large scale vulcano molten core concrete … 2019 - final... · 3.2.1. concrete the 1f1 concrete...

The 9TH European Review Meeting on Severe Accident Research (ERMSAR2019) Log Number: 107

Clarion Congress Hotel, Prague, Czech Republic, March 18-20, 2019

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LARGE SCALE VULCANO MOLTEN CORE CONCRETE INTERACTION

TEST CONSIDERING FUKUSHIMA DAIICHI CONDITION

V. Bouyer, C. Journeau, J.F. Haquet, P. Piluso,

CEA, DEN, Cadarache, DTN, SMTA

13108 St Paul lez Durance, France

[email protected], [email protected], jean-franç[email protected],

[email protected]

A. Nakayoshi, H. Ikeuchi, T. Washiya, T. Kitagaki

Japan Atomic Energy Agency

Collaborative Laboratories for Advanced Decommissioning Science

4-33 Muramatsu, Tokai-mura, Naka-gun, Ibaraki-ken, 319-1194, Japan;

International Research Institute for Nuclear Decommissioning

2-23-1 Nishi-Shimbashi, Minato-ku, Tokyo, 105-0003, Japan

[email protected], [email protected], [email protected],

[email protected]

ABSTRACT

Fuel debris removal is one of the most important processes for decommissioning a severely

damaged nuclear power plant (NPP) such as Fukushima Daiichi NPP (1F). In order to develop

relevant removal tools, characteristics of fuel debris are required. Assuming that the test products

generated in a MCCI experiment under similar conditions to 1F have similar characteristics to that

encountered in actual 1F MCCI products, a VULCANO MCCI test was performed in order to

obtain prototypical corium samples and analyze them. The objective of the test was to reach a

concrete ablation ratio Δ𝑉/𝑉 (where Δ𝑉 is the concrete ablation volume, and V is the initial corium

volume) close to the concrete ablation ratio of 1F unit 1 (1F1) estimated with the MCCI simulation

code TOLBIAC-ICB (~1.6 for 3 days of MCCI).

The test named VF-U1 was carried out on January 19th, 2017. About 40 kg of a metal and oxide

corium pool has been obtained thanks to inductive heating. Corium was directly melt into the test

section made of a representative Fukushima 1F unit 1 concrete with Japanese basaltic aggregates.

The test section was 2D cylindrical with an inner diameter of 250 mm, an outer diameter of 500

mm surrounded by the induction coils. The maximum concrete thickness that could be ablated

radially and axially was about 100 mm. During 12 minutes, a representative MCCI in terms of heat

fluxes and ablation velocities occurred. On the whole experiment that lasted 18 minutes, the best-

estimate relative ablation volume ratio was 1.68 which was consistent this the target value.

Dismantling of corium has been performed and shows a separation of oxide and metal phases.

From practical point of view, technical issues were pointed out which are based on the insights

from the dismantling of the test section.

KEYWORDS

MCCI, Fukushima 1F, VULCANO, experiment

mailto:[email protected]


mailto:jean-franç[email protected]







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1. INTRODUCTION

Fuel debris removal is one of the most important processes for decommissioning a severely damaged nuclear

power plant (NPP) such as Fukushima Daiichi NPP (1F). In the roadmap towards the decommissioning,

Japan had planned in 2019 the decision on the fuel debris retrieval methods in order to start removing debris

in 2021.

In order to develop debris relevant removal tools, some physical, chemical and mechanical properties of

fuel debris are required. These characteristics can be obtained provided corium samples are available.

It is assumed that at Fukushima 1F unit 1, almost all fuel debris have dropped to the bottom of the primary

containment vessel (PCV) generating ablation of concrete through MCCI process. However, the sample of

a small amount of deposit at the unit 1 bottom is scheduled in 2019.

Therefore, one of the purposes of the JAEA/CEA collaboration was to produce and analyze representative

simulated MCCI corium debris of Fukushima Daiichi 1F – unit 1. The approach was the following: (1)

define the “best estimate” MCCI conditions of the reactor, (2) with these conditions, calculate the possible

final state in the reactor pit, (3) from the calculation results, define the MCCI test to perform, (4) realize the

test, (5) analyze corium samples. The general outline of the experiment is based on the use of an oxide and

metal (steel) corium pool and a Japanese basaltic concrete.

This paper deals with steps (3) & (4). After a description of the experimental device and process, objective

and initial conditions of this MCCI test, named VF-U1, are presented. Course of the test is explained and

ablation of the concrete is quantified in term of volume, depths and velocities. Outstanding observations

during the dismantling of the test section are commented. An analysis of these results is proposed in

comparison to both experimental and numerical related works, using siliceous concrete and oxide and metal

corium.

2. VULCANO MCCI EXPERIMENTAL FACILITY

2.1. General description of VULCANO

VULCANO is a facility where several types of corium tests have been already performed using prototypic

corium i.e. with depleted uranium dioxide [1], among them, spreading [2], MCCI [3][4] and coolability [5]

tests. Several melting technics have been developed and used to synthetize corium at high temperature

(above liquidus temperatures) such as plasma arc rotating furnace [6], thermite reaction [7] and induction

heating [8] in order to have controlled initial conditions for the understanding and modelling of the studied

phenomena. Decay heat in corium can be simulated using induction heating, to represent real conditions of

reactor severe accident. VULCANO experimental set up can thus be adapted to the specificity of each

experiment.

2.2. Description of VULCANO MCCI VF-U1 set up

VF-U1 test introduces a new geometry design and a new melting process for the MCCI test. The MCCI

experimental program conducted so far consisted in arc plasma melting of corium and pouring in a hemi

cylindrical concrete cavity. For VF-U1, direct in-situ melting of corium is obtained using induction heating

and the geometry of the cavity becomes cylindrical. The experimental set up in VULCANO is represented

on Figure 1.



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2.2.1. Concrete test section

The test section has a 2D axisymmetric configuration (see Figure 2): the inner crucible is cylindrical with a

diameter of 250 mm and a height of 200 mm. The maximum concrete thickness that can be ablated radially

and axially is about 100 mm. The objective is to obtain a corium pool with an initial thickness of about two

third of the crucible height. Taking into account the lower initial powder mixture density compared to the

final melted corium in liquid state, a zirconia tube of 250 mm height is disposed on top of the test section in

order to contain initial corium powders (Figure 2 right).

Figure 1. VF-U1 experimental set up in VULCANO.

Figure 2. Sketch of VF-U1 concrete test section (left). Picture of the top of the test section (right).

crucible

Induction coils

Holes for sheated

thermocouples

Top of the concrete test

section Induction coils

Zirconia tube for filling

powders Thermocouples wires



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136 type K (chromel–alumel) thermocouples are located in the test section at four azimuths (separated by

90°). Thermocouples measurements enable to follow the displacement of ablation front, identified as being

the thermocouples failure. The signals also give information on the heating of the concrete.

2.2.2. Heating and melting

Melting of the corium mixture is obtained using induction heating. To perform this, the whole upper part of

the concrete test section (with a 500 mm diameter) is surrounded by two cylindrical copper coils. The

induction system is composed of a HF generator of maximum power 400 kW with a frequency between 70

and 300 kHz, a matching box, an induction line connecting the matching box to the inductor coils, cooling

systems (with flowmeters and thermocouples for thermal balance), a Faraday cage around the experimental

device. The instrumentation of the cooling systems and the measurement of the inductor current with a

Rogowski probe enable to determine the injected power into the corium pool during the MCCI test.

Direct heating of the corium from room temperature up to melting is possible when metallic elements are

present. Indeed, oxidic powders are not electrically conductive at room temperature, which is not the case

of metal. Melting of the pool occurs in two steps: first, we overheat the metal present in the corium powders

mixture until its melting; oxide powders close to metal are then melt by conduction; finally, local areas of

electrically conductive melt oxide can be heated by induction enabling the melting process to go forward

into the corium load. Once the oxide is melt, because of the high frequency of heating (about 130 kHz) and

the respective conductivities of the two liquids, most part of the induced power goes into the oxide.

3. VF-U1 EXPERIMENT

3.1. Objective

The objective of the test was to reach a concrete ablation ratio Δ𝑉/𝑉 (where Δ𝑉 is the concrete ablation

volume, and V is the initial corium volume) close to the concrete ablation ratio of 1F unit 1 (1F1) estimated

with the MCCI simulation code TOLBIAC-ICB. The value of Δ𝑉/𝑉 is ~1.6 after 72 hrs of MCCI [9].

Using TOLBIAC code again, considering test section geometry and initial thickness of the corium pool, a

constant volumetric internal pool power of about 32 kW applied during less than one hour have been

determined to reach the target ablation ratio.

3.2. Initial conditions

3.2.1. Concrete

The 1F1 concrete composition (Table I) has been estimated from analytical results of the concrete sample

picked up from 1F1 reactor building [9] MCCI calculations were based on this composition. We defined

composition of experimental concrete for the experiment so that the chemical composition is close to 1F1

concrete composition.

Table I. Estimated chemical composition of concrete of 1F1 (deduced from [9]).

Compounds Al2O3 CaO SiO2 H2O Fe2O3

Weight (%) 14.7 12.2 59.6 7.8 5.7



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All the components for manufacturing the concrete came from Japan. Weight composition is given in Table

II and Table III). Aggregates are brought in the form of pebble and gravel with a large range of size

distribution (a few centimeters, see Figure 3). Taking into account atomic composition of each component,

we can estimate the composition of final dry concrete of VF-U1 test section (see Table IV) which puts in

evidence the siliceous nature of this basaltic concrete.

Table II. Weight composition of VF-U1 concrete for manufacturing.

Compounds Cement Wet sand Gravels Water

Weight (%) 14.3 33.4 43.6 8.7

Table III. Weight composition of VF-U1 concrete after drying.

Compounds Cement Sand Gravels Water

Weight (%) 15.2 35.4 46.1 3.3

Table IV. Estimated chemical composition of concrete of VF-U1 test section.

Compounds Al2O3 CaO SiO2 H2O Fe2O3

Weight (%) 12.2 11.8 66.9 3.3 5.8

Figure 3. Picture of Japanese gravel.

3.2.2. Composition of corium

The best estimate corium composition (Table V) has been calculated from the estimated mass of the molten

core in a sump pit [9]. The corium contains 26% of metal (with 13.2 % of steel). U/Zr ratio is close to that

for BWR inventory.

46.4 kg of mixture for corium has been prepared that enable to fill the crucible at least at two thirds the

height (volume of about 7.4 liters estimating a density for the corium at liquid state at about 6.3 kg/m3,

estimated value from MCCI code calculation). Composition is given in Table VI. UO2, ZrO2 and Zr are

introduced as powders in the mixture. In order to optimize powders density and avoid agglomeration



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formation, calcia-stabilized zirconia has been used (96.4% ZrO2 / 3.6%CaO). The composition of 304L

stainless steel enables to recover (Ni, Cr, Fe) composition so stainless steel balls (3 cm diameter) are added

to the mixture. Balls are located at several levels into the powder and lowest level is at about 70 mm from

the bottom of the crucible.

The initial liquidus temperature of the corium mixture (metallic and oxidic) at thermodynamic equilibrium

has been calculated using Gibbs Energy Minimizer Gemini-2 and the NUCLEA-10 thermodynamic

database and corresponds to 2790 K.

Table V. Best-estimate composition of corium for 1F1.

Compounds UO2 ZrO2 Zr Ni Cr Fe

Weight (%) 58.8 16.2 11.8 1.6 2.2 9.4

Table VI. Quantities of each compound of corium for VF-U1 test.

Compounds UO2 CaO stabilized ZrO2 Zr Stainless

Steel balls

Weight % 58.8 16.2 11.8 13.2

Weight (kg) 27.3 7.5 5.5 6.1

3.3. Course of the test

The main steps for the heating procedure with inductive heating were the following: 1) Steel heating,

2) Steel melting, 3) Oxides heating and melting, 4) MCCI. Control of the induction heating phase of the

corium is based on temperature measurement in the corium load and also on video supervision record. 3

type K thermocouples numbered TCconv146-147-148 are located on steel balls and monitor the heating then

the melting of steel. 2 type C thermocouples numbered TCconv138-137 in a ceramic sheath give an

indication on the increase of temperature in the corium at the bottom of the crucible. Injected power into the

corium pool is monitored so the generator power can be adjusted to the objective value. The observation of

the ablation phase relies on signals of type K thermocouples embedded in the concrete test section. Thus,

the course of the test can be monitored (see Figure 4).

Heating begins at 9:26. After 2 stops at 9:35 and 9:52, the decrease of steel temperature is observed so

heating is again started. Immediately after the 3rd stop at 9:59 or a few minutes later, temperature signals of

thermocouples near the steel balls increase up to about 750 to 1000°C: corium is actually heated thanks to

heat conduction. Heating restarts at 10:15 when temperature on TCconv146 slightly decreases. Power is

increased until completer stainless steel melting which is considered to be obtained at about 10:26. Power

is increased again in order to melt oxide. Early concrete ablation on the radial wall is already observed at

this time.



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Figure 4. Course of VF-U1 test.

Protected type C thermocouples give important information on temperature increase, but not the exact value

of the temperature inside corium, due to the ceramic sheath and local conditions [10]. The important

criterion is to determine when the corium pool is completely formed. Thanks to video camera recording, we

determined this moment at 10:28:42 when injected power is ~ 200 kW. Ablation at the bottom of the crucible

is observed at 10:27:34. It appears that injected power was still increasing from 200 kW to 240 kW after

effective melting of the corium during 2 minutes. At 10:30:56, generator power is decreased in order to get

the target injected power of 32 kW.

Then between 10:31:18 and 10:43:29, an average power of 38 kW has been injected. Last row of type K

thermocouple at the bottom of concrete was reached at 10:41. Following safety criteria, stop of induction is

required at 10:43:30. Duration of MCCI with complete corium pool is nearly 900 s with about 750 s at

38 kW average power, which corresponds to the representative MCCI i.e. with heat fluxes at the walls of

about 150 kW/m2.

Main events for MCCI analysis are listed in Table VII. We consider time zero when complete melting of

corium occurred.



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Table VII. Main events for VF-U1 MCCI analysis.

Event Time Duration

(seconds)

First rupture of Type K thermocouple (at the vertical wall) 10:25:08 -214

Complete melting of steel 10:25:59 -163

First rupture of Type K thermocouple (at the bottom of the

crucible) 10:27:24 -78

Complete melting of oxide 𝑡1 =10:28:42 0

Decrease of power in the pool (average power 38 kW) 𝑡𝑖 =10:30:56 134

Stop of power induction system 𝑡𝑓 =10:43:30 888

4. MAIN RESULTS AND ANALYSIS

4.1. Ablation results

Analysis of the signals of thermocouples located into the concrete test section shows almost no differences

of radial and axial ablation according to the azimuth, while slight discrepancies of ablation in the corners

appear. We calculate a mean final ablation profile from these measurements. Final ablation profile observed

during dismantling highlights a progression of ablation behind the last raw of broken thermocouples. Taking

into account the location of broken/unbroken thermocouples as well as the observed ablation during

dismantling, we obtain a best estimate final ablation profile (Figure 5). Ablation thicknesses are respectively

of about 80 mm axially and between 25 to 35 mm radially.

Using this best estimate final ablation profile, we can calculate a final cavity volume 𝑉𝑐𝑎𝑣𝑖𝑡𝑦 = 15.3 𝑙𝑖𝑡𝑒𝑟𝑠.

Ablation volume ratio corresponds to: ∆𝑉

𝑉=

𝑉𝑎𝑏𝑙𝑎𝑡𝑖𝑜𝑛

𝑉𝑖𝑛𝑖𝑡𝑖𝑎𝑙=

(𝑉𝑐𝑎𝑣𝑖𝑡𝑦−𝑉𝑖𝑛𝑖𝑡𝑖𝑎𝑙)

𝑉𝑖𝑛𝑖𝑡𝑖𝑎𝑙, 𝑉𝑖𝑛𝑖𝑡𝑖𝑎𝑙 being the initial volume de corium

minus the ejected volume. 𝑉𝑖𝑛𝑖𝑡𝑖𝑎𝑙 = 5.7 𝑙𝑖𝑡𝑒𝑟𝑠, thus 𝑉𝑎𝑏𝑙𝑎𝑡𝑖𝑜𝑛 = 9.6 𝑙𝑖𝑡𝑒𝑟𝑠 so the best estimate ablation volume

ratio is equal to ∆𝑉

𝑉= 1.68.

Figure 5. Best estimate final ablation profile of VF-U1 test.



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We have determined ablation velocities during the representative MCCI phase i.e. at injected power of

38 kW. The obtained mean values of axial and radial velocities are respectively 𝑉�̅� = 27.2 ± 2.9 𝑐𝑚 ℎ⁄ and

𝑉�̅� = 18.3 ± 2.5 𝑐𝑚/ℎ. Besides, radial ablation stops 521 s before axial ablation stop when ablation in the

corners of the cavity stops about 85 s before.

4.2. Dismantling

The test section concrete has been mechanically cut Figure 6. Then corium has been manually dismantled.

The main observations on the pool structure are the following (see Figure 7). There is a continuous crust at

the upper level of the corium pool under the top of the test section with a foam appearance. The oxidic

corium pool is about 15 to 19 cm height. It seems that there are two main layers: an upper layer (8-9 cm

thick) with hard corium but many porosity in it; a lower layer with hard corium with apparently a different

porosity feature. However, density and porosity analysis performed on samples of both layers do not exhibit

any differences [11]. We can observe much porosity in the corium at the corium concrete vertical interface

and this is confirmed by material analysis [11]. At the bottom, corium in contact with the concrete is less

porous (same pattern as the main bottom pool layer). A continuous metallic phase is mainly located at the

bottom of the cavity and a few metallic balls are found in the middle of the pool or near the concrete

interface. Some metal has climbed on the vertical walls on heights in the range [4 cm, 8.5 cm] (Figure 8).

The metallic phase is continuous but does not cover the entire horizontal bottom concrete surface. Some

areas with a direct contact between oxidic corium and concrete exists.

Figure 6. Test section after removal of a sector of concrete (use of a disc grinder).



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Figure 7. Cross section of VF-U1 test section.

Figure 8. Side view of the bottom of the crucible with metal parts and corium at the walls.

Metal (~cm)

Metal at the bottom (~several cm)

Upper layer of corium

Lower layer of corium

Upper crust

Metal mixed with corium

metal



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Dismantling work gave relevant information to JAEA for future Fukushima decommissioning. Despite

apparent porosity, corium is hard to crush. Micro hardness measurements [11] gave values between 6 and

16 GPa for the homogeneous oxidic phase. Cutting concrete using a disc grinder produces a large amount

of dust inducing poor visibility but also which disturbs radiation measurement detectors. Moreover, gripping

thermal degraded concrete is not obvious. When removing large corium pieces, because of porosity, many

small corium debris and dust are generated so adapted tools have to be developed. VF-U1 test shows a

separation of oxide and metal phase (even if some metallic phases are centimetric) so different tools may

be applied if this configuration is confirmed at Fukushima Daiichi.

4.3. Analysis of MCCI results

Owing to the way of melting the corium, concrete ablation can occur before complete melting of corium

load. The reason why some radial thermocouples have been melted before axial ones can be clarified:

melting has begun in the upper part of the crucible where steel balls where located. The lower part of filled

with only corium powders melted lately. Once all the corium is melted, thermocouple signals do not put in

evidence any delay of the axial ablation compared to the radial one. The early stop of radial ablation

compared to axial erosion is not yet explained.

The VF-U1 test conducted with a silica-rich basaltic concrete and a mixed metal-oxide corium puts in

evidence an anisotropic ablation behavior. This is an important result of this test because what is commonly

observed for siliceous (crystalline quartz) concrete interacting with oxide corium with depleted UO2

(VULCANO and CCI programs or metal-oxide corium [12] or metal oxide melt (VBS series on VULCANO

[13]) is an anisotropic ablation behavior with a more pronounced radial ablation. In this case, axial ablation

prevails. The basaltic nature of silica could explain this difference. Whereas quartz is crystalline silica, basalt

is made of a (glassy or fine grained) matrix containing large crystals. Quartz has a higher melting point than

basalt. An important finding from the recent experiment made in MOCKA facility with Swedish basalt

concrete (without reinforcement bars) is that, similarly to this VULCANO VF-U1 test the cavity erosion

behavior is different in comparison to all other MOCKA tests using either a siliceous or Lime Common

Sand concrete [13]. Concrete spalling has been suggested as the observed differences [13]. Work must be

pursued to better understand the observed ablation difference between basaltic and siliceous concretes.

Another significant result of this experiment is the segregation of metal at the bottom of the concrete cavity

with nonetheless a few metallic drops inside the corium pool. The metallic phase at the bottom is in the form

of a horizontal layer with some vertical tongues along the vertical walls of cavity (Figure 8). The same

pattern was observed on VULCANO VBS experiments [15]. These VBS tests put in evidence a more

pronounced ablation where metal has been found post-test. It is the case for axial ablation in VF-U1 test but

it is not obvious for the radial ablation. Indeed, in the corner of the cavity, the thickness of eroded concrete

is of the same order than on top.

This oxide and metal phases configuration could not be predicted by our current MCCI code. Using a

multiphase Volume Of Fluid code, and modelling the corium as a 2D dispersed medium with metal drops

and gas bubbles, it has been possible to calculate this spatial phase hydrodynamic distribution [16]. The

segregation of metal should thereby be independent from the way of heating the corium pool.

A significant part of the initial metal mass is oxidized during the MCCI process. The weight of the metallic

phase recovered at the bottom of the concrete cavity is ~3 kg. The oxidation rate is at least 74%.

5. CONCLUSIONS

In the frame of a JAEA-CEA cooperation under a research program entrusted to IRID, we have performed

a MCCI test on VULCANO using a prototypic metal and oxide corium (58.8% UO2, 16.2% ZrO2, 11.8%

Zr, 13.2% Stainless steel) representative from Fukushima Daiichi unit 1 conditions. The test section



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concrete, made with Japanese components, is siliceous with basaltic origin. Following the VBS series

performed a few years ago on VULCANO facility, VF-U1 test is the first experiment using a 2D

axisymmetric geometry and carrying on direct melting of corium using a more powerful inductive heating

system than previous tests.

The main objective of the test was to get a significant ablation leading to an ablation volume ratio of 1.6.

We manage to obtain a ratio of 1.68 in order to produce fuel debris with a composition corresponding to

expected conditions in the damaged plant. Therefore, the corium produced is well representative.

Conclusions arising from the material analysis of the selected samples will be relevant for future dismantling

operations. A bank of Fukushima Daiichi prototypic MCCI debris is thus available for R&D issues linked

to future Fukushima Daiichi fuel debris retrieval.

On a phenomenological point of view, it must be noted that the concrete ablation was clearly anisotropic

with a predominantly downwards ablation contrary to previous experiments with silica and limestone

concrete. Experiments in MOCKA with basaltic concrete also presented a different ablation pattern than

other types of concrete.

ACKNOWLEDGMENTS

This work was done in the frame of a JAEA-CEA contract and includes the results obtained under the

research program entrusted to the International Research Institute for Nuclear Decommissioning (IRID) by

the Agency for Natural Resources and Energy, Ministry of Economy, Trade and Industry (METI) of Japan.

The work and efforts of the whole PLINIUS experimental team are gratefully acknowledged. Thanks also

to Laurence Godin-Jacqmin at CEA.

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large scale vulcano molten core concrete … 2019 - final... · 3.2.1. concrete the 1f1 concrete...

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