The first-of-a-kind (FOAK) nuclear plants built in the last 20 years are 2X over budget and schedule in the US and some European countries. One of the nuclear industry's proposed remedies is the small modular reactor (SMR). SMR designs leverage five factors to be more economically competitive than large reactors: 1) multiple units; 2) increased factory production and learning; 3) reduced construction schedules; 4) plant design simplification and 5) unit timing. There are currently no studies that quantitatively account for these factors and compare different near term SMRs with Gen III+ large plants. This work presents a nuclear plant cost estimating methodology using a detailed bottom up approach for over 200 structures, systems, and components. The results compare relative cost for two large pressurized water reactors, one with active safety and one with passive safety, to two SMR designs, one with multiple reactor power modules and one with a single reactor module. Passive safety systems showed noticeable savings at both the large and small scale reactors. The power uprating of a SMR by 20% resulted in ~15% savings in the overnight unit capital cost. Overall, if built by an inexperience vendor and work force, the two SMRs' overnight cost were higher than large reactors since significant on-site labor still remains while losing economy of scale. However, the single-unit SMR had significantly less total person-hours of onsite labor, and if built by an experienced workforce, its overnight construction cost showed potential to be competitive and avoid cost-overrun risks associated with megaprojects.
Highlights:• Bottom-up cost estimation of large and small nuclear plants are made.• Typical SMRs require at least similar unit on-site labor hours vs. large reactors.• Introduction of passive safety and power uprate are effective at reducing cost.• FOAK overnight unit cost of SMRs can be noticeably higher than large reactors.• Experienced vendor and work force could make SMRs competitive with large plants.