ASME Turbo Expo 2014
Dsseldorf Germany, June 16-21, 2014
Fundamentals of Supercritical CO2
Presentation by:
Jason C. Wilkes, Ph.D.
Southwest Research Institute
June 16, 2014
This tutorial provides an introduction to S-CO2 in
power cycle applications
7.37 MPa
CO2
Supercritical
region
Increasing
isobars
31 C
Supercritical CO2 (S-CO2)
Pcrit = 7.37 MPa (1070 psi)
Tcrit = 31 C (88 F)
Two-phase
region
S-CO2 loop hardware
[6-3]
[6-1]
Concentrated
Solar Power
[6-2]
Geothermal
Fossil Fuel
Power cycle applications
[6-5]
[6-4]
Ship-board
Propulsion
Research and future trends
There are both industrial and natural contributors
of CO2 in our atmosphere
CO2 in atmosphere
respiration
respiration in
decomposers
respiration
non-energy
uses, oil+gas combustion
production
byproducts, etc.
photosynthesis
volcanic
activity
Organic compounds in animals
Carbon in
fossil fuels
feeding
fossilization
Carbon compounds
in dead matter
(biomass)
Image source [1-3]
Carbon compounds in
geological formations
Organic compounds in plants
6
CO2 has many industrial applications
Food &
beverage
Agriculture
Welding (shield gas)
Oil & gas production
(more info with S-CO2)
Fire extinguishers
Various image sources [1-4]
11
What is Supercritical CO2?
The fluid critical point was discovered by
Cagniard de la Tour using a pressure cooker
Steam digester
Invented by Denis Papin
Cagniard de la Tour (1777-1859)
Placed a flint ball in the digester filled with liquid such
that rolling the digester produced a splashing sound
The splashing sound stopped after heating much
higher than the liquid boiling temperature
Experiments with a sealed glass tube at constant
pressure allowed observation of phase transformation
Image Source: [2-1]
Measured the critical temperature of alcohol, ether,
and water
Berche et al. (2009)
14
Video of Supercritical CO2
Image source: [2-2]
15
A fluid is supercritical if the pressure and
temperature are greater than the critical values
7.37 MPa
CO2
Supercritical
region
31C
Two-phase
region
Increasing
isobars
Pcrit = 7.37 MPa (1070 psi)
Tcrit = 31C (88F)
REFPROP (2007), EOS CO2: Span & Wagner (1996)
16
Fluid thermal conductivity is enhanced near the
critical region
0.092
Water (304K) = 620 mW/m/K
Btu
hr ft R
160
CO2
305K
140
120
307K
100
Thermal
Conductivity
[mW/m/K]
80
309K
60
350K
40
0.012
Btu
hr ft R
Atm air (304K) = 26 mW/m/K
20
0
100
Critical density
300
500
700
900
Density [kg/m3]
REFPROP (2007)
22
The ratio of specific heats peaks near the critical
region
10
CO2
8
8.0 MPa
6
Ratio of
Specific
Heats
12 MPa
4
4.0 MPa
16 MPa
20 MPa
0
200
Critical
temperature
300
400
500
600
Temperature [K]
Air = 1.4
REFPROP (2007)
23
Power Cycle Basics
Power Cycle Basics Overview
Carnot the standard
Brayton gas cycle
Rankine vapor cycle
Ideal vs. Actual
Variations
40
Qin
Brayton Cycle (Ideal)
2
Processes
(1-2) Isentropic compression
(2-3) Const. pres. heat addition
(3-4) Isentropic expansion
(4-1) Const. pres. heat reject.
HP-HE
Comp.
Turb.
Wnet
4
LP-HE
th,Brayton = 1 PR(1-k)/k
Qout
PR, k : th
Tmin
Entropy, S
Temperature, T
3
Tmax
Temperature, T
Open- or closed-loop
Optimal PR
for net work
Closed-loop
Qin
2
4
Qout
1
Entropy, S
43
Qin
Rankine Cycle (Ideal)
2
Boiler
Processes
(1-2) Isentropic compression
(2-3) Const. pres. heat addition
Pump
(3-4) Isentropic expansion
WP,in
(4-1) Const. pres. heat reject.
Same processes as
Brayton; different
hardware
Phase changes
E.g., steam cycle
th = 1 Qin/Qout
WT,out
Condenser
Qout
Qin
Temperature, T
Turb.
Liquid+
Vapor
3
Liquid
2
Gas
4
Qout
Entropy, S
44
Ideal vs. Actual Processes
Brayton
Rankine
1-2, 3-4: Irreversibilities
2-3, 4-1: Pressure losses
45
Power Cycle Variations
Regeneration
Intercooling
Reheating
Recompression
What is supercritical power cycle?
46
What is a Supercritical Power Cycle?
Temperature, T
Supercritical
region
Pcrit
Tcrit
Liquid
region
Gas
region
Liquid + vapor
region
Entropy, S
55
S-CO2 in Power Cycle Applications
Heat Source Operating Temperature
Ranges & Efficiencies with S-CO2
Source: Wright (2011)
106
Supercritical CO2 in Power Cycle
Applications
[6-3]
[6-1]
Concentrated
Solar Power
[6-2]
Geothermal
Fossil Fuel
[6-5]
[6-4]
Nuclear
Ship-board
Propulsion
107
Heat Source Operating Temperature
Range & Efficiency
Assumptions (Turbomachinery Eff (MC 85%, RC 87%, T 90%), Wright (2011)
108
Supercritical CO2 in Power Cycle
Applications
[6-3]
[6-1]
Concentrated
Solar Power
[6-2]
Geothermal
Fossil Fuel
[6-5]
[6-4]
Nuclear
Ship-board
Propulsion
109
S-CO2: Solar Power Requirements
(Sunshot Program)
Effective Dry Cooling
Thermal Energy Storage
Affordable $.06/kWh
Component Size
Southwest Research Institute 2012
110
Concentrated Solar Power (CSP)
The Sun-Motor (1903)
Steam Cycle
Pasadena, CA
Delivered 1400 GPM of water
Solar One (1982)
10 MWe water-steam solar
power tower facility
Barstow, CA
Achieved 96% availability during
hours of sunshine
Image source: [6-6]
Solar Two (1995)
Incorporated a highly efficient
(~99%) molten-salt receiver and
thermal energy storage system
into Solar One.
Currently
5GW Worldwide
1.8GW US
Image source: [6-7]
111
CSP Improvement Opportunities
Advanced power
cycles
Supercritical steam
Rankine
High temperature
air Brayton
Supercritical CO2
Cooling
650 gal H20/MWh
Dry-cooling technology
is needed in most
desert venues for CSP
43C Dry bulb
Printed circuit heat
exchangers may
provide a solution
Image source: [6-1]
112
S-CO2 CSP Process Diagram
Heliostats
Dual-shaft, tower receiver S-CO2 Brayton Cycle solar thermal power
system with thermal energy storage, Zhiwen and Turchi (2011)
113
CSP Efficiencies vs. Power Cycle
100%
80%
Supercritical CO2
60%
Supercritical CO2 CC
Air Brayton CC
Supercritical H2O
Cycle
Efficiency
Subcritical H2O
40%
Air Brayton
Commercial
Lab/Pilot
Concept
Demonstration
20%
0%
0
250
500
750
1000
Cycle Temperature [C]
1250
1500
Data from Stekli (2009)
114
Supercritical CO2 in Power Cycle
Applications
[6-3]
[6-1]
Concentrated
Solar Power
[6-2]
Geothermal
Fossil Fuel
[6-5]
[6-4]
Nuclear
Ship-board
Propulsion
115
S-CO2: Nuclear Requirements
Moderate temperature Reactors
Affordability (less expensive reactors)
Safe and Reliable
Southwest Research Institute 2012
116
Rankine Cycle Application: Nuclear
Power Generation
Image source: [6-8]
117
S-CO2 for Nuclear Applications
(550C-700C, 34 MPa)
Image source: [6-9]
Image source: [6-4]
118
Proposed Nuclear S-CO2 Cycles
Direct Cycle
No primary and
secondary Na
loops
Lower Void
Reactivity
Indirect Cycle
No secondary
Na Loops
Smaller core
size
Kato et al. (2007)
119
Nuclear Plant Efficiency vs. Cycle Prop.
Kato et al. (2007)
121
Advantages of CO2 Cycle vs. Helium
Cycle in Nuclear Applications
Pro
Con
Smaller turbomachinery than steam or
helium
Helium preferred to CO2 as a reactor
coolant for cooling capability and
inertness
CO2 Brayton cycles are more efficient
than helium at medium reactor
temperatures
CO2 requires a larger reactor than
helium or an indirect cycle
CO2 is 10 cheaper than Helium
New technology
122
Supercritical CO2 in Power Cycle
Applications
[6-3]
[6-1]
Concentrated
Solar Power
[6-2]
Geothermal
Fossil Fuel
[6-5]
[6-4]
Nuclear
Ship-board
Propulsion
123
S-CO2: Fossil Fuel Needs
Emission Reduction (Sequestration)
Affordability
Southwest Research Institute 2012
124
Oxy-Fuel Combustion
Conventional Combustion
Air
(78% N 2 , 21% O 2 )
Fuel
(Solar Turbines 2012)
Oxy-Fuel Combustion
O2
CO 2
Fuel
H 2O
125
Direct Oxy-Fuel Combustion
NG
O2
CO2 Turbine
CO2 Compressor
Oxy
Combustor
CO2
Power
Generator
Out
CO2
Electricity
Condenser
HRSG
CO2
Water
Steam
Rankine
Cycle
Generator
Electricity
Steam Turbine
126
Indirect Oxy-Fuel Combustion
Zero Emission Oxy-Coal Power Plant with Supercritical
CO2 Cycle, Johnson et al. (2012)
127
Supercritical CO2 in Power Cycle
Applications
[6-3]
[6-1]
Concentrated
Solar Power
[6-2]
Geothermal
Fossil Fuel
[6-5]
[6-4]
Nuclear
Ship-board
Propulsion
128
S-CO2: Ship-board Propulsion
Size
Weight
Efficiency
Speed
Southwest Research Institute 2012
129
Ship-board Propulsion
Nuclear S-CO2 cycles?
No implementations yet
Improved power to weight
Rapid startup
Bottoming cycles
Image source: [6-10]
Source: Dostal (2004)
130
Supercritical CO2 in Power Cycle
Applications
[6-3]
[6-1]
Concentrated
Solar Power
[6-2]
Geothermal
Fossil Fuel
[6-5]
[6-4]
Nuclear
Ship-board
Propulsion
131
Geothermal
Low Temperature Heat Source
T 210C, P 100 bar
Pruess (May 19, 2010)
132
Other S-CO2 Power Cycle Applications
Image source: [6-11]
Waste Heat
Recovery
Zhang (2005)
Non-Concentrated
Solar Power
133
Waste Heat Recovery (Bottoming)
Rankine Cycle Description
1. Liquid CO2 is pumped to supercritical pressure
2. S-CO2 accepts waste heat at recuperator and
waste heat exchanger
3. High energy S-CO2 is expanded at turboalternator producing power
4. Expanded S-CO2 is cooled at recuperator and
condensed to a liquid at condenser
2
1
4
3
Image source: [6-11]
Image source: [6-12]
134
S-CO2 Rankine Cycle in NonConcentrated Solar Power
NCSP (Trans-critical Rankine) Tt = 180C
e,exp = 8.75%-9.45%
Photovoltaic
e,exp = 8.2%
Zhang (2005)
Zhang (2007)
135
S-CO2 as a Refrigerant
Image source: [6-13]
Image source: [6-14]
136
S-CO2 vs R-22 in Refrigeration
Employed MCHEs
Summary
CO2 COP vs. R-22
42% Lower at 27.8C
57% Lower at 40.6C
Majority of entropy
generation in CO2
cycle was in the
expansion device
Brown (2002)
137
S-CO2 in Heat Pumps
S-CO2 replaced as a
refrigerant in domestic heat
pump hot water heater in
Japan.
COP = 8, 90C (194F)
Compared to COPtyp=4-5
Qh + We
COP =
We
Image source: [6-14]
EcoCute Heat Pump (2007)
138
S-CO2 Power Cycle
Research Efforts
SwRI Machinery Program Projects
Supporting sCO2 Power Cycle and
Component Development
Machinery Program
sCO2 Related Projects
CO2 Pipeline Pulsation Analysis and Mitigation
Novel Concepts for the Compression of Large Volumes of CO2 (FC26-05NT42650)
Development of a High Efficiency Hot Gas Turbo-Expander and Low Cost Heat Exchangers for
Optimized CSP Supercritical CO2 Operation (DE-EE0005805)
Novel Supercritical Carbon Dioxide Power Cycle Utilizing Pressurized Oxy-combustion In
Conjunction With Cryogenic Compression (DE-FE0009395)
Electrothermal Energy Storage with A Multiphase Transcritical CO2 cycle (DE-AR0000467)
Physics-Based Reliability Models for Supercritical CO2 Turbomachinery Components (DE-FOA0000861, PREDICTS)
Utility-Scale sCO2 Turbomachinery and Seal Test Rig Development (DE-FOA-0001107)
High Inlet Temperature Combustor for Direct Fired Supercritical Oxy-Combustion (DEFE0024041)
High Temperature, High Pressure Compact Heat Exchanger Development (DE-FOA-0001095)
Development of a Thin Film Primary Surface Heat Exchanger for Advanced Power Cycles (DEFOA-0001095)
High-Pressure Gas Property Measurements
DOE CO2 Compression Project
Development of Isothermal Compression
Pilot-scale
demonstration of an
internally cooled
compressor design
Isothermal compressor
and liquefaction / CO2
pump equipment design
Thermodynamic analysis
of CO2 separation,
compression, and
transport
CO2 liquefaction loop for
proof of concept
demonstration
sCO2 Expander Test Loop
Development
143
Objectives & progress
Scope: Mechanical design of the 1 MW turbine, primary
objective of mechanical integrity and safety while
performance is a secondary objective.
Final mechanical design review of 1 MW turbine to be
tested under the SunShot program recently completed
Pending approval to advance to phase 2 fabrication
144
Test Configuration
SwRI B278
Heater
Compressor
sCO2 Pump
Cooler
145
Test Configuration
Pipe Section
Pump to heater
Mixing line
Recuperator to heater
HT heater to expander
Expander to recuperator
Recuperator to existing
Existing piping to pump
Color
Dark blue
Yellow
Orange
Red
Dark
green
Light
green
Light blue
146
Development of a Supercritical Oxy-combustion Power
Cycle with 99% Carbon Capture
Southwest Research Institute and Thar Energy L.L.C.
Engineering development, technology
assessment, and economic analysis used to
evaluate technical risk and cost of a novel
supercritical oxy-combustion power cycle
Optimized cycle couples a coal-fired
supercritical oxy-combustor with a supercritical
CO2 power cycle to achieve 40% efficiency at
low firing temperature, 650 C
COE $121/MWe with 99% carbon capture
Cycle is limited by TRL of critical components
49% increase over Supercritical Steam Without
Carbon Capture ($81/MWe), exceeding the 35%
target
21% reduction in cost as compared to
Supercritical Steam with 90% Carbon Capture
($137/MWe).
Phase 1 completed in September 2013,
Extended to March 2014 to cover closeout
Budget $1.25 million
Ready to demonstrate supercritical oxycombustor and critical low TRL technologies
Supported by DOE Project DEFE0009395
Project Scope
Evaluate a novel supercritical oxy-combustion power
cycle for meeting the DOE goals of:
Over 90% CO2 removal for less than 35% increase in cost
of electricity (COE) when compared to a Supercritical
Pulverized Coal Plant without CO2 capture
Cycle evaluation based on:
Cycle and economic modeling to qualify cost and cycle
performance
Technology gap assessment to identify critical low TRL
components and technologies
Bench scale testing to back up cycle models and evaluate
state of low TRL technologies
Propose development path to address low TRL
components
DE-FE0009395 Project Closeout 2/21/2014
Final Supercritical Oxy-combustion
Cycle Configuration
P3
HXLOW
HXHIGH
P7a
P6
High Temperature Power Loop
Recompression sCO2 Power Cycle
P7
Sequestration
Ready CO2
COMP1
P7b
P2
EXPANDER
COMP2
P5
P4
COOLING OUT
COOLING IN
BOOST
P8
C6
P4a
C5
P1
P4b
C2
PRECOOL
HXMAIN1
C1
O2
C7
BOOST
HXCLEAN
C3
Coal Slurry
H2O, CaCO2, CaSO4, Hg
C4
CYCLONE
Combustor
C1b
H2O, O2, CaCO2
FLUE GAS
CLEANUP
C0
Combustion Loop
Coal Fired Supercritical Oxy-Combustion
Power
Block
Thermal Loop
Overall
Efficiency [%]
48 Thermal
78.9 HHV / 81.8
LVH
37.9 HHV / 39.3
LHV
CO2 Flow [kg/s]
4887
4930 Recycle
P high / P low
[atm]
290 / 82
100 / 93
T high / T low [C]
650 / 20
653 / 78
DE-FE0009395 Project Closeout 2/21/2014
Combustion Loop TRL
Combustion Loop
Coal Pulverizer
Slury Pump
Supercritical oxy-combustor
Pressure [atm]
Temperature [C]
Technology Type
Pressure [atm]
Component/Sub-system
Temperature [C]
Operating Conditions
Inlet
Outlet
Assumed or Specified Performance
Characteristics
Generic
Generic
New vertical flow swirl
combustor
25
25
450
1
1
95
25
30
93
1 < 9 kw-h/ton
92.25 60% Efficiency
92.25 98+% combustion efficiency
Dry pulverized coal feed
Dry pulverized coal feed
Supercritical CO2 slurry
Posimetric Pump
25
25
1
1
<450
<450
Removal of solid products of
combustion
Lock-hopper
703
92
80
Fluid and thermal losses, impact on efficiency
unknown
Cyclone Separator
Generic
703
93
703
91
98% Removal
3 atm dP
Recouperator (HXMAIN)
Compact micro-channel heat
exchanger
703
91
460
88
Pre-heater (HXCLEAN)
Compact micro-channel heat
exchanger
460
88
162
Sulfur Cleanup
Under evaluation for hot, high
pressure cleanup
162
85
Water Removal
Under evaluation for hot, high
pressure cleanup
162
Boost Pump
Generic
Air Separation Unit
Cryogenic
110 Minimal added water content
110 Dry feed
Assumptions Regarding
Anticipated Application Issues
Combustor to be
demonstrated in Phase 2
Demonstrated systems can
not achieve pressure ratio
Technology
Readiness
TRL 9
TRL 9
TRL 6 at the
completion of Phase
2 demonstration
TRL 2
TRL 4
TRL 4
Materials considerations and
thermal insulation for hot gas
cleanup
TRL 9
5 C Pinch Point
3 atm dP
See Note 3
TRL 7, See Note 1
85
5 C Pinch Point
3 atm dP
See Note 3
TRL 7, See Note 1
Under Evaluation to identify technologies
compatible with loop conditions
High efficiency requirements
drive the need for hot, high
pressure cleanup
TRL 5 - 9
depending on cleanup
conditions
85
Under Evaluation to identify technologies
compatible with loop conditions
High efficiency requirements
drive the need for hot, high
pressure cleanup
TRL 5 - 9
depending on cleanup
conditions
150
80
95
Seals and materials for
supercirtical CO2
TRL 9
30
450
93
140 kWh/t for 95% O2 based on literature
Note 1: TRL 7 at the completion of a compantion DOE SunShot Project in 2016 (DE-EE0005804)
Note 2: TRL 7 at the completion of a compantion DOE SunShot Project in 2013 (FC26-05NT42650)
Note 3: Materials and manufacturing assumptions for cost and performance
Note 4: Turbomachinery layout and design is being adressed in other DOE sponsored programs (DEEE0005804)
DE-FE0009395 Project Closeout 2/21/2014
TRL 9
Power Loop TRL
Power Loop
Pressure [atm]
Temperature [C]
Technology Type
Pressure [atm]
Component/Sub-system
Temperature [C]
Operating Conditions
Inlet
Outlet
Assumed or Specified Performance
Characteristics
Assumptions Regarding
Anticipated Application Issues
Supercritical CO2
Recompression Cycle
sCO2 Turbo-expander
Technology
Readiness
TRL 7, See Note 1
650
290
509
86
90+% efficiency
See Note 4
TRL 7, See Note 1
Recouperator (HXHIGH)
Compact micro-channel heat
exchanger
509
86
213
84
5 C Pinch Point
3 atm dP
See Note 3
TRL 7, See Note 1
Recouperator (HXLOW)
Compact micro-channel heat
exchanger
213
84
70
83
5 C Pinch Point
3 atm dP
See Note 3
TRL 7, See Note 1
sCO2 Pump/Compressor
70
83
190
290 05+% efficiency
See Note 4
TRL 7, See Note 2
sCO2 Pump/Compressor
25
82
60
290 05+% efficiency
See Note 4
TRL 7, See Note 2
70
83
25
82
See Note 3
TRL 7, See Note 1
Pre-cooler
Compact micro-channel heat
exchanger
5 C Pinch Point
3 atm dP
Note 1: TRL 7 at the completion of a compantion DOE SunShot Project in 2016 (DE-EE0005804)
Note 2: TRL 7 at the completion of a compantion DOE SunShot Project in 2013 (FC26-05NT42650)
Note 3: Materials and manufacturing assumptions for cost and performance
Note 4: Turbomachinery layout and design is being adressed in other DOE sponsored programs (DEEE0005804)
DE-FE0009395 Project Closeout 2/21/2014
Technology Development: Proposed
follow on
1 MWth Supercritical Oxy-combustor
Demonstration
Test bed for technology development
Supercritical oxy-combustor
Particulate cleaning of the compact
microchannel heat exchanger
Solids injection at pressure
Solids removal at pressure
Supercritical
Oxy-combustor
Water
Scrubber
Cyclone
Separator
Boost
Compressor
Underflow
Particulate
Separation
Water
Scrubber
Advance technologies from TRL 2,
Technology Concept, to TRL 6, Pilot
Scale System Demonstrated in a
Relevant Environment
Operate with coal water slurry, plan
for dry feed or sCO2 slurry extension
Cyclone
Separator
Cooling Tower
Underflow
Particulate
Separation
DE-FE0009395 Project Closeout 2/21/2014
Supercritical
Oxy-combustor
Oxy-Combustion Test Loop
Major components
Charge Compressor or Pressurized CO2
Feed
Combustor
450 650 C (800 1200 F)
102 atm (1500 psi)
Flow Rates: 1 MWth
Solids removal and handling
Recuperater
Water scrubber and cleanup
Operating Conditions
Cyclone separator
Oxygen feed
Coal slurry feed
Boost Compressor
Liquid removal and handling
CO2 removal and handling
3.4 kg/s Hot side flow rate
3.2 kg/s CO2 recycle
0.05 kg/s Coal feed
0.08 kg/s O2 Feed
4.25 kg/s H2O Recycle
Cooling Tower
Coal Fired Supercritical Oxy-Combustion Test Loop
C6
HXCLEAN
C1
O2
C5
CO2 Capture
and Disposal
BOOST
C2
Coal Slurry
Combustor
C0
H2O, Products of Combustion
C4
CYCLONE
C1b
CO2
H2O
Solids
Underflow Particulate
Removal
DE-FE0009395 Project Closeout
2/21/2014
C7
H2O
FLUE GAS
CLEANUP
Analysis of the Recuperated
Cryogenic Pressurized OxyCombustion Cycle (CPOC)
Aaron McClung, Ph.D.
Sr. Research Engineer
[email protected]210-522-2677
Initial Cycle: Cryogenic
Pressurized Oxy-combustion (CPOC)
Transcritical cycle (gas, liquid, and supercritical
states)
Leverage iso-thermal compression to minimize
compression work
DE-FE0009395 Project Closeout 2/21/2014
Recuperated CPOC
Add high temperature recuperator after expander, low temperature
recuperator after compressor
-963172
81204
B6
-830067
S8
183.57
th = 63.8%
175.00
1.00
1.00000
1.00
C-CL-T
CALCULATOR
0
1.00
1200.00
175.00
175.00
1.00000
1.00000
-19.22
S12
5.00
W=81204
1.00000
-30.83
1.00
1.00
175.00
COMBUST
1.00000
435.57
S2
S1
EXPANDER
T emperature (C)
0
S4
RECOUPH
1.00000
1
W=-963172
S14
S6
-31.34
Q=10103
S3
Power(Watt)
-62.27
5.00
5.00
1.00000
1.00000
V apor Frac tion
Duty (Watt)
0.00
RECOUPL
V olume Flow Rate (c um/s ec)
1.00
0
REFHX
S7
0.00
CRYOPUMP
S5
Q=-385489
High temperature recuperator
Hot stream: Turbine outlet
Cold stream: Low temperature recuperator
Assume 10 C pinch point
Low temperature recuperator
Hot stream: Iso-thermal compressor outlet
Cold stream: Dense phase pump
Assume 5 C pinch point
51900
0.00
Q=451878
S10
175.00
1.00000
1.00
Pressure (bar)
-36.34
1.00
1.00
Q=1300359
Mas s Flow Rate (kg/s ec)
C-CRYOP
CALCULATOR
COMP
S13
183.57
WNET
-20.83
1.00000
D-TINOUT
DESIGN-SPEC
S9
W=51900
Performance tweaks
Iso-thermal compressor
Reduce pressure ratio (Increases refrigeration
requirements)
Assume 20% of adiabatic temperature rise
Turbine inlet pressure between 145 and 175 bar
Assume 5C of sub-cooling for refrigeration
Baseline Recompression Cycle
24847
S17
T emperature (C)
206.66
Pressure (bar)
85.26
1.00000
Mass Flow Rate (kg/sec)
0.01017
Volume Flow Rate (cum/sec)
1.00
Dut y (Wat t)
Power(Wat t)
-221798
B1
Vapor Fraction
S3
1220.00
73.07
203.66
204.00
958.57
293.84
293.84
293.84
293.84
293.84
0.65000
0.65000
1.00000
1.00000
1.00000
0.00189
0.00094
W=24847
WPOWER
HXLOW
1.00
Q=992454
S16
0.00291
1.00
0.01027
0.00858
33235
HXHIGH
1.00
1.00
1.00
DUMMY
MIXER1
COMP1
S14
S13
S1
S9
S8
Q=345891
Q=159430
204.65
80.11
83.96
293.84
1.00000
0.35000
0.00102
0.00598
30.00
80.11
82.96
S7
1.00
1220.00
1.00
1.00000
SPLIT1
0.65000
0.00111
204.65
0.00388
0.00
Q=-0
1.00
80.11
S11
83.96
1017.80
293.84
86.86
0.35000
1.00000
0.00102
S6
T-DUMMY
293.84
COOL
83.96
0.65000
S12
S4
CALCULAT OR
S10
-279879
0.01027
1.00
PHOT1
0.02874
1.00
S2
1.00
0.35000
PRECOOL
0.00209
DSPLIT
DESIGN -SPEC
S5
EXPANDER
COMP2
1.00
W=-279879
Q=-123554
T-PRES
TRANSFE R
W=33235
POST
CALCU LATOR
Efficiency Comparison
0.7
Recuperated CPOC performs on par
with the recompression cycle, has
larger thermal input window, higher
power density, and requires less
CPOC
Recompression
recuperation
0.65
0.6
Thermal Efficiency
0.55
Efficiency
63.85%
64.00%
Turbine Inlet Temp (C)
1200
1200
Turbine Inlet Pressure (bar)
150
290
100
Recompression (290
bar)
0.45
Recuperated CPOC
(150/5 bar)
Turbine Outlet Pressure (bar)
Mass flow (kg/s)
1.00
1.00
0.4
Recuperated CPOC
(150/10 bar)
W net (MW)
0.830
0.221
Baseline CPOC
(300/20 bar)
Q in (MW)
1.300
0.345
HX high (MW)
0.451
0.992
HX low (MW)
0.010
0.154
Total Recuperation (MW)
0.461
1.146
0.5
0.35
0.3
0.25
0.2
600
800
1000
Temperature (C)
1200
1400
Scaled to 550 MWe plant, parasitic losses neglected
CPOC
Recompression
Mass flow (kg/s)
662.65
2,488.69
W net (MW)
550.00
550.00
Q in (MW)
861.45
858.60
HX high (MW)
298.86
2,468.78
HX low (MW)
6.63
383.26
Total Recuperation (MW)
305.48
2,852.04
FUNDAMENTAL GAS PROPERTY
TESTING
Fundamental gas property tests
for high H2S and CO2 content
mixtures, falling outside of typical
EOS model limits: speed of sound,
specific heat, and density up to
15,000 psi, 400F.
Adapted high pressure autoclaves
/ adiabatic calorimeters for specific
heat determination.
Specialized test methods for
speed of sound using high
pressure fixture design developed
by SwRI.
Gas sampling and species
determination near critical point.
Controlled long-term tests using
for H2S / CO2 / water mixtures to
characterize gas-liquid behavior.
Gas Fill / Empty
Line and
Pressure Sensor
Miniature pressure
transducer (pressure
wave detection)
Frequency / Pressure
Pulse Generation
(Using Internal-to-Gas
or External Speaker)
Gas
Temperature
Sensor
Additional Miniature
Pressure Transducer
159
COMPRESSOR STATION DESIGN
API 618 Standard Analyses: Pulsation,
Mechanical and Thermal Analysis of
Reciprocating Compressor Systems
1-D / 3-D Pulsation Analysis
Simulation of piping components for design
review: Regulators, check valves, process valves,
heat exchanger components
Larger pipeline system modeling and simulation:
Pump / compressor optimization, Leak detection,
MAOP Limit analysis
Transient surge / Surge control
Blow-down station analysis and
Acoustic-Induced Vibration
Compressor Map with Transient Events from 17800 RPM
Theoretical Surge Line
TRANSIENT #0
TRANSIENT#3
17800 RPM
TRANSIENT#1
TRANSIENT#8
19800 RPM
TRANSIENT#2
MEASURED SURGE LINE
9000
8000
Isentropic Head [ft-lbf/lbm]
7000
6000
19800 RPM
5000
17800 RPM
4000
3000
2000
1000
0
0
200
400
600
800
1000
Actual Flow [cfm]
1200
1400
1600
1800
DOE S-CO2 Test Program
Research compression loop
Turbomachinery performance
Brayton cycle loop
Different configurations possible
Recuperation, Recompression, Reheat
Small-scale proof-of-technology plant
Small-scale components
Different than hardware for commercial scale
Barber Stockwell, Sandia National Laboratories,
173
DOE S-CO2 Test Program
Turbomachinery
100 mm
Source: Wright (2011)
174
S-CO2 Brayton Cycle Test Loop
Source: Wright (2011)
175
S-CO2 Brayton Cycle Test Loop
Source: Wright (2011)
176
S-CO2 Brayton Cycle with Regeneration
Source: Conboy et al. (2012)
177
S-CO2 Brayton Cycle with Regeneration
Source: Conboy et al. (2012)
178
S-CO2 Brayton Cycle with Regen. + Recomp.
Source: Wright (2011)
179
S-CO2 Brayton Cycle Performance
with Regeneration Config.
Maximum Case:
Total Turbine Work, 92 kW
Improve with larger scale:
Windage losses
Thermal losses
Seal leakage
Source: Conboy et al. (2012)
180
DOE S-CO2 Test Program Summary
Major milestones
Test loops operational
Demonstrate process stability/control
Areas for future development
Heat exchanger performance
Larger scale test bed
Utilize commercial-scale hardware
Demonstrate more-realistic (better) performance
CO2 mixtures
181
Printed Circuit Heat Exchanger (PCHE)
S-CO2 test loop used by Sandia/ Barber-Nicholls
Heatric PCHE
Le Pierres (2011)
182
Heat Exchanger Testing (Bechtel)
150 kW
8000 lbm/hr S-CO2
2500 psi
Nehrbauer (2011)
183
Tokyo Institute of Technology (TIT)
(Kato et al., 2007)
184
TIT, New Micro-Channel Heat
Exchanger
(Kato et al., 2007)
185
TIT, Heat Exchanger Testing
(Kato et al., 2007)
3kW
19,21 kW
TokyoTech,
(S-Shaped Fins)
HEATRIC
(Zigzag Fins)
186
TIT, Heat Transfer Rate vs. Pressure
Drop
Kato et al. (2007)
187
Corrosion Loop at Tokyo Institute of
Technology
316 SS, 12% Cr alloy, 200-600C, 10 Mpa CO2, Kato et al. (2007)
188
Other S-CO2 Corrosion Test Facilities
MIT - 650C, 22 MPa
Steels
UW - 650C, 27 MPa
Steels
Guoping (2009)
French Alternative Energies and Atomic
Energy Commission - 550C, 25 MPa
Steels
MDO Labs 54.4C, 12.4 MPa
Elastomers, engineering plastics, rubbers,
etc.
189
Geothermal Research
Explore the feasibility of operating enhanced geothermal systems (EGS) with CO2
as heat transmission fluid
Collaboration between LBNL (Pruess), UC Berkeley (Glaser), Central Research
Institute of the Electric Power Industry, Japan (Kaieda) and Kyoto University
(Ueda)
UC Berkeley: laboratory testing of CO2 heat extraction
Japan: inject brine-CO2 mixtures into Ogachi HDR site (T 210C, P 100 bar)
LBNL: model reactive chemistry induced by brine-CO2 injection
Schematic of EGS with S-CO2
Pruess (May 19, 2010)
Ogachi, Japan HDR Site
Pruess (May 18, 2010)
190
S-CO2 Critical Flow (Univ. Wisconsin)
(Anderson, 2009)
191
S-CO2 High Pressure Compression
(Dresser-Rand)
Tupi - I
Tupi - III
(GT2012-70137)
192
Future Trends for
S-CO2 Power Cycles
Future trends and research needs
Intermediate-scale is needed to demonstrate commercial viability of fullscale technologies (i.e. 10 Mwe)
Materials
Long term corrosion testing (10,000 hrs)
Corrosion of diffusion-bonded materials (PCHE HX)
Coatings to limit/delay corrosion
Corrosion tests under stress
Heat Exchangers
Improved heat transfer correlations near the critical region for varying geometries
Improve resolution of local heat transfer measurements
Heat exchanger durability studying effects of material, fabrication, channel geometry,
fouling, corrosion, and maintenance
Rotordynamics
Analysis of rotor-dynamic cross-coupling coefficients for S-CO2
Pulsation analysis
Development of transient pipe flow analysis models for S-CO2
194
Future trends and research needs
Control System and Simulation
Detailed models of turbo machinery
Improved transient analysis surge, shutdown events
Fluid properties
Mixture of S-CO2 and other fluids
Physical property testing of CO2 mixtures at extreme conditions with significantly reduced
uncertainties (i.e. < 1%)
195
Summary
Both supercritical power cycles and the use of
S-CO2 are not new concepts
S-CO2 is used in a variety of industries as a solvent
S-CO2 is desirable for power cycles because of its near-critical fluid
properties
CO2
Supercritical
region
197
S-CO2 power cycles can be applied to many heat
sources and have a small footprint
The near ambient critical temperature of CO2 allows it to be matched with a
variety of thermal heat sources
Geothermal
Concentrated
Solar Power
Nuclear
Fossil Fuel
Ship-board
Propulsion
The combination of favorable property variation and high fluid density of SCO2 allows small footprint of machinery
1.50
PR = 1.4
PR = 2.0
Air
Air
S-CO2
S-CO2
1.25
1.00
Impeller Dia.
0.75
[m]
0.50
0.25
0.00
0
10000
20000
Shaft Speed [rpm]
30000
198
The near future goal is to improve understanding
and develop commercial-scale power
International S-CO2 power cycle research is ongoing
Power production test loops
Materials corrosion test facilities
Machinery component test loops
Fluid property testing
More research is needed S-CO2 power cycle applications
Intermediate scale (10MW) demonstration
Materials testing at high temperature, pressure and stress
Property testing with S-CO2 mixtures
Rotordynamics with S-CO2
S-CO2 heat transfer and heat exchangers
More detailed dynamic simulation and control systems
Questions?
199
