Developing power plant materials using the life cycle lens

The Spherical Tokamak for Energy Production (STEP) programme is an ambitious but challenging endeavour to design and deliver a prototype fusion power plant. It is a rapid, fast-moving programme, designing a first of a kind device in a Volatile, Uncertain, Complex and Ambiguous (VUCA) environment, and digital tools play a pivotal role in managing and navigating this space. Digital helps manage the complexity and sheer volume of information. Advanced modelling and simulation techniques provide a platform for designers to explore various scenarios and iteratively refine designs, providing insights into the intricate interplay of requirements, constraints and design factors across physics, technology and engineering domains and aiding informed decision-making amidst uncertainties. It also provides a means of building confidence in the new scientific, technological and engineering solutions, given that a full-scale-integrated precursor test is not feasible, almost by definition. The digital strategy for STEP is built around a vision of a digital twin of the whole plant. This will evolve from the current digital shadow formed by system architecting codes and complex workflows and will be underpinned by developing capabilities in plasma, materials and engineering simulation, data management, advanced control, industrial cybersecurity, regulation, digital technologies and related digital disciplines. These capabilities will help address the key challenges of managing the complexity and quantity of information, improving the reliability and robustness of the current digital shadow and developing an understanding of its validity and performance. This article is part of the theme issue ‘Delivering Fusion Energy – The Spherical Tokamak for Energy Production (STEP)’.

Digital: accelerating the pathway

Davis,

Waldon,

Muldrew

et al. 2024

Concept design overview: a question of choices and compromise

Waldon,

Muldrew,

Keep

et al. 2024

The Spherical Tokamak for Energy Production (STEP) programme hypothesizes that a compact machine offers a route to reduced capital cost that directly tackles the barrier to entry of this potentially transformative technology. History has shown that with an unsolved, complex and highly interdependent design challenge, there is a need to balance exploration of the problem with progress. Almost all complex systems arise from the evolutionary improvement of simpler systems which is an approach the programme has adopted by working through a virtual natural selection of design families towards a single concept consistent with the initiating hypothesis. Issues are uncovered and solved more rapidly this way because the effort is focused on an end. In this current phase, STEP has had to be an agile fast-moving programme to work with what emerges as well as what was planned, to sit with uncertainty and to embrace self-organizing principles. The complex decision-making and compromises in emerging trades have led to a concept respectful of the tight aspect ratio hypothesis which carefully balances cost, performance and deliverability. It remains a high-risk and high-reward programme, but the character of the challenge is better understood building confidence and enhancing capability to advance the evolving design further. This article is part of the theme issue ‘Delivering Fusion Energy – The Spherical Tokamak for Energy Production (STEP)’.

Unlocking maintenance—architecting STEP for maintenance and realizing remountable magnet joints

van Arkel,

Lamb,

Robinson

et al. 2024

The architecture of the Spherical Tokamak for Energy Production (STEP) has been developed to enable a hybrid maintenance approach using ports in the vacuum vessel for a limited list of tasks that must be performed shortly after shutdown, and larger openings to simplify and speed up major refits. Robotic handling systems in zero-human entry facilities will prevent workers from being exposed to the most hazardous environments. While the approach is largely grounded in existing technologies, the scale and environment of STEP will require significant technology development. Notably, programmes have been established to develop service connections and in-vessel robotic technologies. The engineering integration of the maintenance strategy into the tokamak remains a priority, as does ongoing work to simplify and reduce the cost of the buildings required to facilitate maintenance. Remountable magnet joints are critical to ensuring life-limited magnet components can be replaced during the STEP lifetime and realizing the STEP maintenance strategy. It is a high-risk endeavour owing to the low technology maturity of the potential solutions and owing to the tough and intertwined technical challenges and constraints imposed by both the fundamental physics and the STEP requirements and architecture. An integrated design approach has been taken to balance many competing factors and integrate with interfacing systems, and a multi-faceted technology development programme has been established to address technical risk and to inform, verify and validate the STEP remountable magnet design. This article is part of the theme issue ‘Delivering Fusion Energy – The Spherical Tokamak for Energy Production (STEP)’.