ITER – Nuclear Cylinder

Pioneering work in extreme environments

How KONSTANDIN supports fusion research at ITER and develops and supplies key components

The ITER research project is one of the world’s largest scientific endeavors in the field of nuclear fusion research. The goal of ITER is to demonstrate the feasibility of nuclear fusion as a clean, emission-free, and virtually inexhaustible energy source. By fusing hydrogen nuclei together, the aim is to generate more energy than is required to maintain the reaction for the first time – a decisive step toward commercial fusion power plants. The facility is designed to deliver a fusion power of 500 megawatts.

This mammoth project is supported by 35 nations, including China, the European Union, India, Japan, Russia, South Korea, and the USA. The historic initiative dates back to 1985, when US President Ronald Reagan and Soviet leader Mikhail Gorbachev agreed on the cooperation. The facility is currently under construction in southern France; commissioning is planned for 2034.

Energy – Our entire existence is built upon it…

In today’s world, energy is above all the foundation for prosperity, mobility, and technological progress. It has evolved into one of the most central topics of our society, economy, and personal lives. As fossil resources dwindle and geopolitical crises threaten supply, sustainable alternatives in the energy sector are becoming increasingly important – they are the key to true independence and future viability. Energy is a strategic resource that determines political dependencies and drives change in ever new directions. Without a determined shift toward regenerative sources, this supply risks collapsing, which would lead to an immediate system failure – a total standstill in the dark.

Partnership since 2008

KONSTANDIN is proud to be part of the world’s largest research project in the energy sector. The high vacuum required for nuclear fusion is generated by eight cryopumps. For these, KONSTANDIN developed, produced, and delivered eight stainless steel cylinders with extreme low-friction properties, as well as the corresponding eight control boxes. This system precisely controls the opening and closing of the pump flaps. The particular challenges lay in the extreme environmental conditions: absolute resistance to heat, magnetic fields, radiation, and vibrations was required. Furthermore, the large pump inlet valves, with a diameter of almost one meter, require a control precision of exactly one millimeter.

Renewed Trust in KONSTANDIN’s Engineering Expertise

In the Tokamak vacuum chamber, extremely strong magnetic fields confine a 150-million-degree plasma in a ring-shaped torus. For this highly sophisticated environment, ITER approached KONSTANDIN again: a cylinder was required that could withstand the extreme radioactive conditions in the heart of the reactor and function with absolute reliability. The component is attached to the outside of the chamber and controls the opening and closing of a flap. Through this, an endoscope is inserted into the interior to precisely record important measured values.

Challenge

A radioactive environment, extreme magnetic fields, high temperatures, and a required failure rate of 0% defined the demanding framework of this project. Due to safety regulations, the use of fluorine and other halogens was strictly prohibited to rule out the formation of highly toxic hydrofluoric acid in the event of a fire. The stainless steel also had to meet the highest requirements: the cobalt content could not exceed 0.05%, as the material must withstand permanent neutron radiation, a continuous temperature of +230°C, and a magnetic field of approximately 0.3 Tesla. The specified service life is 30,000 strokes (approx. 10 strokes per day).

The biggest hurdle in material development for all components was the continuous temperature of +230°C in combination with the ban on halogens. Conventional high-temperature seals and lubricants for ranges above +200°C (such as FKM, FFKM, PTFE, or PFPE) are usually based on fluorine compounds and were therefore completely ruled out.

The Solution: A Masterpiece of Materials Engineering

The nuclear high-temperature cylinder developed and produced by KONSTANDIN is a high-tech component that easily withstands extreme temperatures up to +230°C and is optimized for long-term use in nuclear environments.

Components made of the high-performance plastic PEEK are used for the custom-made sealing system. This brought the next technological challenge: since PEEK is a very hard material, extremely tight manufacturing tolerances had to be achieved. In combination with a specially designed permanent lubrication, permanent leak-free operation is guaranteed. A special nuclear grease is used as a lubricant, which is completely free of fluorine and heavy metals. This is the only way to ensure the long-term tightness and the required service life of the cylinder.

This sophisticated product within a globally pioneering large-scale project perfectly reflects the core competencies of KONSTANDIN: innovation, flexibility, absolute reliability, and the highest quality determine our performance.

Learn more about KONSTANDIN’s solutions, the highly developed nuclear high-temperature cylinder, and the ITER research project directly on our special pages.