The Current Status of Liquid Fuel and Material Technology Development for Chloride-Based Molten Salt Reactors (MSRs) at KAERI Part I. Liquid Fuel Fabrication and Natural Convection Loop Operation for Corrosion Characteristics

다국어 초록 (Multilingual Abstract)

The efficient fabrication of uranium-based liquid fuels and the structural integrity of reactor materials are critical challenges for the deployment of chloride-based molten salt reactors (MSRs). As part of KAERI’s ongoing MSR development, this study investigates an optimized uranium chlorination process and a corrosion assessment of candidate structural materials under conditions more closely resembling actual reactor cores. To enhance process efficiency and scalability, metallic uranium was converted into uranium trihydride (UH3 ) via hydriding, achieving 34.1% efficiency. UH3 was chlorinated with ammonium chloride (NH4 Cl), yielding uranium trichloride (UCl3 ) with a conversion rate over 98% and purity above 99%, as confirmed by ICP-OES. The UCl3 was used to fabricate various uranium-based liquid fuels for MSR applications. Simultaneously, the corrosion behavior of SS304, SS316, and Hastelloy-N was evaluated using a natural convection loop filled with a NaCl MgCl2 eutectic salt mixture. The system operated for 500 hours at 500–580°C to replicate MSR conditions. Corrosion analysis revealed that SS304 suffered severe degradation, SS316 showed moderate resistance, and Hastelloy-N demonstrated superior stability, although some cold leg samples experienced mass gain due to corrosion product deposition. These findings provide key insights into optimizing liquid fuel synthesis and selecting corrosion-resistant materials for safe, long-term MSR operation.