bucket load of salt
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Bucket Tray Analysis
Positives: • Simple design with minimal moving parts. • Heat Loss from the ER can be minimized• Low setup Time • Uses hot-cell proven tray concepts from last design without as much handling
time
Drawbacks:• Removes the demanded amount of in two bucket cycles • Most handling intensive • Salt can freeze moving parts such as the bucket valve or hinges
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Evaluation of Bucket Tray System Concept
General Requirement Weighting Performance Rating Total
Evolution 5 3 15
Assembly 2 3 6
Size 4 3 12
Materials 3 3 9
Handling 4 3 12
Life Expectancy 1 2 2
Electrical Power 3 3 9
Salt Cubes 5 2 10
Interaction with vessel 2 3 6
Total 81
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Deliverables By May 15th we will deliver: One Completed Design that Satisfies the Specifications Agreed On• Full Scale Prototype• Drawing Package • Manufacturing Notes • Applicable Math Models
By Dec 15th we will deliverAll Feasible Ideas• Rendered Images • Solid Model images with
major features explained• Basic Feasibility Math Models
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