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Enclosure 2: Public Session Presentation Materials for the Pre-Submittal Meeting on the Kairos Power Atlas Fuel Fabrication Facility Application
	ML21342A244
Person / Time
Site:	99902069, 07007034
Issue date:	12/08/2021
From:	; Kairos Power
To:	; Office of Nuclear Material Safety and Safeguards, Office of Nuclear Reactor Regulation
Shared Package
ML21342A239	List: ML21342A241; ML21342A244;
References
	KP-NRC-2112-001
	Download: ML21342A244 (47)
	v • d • e

KP-NRC-2112-001 Enclosure 2 Public Session Presentation Materials for the Pre-Submittal Meeting on the Kairos Power Atlas Fuel Fabrication Facility Application

No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC

Kairos Powers mission is to enable the worlds transition to clean energy, with the ultimate goal of dramatically improving peoples quality of life while protecting the environment.

In order to achieve this mission, we must prioritize our efforts to focus on a clean energy technology that is affordable and safe.

2 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Atlas Fuel Fabrication Facility Presentation

Introduction and Opening Remarks

Kairos Power

Kairos Power Fuel Design

Fabrication Facility Scope

Key Fuel Fabrication Processes

Overview of Proposed Facility

Regulatory Approach Copyright © 2021 Kairos Power LLC. All Rights Reserved.

3 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Overview of Kairos Power Kairos Power Headquarters

Nuclear energy engineering and design company singularly focused on the commercialization of the fluoride salt-cooled high temperature reactor (FHR)

Founded in 2016 Current Staffing 232 Employees

~90% Engineering Staff

Private funding commitment to engineering design and licensing program and physical demonstration through nuclear Kairos Power Team and non-nuclear technology development program

Schedule driven by US demonstration by 2030 (or earlier) and rapid deployment ramp in 2030s

Cost targets set to be competitive with natural gas in the US electricity market Copyright © 2021 Kairos Power LLC. All Rights Reserved.

4 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Kairos Power Locations Molten Salt Pilot Plant Elmore, OH HQ / R-Lab / S-Lab Alameda, CA T-Facility / Engineering Test Unit Production Development Facility Albuquerque, NM Hermes Reactor Licensing Office Atlas Fuel Production Facility Charlotte, NC Oak Ridge, TN Kairos Power Facilities Copyright © 2021 Kairos Power LLC. All Rights Reserved.

5 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Kairos Power Highlights Feb. 2020 Kairos Power Dec. 2016 Sep. 2018 acquires May 2020 Kairos Power RAPID Lab Albuquerque Decision to build starts business operations manufacturing Hermes non-power operations begin & testing facility reactor is made Sep. 2017 Oct. 2018 Mar. 2020 Site selection Pre- Kairos Power Jul. 2020 for KP-HQ application forms strategic Salt Lab is and R-Lab in engagement partnership w/ commissioned Alameda with NRC Materion to in Alameda Point begins supply beryllium fluoride Copyright © 2021 Kairos Power LLC. All Rights Reserved.

6 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Kairos Power Highlights Dec. 2020 Jun. 2021 Kairos Power wins $303M T-Facility DOE ARDP award. T-Facility completed. Nov. 2021 construction begins. Site First non- ETU vessel announced for Hermes nuclear pebble delivered to reactor in Tennessee manufactured KP-SW in PDL Jan. 2021 May 2021 Sept./Oct. 2021 Pebble Cooperative CPA for Hermes Development Lab development reactor submitted construction begins agreement to NRC with TVA Copyright © 2021 Kairos Power LLC. All Rights Reserved.

7 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Technology Basis Fluoride Salt-Cooled High-Temperature Reactor (FHR)

Coated Particle Fuel Liquid Fluoride Salt Coolant TRISO Flibe (2LiF-BeF2)

8 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Kairos Power NRC Status 2018 2019 2020 2021 2022 2023

Construction Permit Application accepted for Topic 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q review Design Overview of KP-FHR (Technical Report) Rev 1 Approved Complete/submitted

11 topical reports to date with multiple iterations Testing and Development Program for KP-FHR (Technical Report)

In development/review Proposed NRC review duration and five technical reports Selection of Principal Design Criteria (Topical Report) DSER FSER Announced milestone Actual milestone

Multiple audits, onsite reviews (including PIRT Regulatory Gap Analysis Summary (Topical Report) DSER acceptance) Separate Effects Test and Integral Effects Test Scaling Methodology DSER FSER (Topical Report)

ACRS review of several topicals Reactor Coolant (Salt) Qualification Program (Methods - Topical DSER FSER Report)

NRC topical report approvals: Licensing Basis Event (LBE) Selection and SSC Classification Methodology (Topical Report) DSER FSER Principal Design Criteria Regulatory Engagement Plan (Technical Report) Rev 1 Test Scaling Methodology Fuel Performance Analysis Methodology (Methodology and DSER FSER Salt Coolant Qualification Approach - Topical Report)

Licensing Basis Event Selection Quality Assurance Program Description (Topical Report) FSER High Temperature Materials Qualification Plan (Metallics - Topical Quality Assurance Report)

Rev 1 FSER Radiological Source Terms for Accident Analysis (Methods and DSER

Topical reports under review: FSER Governing Physics - Topical Report)

Regulatory Analysis Fuel Qualification Program (Topical Report) FSER Fuel Performance High Temperature Materials Qualification Plan (Graphite - Topical Rev 0 Rev 1 Report)

High-Temp Metallic Materials Transient and Accident Analysis Methodology (Methods and Governing Physics - Technical Report) Rev 0 Mechanistic Source Term Core Design and Analysis (Technical Report) Rev 0 Fuel Qualification High-Temperature Graphite Materials Hermes Preliminary Safety Analysis Report Construction Rev 0 Permit Application Hermes Environmental Report Rev 0 Copyright © 2021 Kairos Power LLC. All Rights Reserved.

9 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

10 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

11 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Atlas Fuel Fabrication Facility Scope

Scope of the facility is to manufacture HALEU TRISO particles and annular pebbles (containing TRISO particles)

Atlas will be a Category II facility under the regulations in 10 CFR 70 and will be located near the Hermes demonstration test reactor at the East Tennessee Technology Park in Oak Ridge, Tennessee Facility will not perform enrichment

Currently developing TRISO and pebble manufacturing equipment designs and processes Copyright © 2021 Kairos Power LLC. All Rights Reserved.

12 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Fuel Fabrication Process Overview

Kernel Manufacturing

Waste Management Dissolution of the U3O8 powder Recovery and treatment of the effluent waste streams from the Preparation of a uranium casting solution various process steps, plus solid waste handling Casting of spherical uranium kernels Heavy metal recovery (collection and storage)

Aging, washing, and drying and of the kernels Off-gas treatment Calcining and sintering to convert the kernels to UCO

Balance of Plant (UO2 + UC + UC2) Utility and service systems Sieving, sorting, sampling, portioning to separate out Gases, reagents, waters, and power supply only the spherical kernels HVAC, process ventilation, fire, gas, radiological protection

Coated Particle Manufacturing systems Deposition using chemical vapor deposition of multiple Civil and Structural carbon and SiC layers on the uranium kernel Process areas, offices, change rooms Separation and handling of the soot from the CVD General and Support coater Communications, facility monitoring, security, decontamination, Graphite component handling Maintenance, emergency response

Pebble Manufacturing Matrix graphite powder preparation Pebble pressing and heat treating Copyright © 2021 Kairos Power LLC. All Rights Reserved.

13 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Facility Process Overview Balance of Plant Systems Matrix Graphite Effluent Powder Treatment Manufacturing Storage of HM Discharge Kernel Coated Particle Fuel Sphere Storage of Manufacturing Manufacturing Manufacturing Fresh Fuel Transport to Reactor Rejected Kernels Rejected CPs Heavy Metal Rejected FS Scrap Storage Copyright © 2021 Kairos Power LLC. All Rights Reserved.

14 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

15 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Kernel - Overall Process Description

Gelation is used to produce uranium oxycarbide (UCO) kernels The uranium powder for manufacturing is a maximum 19.55 wt% U-235 enriched U3O8 powder called High Assay Low Enriched Uranium (HALEU).

The kernels are produced using nuclear grade U3O8 powder or recovered U3O8 powder as feed material.

UCO kernels are dense sintered microspheres consisting of uranium dioxide (UO2), uranium di-carbide (UC2) as well as uranium carbide (UC) with an approximate ratio of C/U of 0.1 - 0.4 and a specified diameter of 425 µm.

Aging, washing, and drying are process steps that solidify the spherical, cast kernels and remove impurities

The calcining and sintering process steps convert the kernels first to UO3 and then to UO2 while producing the desired phase distribution of UC + UC2

Sieving, sorting, sampling and portioning removes the undersized and oversized kernels, removes the aspherical kernels, and separates them into batches that correspond to a lot Copyright © 2021 Kairos Power LLC. All Rights Reserved.

16 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Solution Gelation - Dissolving and Casting Preparation WATER NITRIC ACID NH4OH Pre-Neutralizing U3O8 DISSOLVING Carbon Alcohol Black U3O8 F

WATER &

polymer WATER DISPERSING AGENT TEMP CASTING FLUID CONTROL polymer PREPARATION STORAGE STORAGE F

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Aging, Washing, and Drying Continuous Casting TEMP Aging Washing CONTROL Fluid Fluids VIBRATOR DRYING VESSEL AGEING VESSEL WASHING VESSEL RT °C Air Forming Fluid Forming Fluid 80°C CASTING VESSEL PRE-AGEING VESSEL (Below Column)

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Calcining and Sintering 1680°C & 1890°C SIEVE QC SCRAP SORT CO/Ar CARBOTHERMIC REDUCTION & SINTERING FURNACE 430°C Air & Ar

CARBOTHERMIC REDUCTION - CONVERT UO2 TO UCO

SINTERING - PRODUCE DENSE UCO 600 °C in H2/Ar CALCINING & URANIUM REDUCTION FURNACE

CALCINING - CONVERT TO UO3

URANIUM REDUCTION - CONVERT TO UO2 PORTIONING Copyright © 2021 Kairos Power LLC. All Rights Reserved.

19 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

20 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Particle Coating

Chemical Vapor Deposition (CVD) is used for the coating of uranium oxycarbide (UCO) kernels with pyrolytic carbon and silicon carbide to produce tristructural isotropic (TRISO) coated particles Coating Gas: Carrier Gas UCO Kernel -

Porous Carbon C2H2 in Ar Buffer Layer IPyC Layer C3H6/C2H2 in Ar SiC Layer MTS (Methyltrichlorosilane, CH3Cl3Si) in H2 OPyC Layer C3H6/C2H2 in Ar Copyright © 2021 Kairos Power LLC. All Rights Reserved.

21 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Coated Particle Process UCO KERNELS SIEVE SORT QC STORAGE MTS EITHER OR

~3 kg COATED PARTICLE HEATING COLLECTION COOLING OFF GAS ELECTRIC COOLERS HEATING ELEMENT COATER CAUSTIC OFF GAS BAG NEUTRALISATION TREATMENT FILTER HYDROGEN / ARGON ACETYLENE / PROPELYNE EFFLUENT TO RECOVERY Copyright © 2021 Kairos Power LLC. All Rights Reserved.

22 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

23 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Matrix Graphite Powder Manufacturing HOMOGENISATION PHENOL BINDER Coarse ELECTROLYTIC GRAPHITE Milling NATURAL GRAPHITE METHANOL MIXING RECYCLED MGP DISSOLVING (SWARF)

(TO PRESSING)

METHANOL KNEADING FINE MILLING EXTRUDER (TO OVERCOATING)

24 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Pebble Facility - Overcoating, Drying and Portioning MATRIX GRAPHITE POWDER COATED

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Pebble Facility - Pebble Pressing MATRIX GRAPHITE POWDER OVERCOATED PARTICLES MATRIX GRAPHITE POWDER GRAPHITE ANNULAR CORE FUEL ZONE CORE PRESSING PRESSING INTERMEDIATE PEBBLE PRESSED PEBBLE SHELL PRESSING Copyright © 2021 Kairos Power LLC. All Rights Reserved.

26 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Pebble Facility - Machining SWARF TO WASTE MACHINED PEBBLES BUFFER STORAGE LATHE REJECTS TO STORAGE VACUUM 800°C 1950°C FINAL STORAGE QC CARBONISING FURNACE DIMENSION & VISUAL ANNEALING FURNACE INSPECTION, MASS CHECK, X-RAY Copyright © 2021 Kairos Power LLC. All Rights Reserved.

27 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Fuel Specifications and Inspections Specifications are established to guide product inspections and ensure product quality, customer defined expectations, and fuel performance. The specifications cover:

Raw materials and consumables

Intermediate product forms Kernels Kernel Coatings (TRISO particles)

Matrix graphite powder product

Final annular fuel pebbles Copyright © 2021 Kairos Power LLC. All Rights Reserved.

28 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

29 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Waste Management - Overall Process Description

The waste streams in this facility include liquid effluents, off-gases, or contaminated solids from the various steps in the fabrication process

The effluents are either purified to be re-used or treated to the required specification to be released or sent for disposal

Off-gases are treated to the required release specification before being released to the atmosphere. Some chemicals are recovered from off-gases prior to release, as required.

The small quantity of contaminated solids are collected, repackaged and stored for later treatment or disposal

Liquid effluents with potential for uranium contamination will be stored or processed in vessels with a critically safe geometry Copyright © 2021 Kairos Power LLC. All Rights Reserved.

30 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

31 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Balance of Plant Systems The balance of plant (BOP) systems are:

Utility and services systems: gases, reagents, waters and power supply

Heating ventilation air conditioning, fire, gas, and radiological protection systems

Civil and structural: process areas, offices, change rooms, tanks

General and support: communication systems, facility monitoring and security, decontamination, maintenance and support, emergency response Copyright © 2021 Kairos Power LLC. All Rights Reserved.

32 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Balance of Plant Systems - Utilities and Services Utility Gases:

Acetylene - manifold cylinder pallet

Ammonia - multiple cylinders

Argon - bulk liquid argon system

Carbon monoxide - cylinder supply

Compressed air - a compressor unit with dryer and accumulator

Hydrogen - multiple cylinders

LPG - bulk LPG system

Nitrogen - MCP

Propylene - cylinder supply

Steam - a boiler with condensate return system

MTS - methyl trisilicate Copyright © 2021 Kairos Power LLC. All Rights Reserved.

33 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Balance of Plant Systems - Utilities and Services Utility liquid reagents :

Aqueous ammonia solution

Ammonium nitrate

Aqueous nitric acid solution

Isopropanol (IPA)

Surfactant (SPAN 80) tetrahydrofurfuryl alcohol (THFA)

Trichloroethylene (TCE)

34 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Balance of Plant Systems - Utilities and Services Utility solid reagents:

Carbon black

Dispersing agent (Tamol)

Hexamethylenetetramine (HMTA)

Polyvinyl alcohol (PVA)

Ammonium hydroxide

Triuranium octoxide

Urea

Caustic The utility reagents are stored in the appropriate storage areas.

35 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Balance of Plant Systems - Utilities and Services Utility water includes:

Chilled water - chiller unit

Cooling water - cooling tower

Demineralized water - demineralized water system

Potable water - tie into the municipal supply

Backup Cooling water - potable water supply

Process water - recovered water or potable water

36 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Balance of Plant Systems - HVAC The functions of the Facility HVAC system/s are to:

Provide sufficient space conditioning to the various areas within the facility

Provide dynamic confinement in the building by means of pressure gradients between the various areas

Capture and remove air-borne hazardous substances generated during operations

Prevent the spreading of fires The Facility HVAC System is comprised of:

Building HVAC (Room supply and extraction)

Process ventilation

37 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Balance of Plant Systems - Fire Protection System The functions of the Fire Protection System are to:

Detect fires at an early stage

Suppress fires at an early stage by means of an inert gas system

Prevent the spreading of fires

38 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

39 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

40 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Regulatory Approach

Application prepared in compliance with 10 CFR 70, Domestic Licensing of Special Nuclear Material and 10 CFR 51, Environmental Protection Regulations for Domestic Licensing and Related Regulatory Function Fuel Facility Environmental Report (ER) will leverage Hermes ER due to proximity of the two facilities

The application will also address the following regulations:

10 CFR 20 Standards for Protection Against Radiation 10 CFR 21 Reporting Defects and Noncompliance 10 CFR 30 Rules of General Applicability to Domestic Licensing of Byproduct Material 10 CFR 40 Domestic Licensing of Source Material 10 CFR 73 Physical Protection of Plants and Materials 10 CFR 74 Material Control and Accounting of Special Nuclear Material 10 CFR 75 Safeguards on Nuclear Material

Application will use guidance in NUREG-1520, Standard Review Plan for Fuel Cycle Facilities License Application

ER will follow guidance in NUREG-1748, Environmental Review Guidance for Licensing Actions Associated with NMSS Programs (NUREG-1748)

Format consistent with Hermes ER

41 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Regulatory Approach (continued)

Other NUREGs that will be used to inform the application are:

NUREG-1140, A Regulatory Analysis on Emergency Preparedness for Fuel Cycle and Other Radioactive Material Licenses" NUREG-1513, Integrated Safety Analysis Guidance Document NUREG-1601, Chemical Process Safety at Fuel Cycle Facilities NUREG/CR-6410, Nuclear Fuel Cycle Facility Accident Analysis Handbook

Application will be informed by Interim Staff Guidance:

FCSS-ISG-04, Baseline Design Criteria FCSS-ISG-12, Reportable Events per 10 CFR 70, Appendix A FCSS-ISG-14 , Acute Uranium Exposure Hazards for Workers FCSS-ISG-15, Natural Phenomena Hazards for Fuel Cycle Facilities Copyright © 2021 Kairos Power LLC. All Rights Reserved.

42 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Outline of Fuel Facility License Application Chapter Title Content 1 General Information Facility and process overview, institutional information, site overview 1.1 Facility and Process Overview Facility layout description, process overview, site overview, descriptive summary of licensed material 1.2 Institutional Information Corporate identity and ownership, financial qualifications, characteristics of the material, authorized uses, special exemptions or special authorizations, protection of SGI, security of classified info, license period 1.3 Site Description Geography, demographics, meteorology, hydrology, geology 2 Organization and Administration Facility organization chart, key management functions, administrative policies and procedures, qualifications of key positions 3 Integrated Safety Analysis and Process safety information, ISA Team, ISA summary (stand alone Integrated Safety Analysis Summary document) 4 Radiation Protection Radiation protection programs, ALARA Program, radiological organization and qualifications, procedures, radiation training, respiratory protection, surveys and monitoring.

43 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Outline of Fuel Facility License Application (continued)

Chapter Topic Content 5 Nuclear Criticality Safety Management measures for criticality, criticality monitoring, criticality analysis methodology, double contingency 6 Chemical Safety Chemical information, chemical hazards analysis 7 Fire Safety Administrative controls, fire protection features and system, fire fighting capability, fire hazards analysis 8 Emergency Management Emergency planning 9 Environmental Protection Effluent monitoring, environmental surveillance, permits, design basis 10 Decommissioning Management, overall plan, recordkeeping, financial assurance 11 Management Measures Quality Assurance, configuration management, maintenance, training/qualification, procedures, audits and assessments, Incident Investigations, records management 12 Material Control and Management, physical inventory, recordkeeping Accounting 13 Physical Protection Physical protection, training and qualification, safeguards contingency Copyright © 2021 Kairos Power LLC. All Rights Reserved.

44 No Reproduction or Distribution Without Express Written Permission of Kairos Power LLC.

Integrated Safety Analysis Regulatory Approach

Integrated Safety Analysis (10 CFR 70.62) will be focused on:

Radiological Safety Fire Safety Nuclear Criticality Chemical Safety

Each Step of the Manufacturing Process (and material receipt and fuel storage) will be assessed:

Radiological Safety is addressed by Items Relied on for Safety (IROFS), which in turn are supported by management measures Criticality addressed by geometry, neutron absorbers, mass control, alarms, double contingency Fire protection addressed by separation, barriers, detection, alarm, and suppression as appropriate Chemical safety addressed by engineering and administrative controls and defense in depth Copyright © 2021 Kairos Power LLC. All Rights Reserved.

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QUESTIONS?

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ML21342A244

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