ASME Turbo Expo 2014

Düsseldorf Germany, June 16-21, 2014

Fundamentals of Supercritical CO2

Presentation by:

Grant Musgrove
Aaron M. Rimpel
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

Supercritical CO2 (S-CO2)

Increasing
isobars

31 C
Pcrit = 7.37 MPa (1070 psi)
Tcrit = 31 C (88 F)
Two-phase
region

S-CO2 loop hardware

[6-3]

[6-1] [6-2]
Geothermal
Concentrated

Power cycle applications

Fossil Fuel
Solar Power

[6-5]

[6-4]
Ship-board
Propulsion

Research and future trends

3
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
Measured the critical temperature of alcohol, ether,
Image Source: [2-1] 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
Increasing
isobars

31°C
Pcrit = 7.37 MPa (1070 psi)
Tcrit = 31°C (88°F)
Two-phase
region

REFPROP (2007), EOS CO2: Span & Wagner (1996)

16
 Fluids operating near their critical point have
dramatic changes in enthalpy
CO2 Air GT TIT

Supercritical
region

∂h 
Cp = 
∂T p CO2 Air

REFPROP (2007)
18
Fluid density sharply decreases near the critical
point

Supercritical region
CO2
Increasing
isobars

REFPROP (2007)
19
Fluid speed of sound sharply decreases near the
critical point

Supercritical region

Increasing
isobars

CO2

REFPROP (2007)
20
Fluid viscosity sharply decreases near the critical
point
Water @ 304K = 769 µPa-s

CO2 Supercritical region

Increasing
isobars

Atmospheric Air @ 304K = 18.5 µPa-s

1 µPa-s = 10-6 kg/m/s

REFPROP (2007)
21
Fluid thermal conductivity is enhanced near the
critical region
Btu
Water (304K) = 620 mW/m/K
0.092
hr ft R 160
CO2
305K
140

120
307K
100
Thermal
80
Conductivity 309K
[mW/m/K]
60
350K
40
Btu
Atm air (304K) = 26 mW/m/K
0.012
hr ft R
20 Critical density

0
100 300 500 700 900
Density [kg/m3]
REFPROP (2007)
22
The ratio of specific heats peaks near the critical
region
10
CO2
8

6 8.0 MPa
Ratio of
Specific
12 MPa
Heats 4
4.0 MPa 16 MPa
20 MPa
2
Critical
temperature
0
200 300 400 500 600
Temperature [K]

Air = 1.4
REFPROP (2007)
23
What is a Supercritical Power Cycle?

Supercritical
region
Temperature, T

Pcrit

Tcrit

Liquid
region

Gas
region

Liquid + vapor
region

Entropy, S

55
S-CO2 Power Cycles
Why S-CO2 for Power Cycles?
Property Effect
High density • Reduced compressor work, large Wnet
near C.P. • Allow more-compact turbomachinery to achieve same
power
• Less complex – e.g., fewer compressor and turbine stages,
may not need intercooling
Near-ambient • Good availability for most temperature sinks and sources
Tcrit
Abundant • Low cost
Familiar • Experience with standard materials

57
CO2 Critical Point Comparison

(psi) MPa Ambient

(3626) 25
H2O

(2901) 20

(2176) 15
Critical
Pressure
(1450) 10
CO2 SO2

(725) 5 Air R134a

He
0
0 200 400 600 800 1000 K
(360) (720) (1080) (1440) (1800) (R)

Critical Temperature

REFPROP (2007)
58
CO2 Cost Comparison*

*Based on current market pricing for laboratory-grade substance

59
S-CO2 Cycle Efficiency Potential

Source: Wright (2011)

60
Relative Size of Components

5m
Steam turbine: 55 stages / 250 MW
Mitsubishi Heavy Industries (with casing)

Helium turbine: 17 stages / 333 MW (167 MWe)

X.L. Yan, L.M. Lidsky (MIT) (without casing)
1m
S-CO2 turbine: 4 stages / 450 MW (300 MWe)
(without casing)

Note: Compressors are

comparable in size

Adapted from Dostal (2004)

Source: Wright (2011)

61
Economic Comparison of Power
Cycles for Nuclear Plants
Steam He

He

Source: Dostal (2004)

62
A typical recuperated Brayton cycle includes a
compressor, turbine, and heat exchangers

[Conboy et al. 2012]

63
 Machinery for
S-CO2 Power Cycles
Machinery Overview

 Loop and sizing overview

 Compressor and turbine sizes
 Heat exchangers
 Seals and bearings
 Materials

65
Compressor and Turbine
Sizing
S-CO2 Component Technology vs. Power
Power (MWe) 0.3 1.0 3.0 10 30 100 300

Speed / Size 75,000 rpm / 5 cm 30,000 rpm / 14 cm 10,000 rpm / 40 cm 3,600 rpm / 1.2 m

Single Stage (Radial Flow) Multi Stage

Compressor
(Axial Flow) Multi Stage

Single Stage (Radial Flow) Multi Stage

Turbine
Single Stage (Axial Flow) Multi Stage

Gas Foil Hydrodynamic Oil

Bearings
Magnetic Hydrostatic

Labyrinth
Seals
Dry Gas

Permanent Magnet Wound, Synchronous

Generator
Gearbox, Synchronous

Dual / Multiple
Shaft Config.
Single Shaft

Adapted from Sienicki et al. (2011) / Wright (2011)

67
Dimensionless parameters can be used to size the
centrifugal compressor diameter and speed
N Q NsD sH1/2 From [Rodgers 1979]: N s,opt=0.7
Ns = 3/4 N= From [Balje 1981]: Ds(Ns=0.7)=4.0
H D
N = speed
D = diameter
DH1/4 H = adiabatic head
Ds = Q = volumetric flow rate
Q 0.5 20

Compressor conditions: 0.4

15
Inlet: CO2 @ 40°C and 7.5MPa
Assume ηcomp=0.80 0.3
PR = 2.0 Impeller Dia. Power
10
[m] [MW]
0.2
(5.0″)
5
0.1
(1.0″)
0.0 0
0 20 40 60 80 100
Shaft Speed [krpm]

Follows approach of [Fuller et al. GT2012-68735] and [Gong et al. 2006]

69
 Supercritical CO2 reduces compressor size in
comparison to air at the same inlet conditions

0.5 10
PR = 1.4 PR = 2.0 PR = 1.4 PR = 2.0
Air Air Air Air
0.4 8
S-CO2 S-CO2 S-CO2 S-CO2

0.3 6
Impeller Dia. Comp. Power
[m] [MW]
0.2 4

0.1 2

0.0 0
0 20 40 60 80 100 0 20 40 60 80 100
Shaft Speed [krpm] Shaft Speed [krpm]

Tinlet = 40°C
Pinlet = 7.5MPa

Follows approach of [Fuller et al. GT2012-68735] and [Gong et al. 2006]

70
Dimensionless parameters are similarly used to
size the centrifugal turbine diameter and speed
N Q NsD sH1/2 From [Rohlik NASA SP-290]: N s,opt=0.6
Ns = 3/4 N= From [Balje 1981]: Ds(Ns=0.4)=4.0
H D
N = speed
D = diameter
DH1/4 H = adiabatic head
Ds = Q = volumetric flow rate
Q 0.5 20

Turbine conditions: 0.4

15
Exit Pressure 7.5MPa
Inlet temperature 500°C 0.3
Impeller Dia. Output
Assume ηturb=0.85 [m]
10
[MW]
PR = 2.0 0.2
(5.0″)
5
0.1
(1.0″)
0 0
0 20 40 60 80 100
Shaft Speed [krpm]

Follows approach of [Fuller et al. GT2012-68735] and [Gong et al. 2006]

72
 Supercritical CO2 reduces turbine size in
comparison to air at the same inlet conditions

0.5 20
PR = 1.4 PR = 2.0 PR = 1.4 PR = 2.0
Air Air Air Air
0.4 S-CO2 S-CO2 S-CO2 S-CO2
15

0.3
Output
Impeller Dia.
[MW] 10
[m]
0.2

5
0.1

0.0 0
0 20 40 60 80 100 0 20 40 60 80 100
Shaft Speed [krpm] Shaft Speed [krpm]

Tinlet = 500°C
Pexit = 7.5MPa

Follows approach of [Fuller et al. GT2012-68735] and [Gong et al. 2006]

73
Matching component speed and mass flow further
illustrates the reduced size of S-CO2 machinery
0.5 5000
Compressor
Air Air
0.4 S-CO2 4000 S-CO2

Turbine
0.3 Air 3000
Impeller Dia. S-CO2 Output
[m] [kW]
0.2 2000

0.1 1000

0.0 0
0 20 40 60 80 100 0 20 40 60 80 100
Shaft Speed [krpm] Shaft Speed [krpm]

Pcomp 
 = 0.39
Compressor conditions: Turbine conditions: Pturbine  S −CO
2
Inlet @ 40°C and 7.5MPa Inlet @ 500°C
Assume ηcomp=0.80 Exit Pressure 7.5MPa Pcomp 
PR = 2.0 Assume ηturb=0.85  = 0.71
Pturbine  Air
PR = 2.0

74
 General considerations in sizing turbomachinery
for S-CO2 applications

Exercise caution when using ideal gas Shaft speed can be reduced by
approximation because of compressibility increasing the number of stages
1.0 NsH3/4
N=
0.8 Q

0.6 4.0 MPa H as stages are added

PZ
Z= 8.0 MPa
ρRT
0.4 12 MPa
16 MPa
20 MPa
0.2
Critical Temp

0.0
200 300 400 500 600
Temperature [K]

76
Heat Exchangers
A compact heat exchanger is preferred to maintain
the small footprint of S-CO2 machinery systems
[Gezelius 2004]

200

150
Comparable PCHE

Specific
Capacity 100
[MW/m3]

50

(Shah 2003)

78
Diffusion bonded heat exchangers have pressure
capability within typical S-CO2 power applications
Data from (Shah 2003) and (Kuppan 2000)
60 1000

50 800
Typical S-CO2
40
600 Max
Max Pressure
30 Temperature
[MPa]
400 [°C]
20

10 Typical S-CO2 200

0 0

Diffusion…
Compabloc…

Lamella

Bavex Plate

Printed circuit
Coiled tube
Plate
Platular plate

Shell and tube

Plate fin
Spiral Plate
Spiral Plate

Brazed plate fin

Double pipe

Diffusion bonded plate fin heat exchanger

Printed circuit heat exchanger
79
Loop Control
Control methods for research loops are making
special considerations for S-CO2 operation
Compressor or pump inlet control
• If operating near the critical point, extra care must be used to measure the
pressure and temperature of the inlet flow

Startup/shutdown speed, pressure, and temperature transients are very

important
• Fast speed transients used to reduce wear on bearings (gas-foil bearings)
• Consideration of two-phase CO2 during startup/shutdown

Vaccuum loop prior to CO2 fill

• Remove other fluids to reduce contamination of CO2 that can affect the thermal
properties of CO2 (i.e. water causes CO3 corrosion)

Slow venting the loop on shutdown

• Mitigates rapid gas depressurization (RGD) that can damage elastomers and
plastics

[Kimball et al. 2013] and [Lee et al. 2013]

85
Materials
Materials research for CO2 is extending beyond
the experience from the oil and gas industry

Oil and Gas Industry experience for handling CO2

Enhanced oil recover (EOR) > 35 years
CO2 transport pipelines
Effects of contaminants (i.e. H2O)

Recent research focusing on high pressure and temperature environments

Corrosion resistance
Effects of duration, temperature and pressure

CO2 mixtures for enhanced power cycle performance

90
Oil and gas industry material experience is
generally for low temperature applications
Materials
•316SS •Fiberglass
•Nickel •Teflon
•Monel •Nylon
Pressures < 21 MPa [Barrie et al. 2004]
•Incoloy •Buna N
Temperatures < ~200°C [Shiladitya et al. 2010]
Coatings to prevent corrosion:
•Glass reinforced epoxy
•Internally plastic coatings
•Nickel plating
•Internally coated hardened rubber
Polymers – Rapid Gas Depressurization (RGD)
Rapid depressurization after a polymer seal is diffused with S-CO2 can
damage the seal as the S-CO2 quickly expands to escape the seal
RGD is increased by:
•High pressure •High temperature
•High gas concentration •Poor seal constraint
•High decompression rate
Image source: [7-7]
[Shiladitya et al. 2010]
91
Corrosion of materials in CO2 is primarily affected
by material, conditions, and contaminants
Contaminants
Methanols and Glycols can inhibit corrosion to prevent hydrate formation
[Fan et al. 2003, Lopez et al. 2003, Shiladitya et al. 2010]

Contaminants in CO2 can enhance corrosion (i.e. H2O and O) – sweet corrosion
CO2 + H2O  H2CO3
CO2 + O  CO3

Material
The formation of thin, stable oxide layers resist corrosion of metals
Some elastomers and polymers resist diffusion of S-CO2 better than others

Operating conditions
Pure CO2 is corrosive at high temperatures (> 400°C) [Deberry et al. 1979]
Pressure (10-20 MPa) does not affect corrosion rate [Loiriers et al. 1968, Furukawa et al. 2010]
Increased temperature can increase corrosion rate [Furukawa et al. 2010]

92
 The majority of corrosion testing has been near
typical Brayton loop cycle temperatures
25 10000

20 8000

15 6000
Pressure Exposure
[MPa] [hr]
10 4000

5 2000

0 0
0 200 400 600 800 1000 0 200 400 600 800 1000
Temperature [°C] Temperature [°C]

[Cao 2012]

[Dunlevy 2009] [Cao 2012]

93
Corrosion rate is dependent on the formation of
an oxide layer on the material surface
Alloy Cr Ni Al Ti
316SS 17 12 - -
310SS 25 21.5 - -
800H 21 32 0.4 0.4

[Cao 2012]

[Cao 2012]

94
Alloys with Ti, Ni, Al, and high Cr typically have
good corrosion resistance
Alloys with high amounts of Cr and Ni and trace amounts of Ti and Al build
a stable oxide layer to resist corrosion

Steel alloys with low amounts of Cr typically build up a duplex layer with a
thick iron oxide layer
Decreasing corrosion resistance

ODS Nickel Austenitic Martensitic 3000hr

Cr ~ 20% Cr > 16% Cr > 16% Cr < 12%
PM2000 IN625 304SS T91
MA754 IN617 310SS F91
MA956 PE-16 316SS HCM12A
[Cao 2012]
MA957 Haynes 230 AL-6XN HT9
UNS S30815 3000hr
800H

[Cao 2012]

95
 S-CO2 diffuses into plastics and elastomers
Engineering plastics

Polybenzimidazole
Nylon 66
Polyimide
PEEK
Teflon
Polyimide
Polysulfone
Polyphenylene Oxide
Polycarbonate

[Tunison 2009]

Elastomers: 3day exposure at 54°C and 12.4 MPa

[Tunison 2009]

Largest leakage of S-CO2 [Tunison 2009]

[Tunison 2009]

96
The thermophysical properties of CO2 mixtures
can improve power cycle performance
[Morrison 1981]
Tc,CO2 = 31°C

Thermal conductivity near 500K (227°C)

[Jeong et al. 2011]

Increasing gas
fraction with CO2

[Harvey et al. 2011]

97
Bearings and Seals
S-CO2 Component Technology vs. Power
Power (MWe) 0.3 1.0 3.0 10 30 100 300

Speed / Size 75,000 rpm / 5 cm 30,000 rpm / 14 cm 10,000 rpm / 40 cm 3,600 rpm / 1.2 m

Single Stage (Radial Flow) Multi Stage

Compressor
(Axial Flow) Multi Stage

Single Stage (Radial Flow) Multi Stage

Turbine
Single Stage (Axial Flow) Multi Stage

Gas Foil Hydrodynamic Oil

Bearings
Magnetic Hydrostatic

Labyrinth
Seals
Dry Gas

Permanent Magnet Wound, Synchronous

Generator
Gearbox, Synchronous

Dual / Multiple
Shaft Config.
Single Shaft

Adapted from Sienicki et al. (2011) / Wright (2011)

99
Annular Gas Seals in Compressor

Image source [7-1]

100
Different Seal Geometries

Fluid properties affect

rotordynamics!

Image source [7-2]

101
Dry Gas Seals
Image source [7-3] Rotating seal
surface…

Image source [7-4]

102
Gas Foil Bearings
 Thrust or radial bearing
 Working fluid as lubricant
• Do not require separate
lube system, seals, etc. Image source [7-5]

 Lower viscosity than

typical oil lube
• Lower load capacity
• Less damping
 Limited to smaller
machinery
Fluid properties affect
rotordynamics!
Source: Milone (2011)
103
 Thrust tilting pad
Hydrodynamic Oil- Radial tilting pad
Lubricated Bearings
 Thrust or radial bearing
 Oil-lubrication must be
separated from process
with seals
 Good load capacity;
used with larger
machinery
 Types Image source [7-6]

• Fixed geometry (low performance)

• Tilting pad (high performance)

104
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] [6-2]
Geothermal
Concentrated
Fossil Fuel
Solar Power

[6-5]

[6-4]
Ship-board
Nuclear 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] [6-2]
Geothermal
Concentrated
Fossil Fuel
Solar Power

[6-5]

[6-4]
Ship-board
Nuclear Propulsion
109
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
Image source: [6-6]
• Achieved 96% availability
during hours of sunshine
 Solar Two (1995)
• Incorporated a highly efficient
(~99%) molten-salt receiver
and thermal energy storage
system into Solar One.

Image source: [6-7]

110
CSP – Improvement Opportunities
 Advanced power  Cooling
• 650 gal H20/MWh
cycles
• Dry-cooling technology
• Supercritical steam is needed in most
Rankine desert venues for CSP
− 43°C Dry bulb
• High temperature • Printed circuit heat
air Brayton exchangers may
• Supercritical CO2 provide a solution

Image source: [6-1]

111
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)

112
CSP Efficiencies vs. Power Cycle
100%

80%
Supercritical CO2 CC
Supercritical CO2
Air Brayton CC
60%
Supercritical H2O
Cycle
Efficiency Subcritical H2O Air Brayton
40%
Commercial
Lab/Pilot
20%
Concept
Demonstration

0%
0 250 500 750 1000 1250 1500
Cycle Temperature [°C]

Data from Stekli (2009)

113
Supercritical CO2 in Power Cycle
Applications

[6-3]

[6-1] [6-2]
Geothermal
Concentrated
Fossil Fuel
Solar Power

[6-5]

[6-4]
Ship-board
Nuclear Propulsion
114
Rankine Cycle Application: Nuclear
Power Generation

Image source: [6-8]

115
S-CO2 for Nuclear Applications
(550°C-700°C, 34 MPa)

Image source: [6-9]

Image source: [6-4]

116
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)

117
S-CO2 Power Cycle for Nuclear

Source: Wright (2011)

118
Nuclear Plant Efficiency vs. Cycle Prop.

Kato et al. (2007)

119
Advantages of CO2 Cycle vs. Helium
Cycle in Nuclear Applications
Pro Con
Smaller turbomachinery than steam or Helium preferred to CO2 as a reactor
helium coolant for cooling capability and
inertness
CO2 Brayton cycles are more efficient CO2 requires a larger reactor than
than helium at medium reactor helium or an indirect cycle
temperatures
CO2 is 10× cheaper than Helium New technology

120
Supercritical CO2 in Power Cycle
Applications

[6-3]

[6-1] [6-2]
Geothermal
Concentrated
Fossil Fuel
Solar Power

[6-5]

[6-4]
Ship-board
Nuclear Propulsion
121
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
122
Direct Oxy-Fuel Combustion
NG O2

CO2 Compressor CO2 Turbine

Oxy Power Electricity

CO2 CO2
Generator
Combustor Out

Condenser
HRSG
CO2
Water Steam
Rankine
Cycle
Electricity
Generator

Steam Turbine

123
Indirect Oxy-Fuel Combustion

Zero Emission Oxy-Coal Power Plant with Supercritical

CO2 Cycle, Johnson et al. (2012)
124
Supercritical CO2 in Power Cycle
Applications

[6-3]

[6-1] [6-2]
Geothermal
Concentrated
Fossil Fuel
Solar Power

[6-5]

[6-4]
Ship-board
Nuclear Propulsion
125
Ship-board Propulsion
 Nuclear S-CO2 cycles?
 No implementations yet
 Improved power to weight
 Rapid startup Image source: [6-10]
 Bottoming cycles

Source: Dostal (2004) 126

Supercritical CO2 in Power Cycle
Applications

[6-3]

[6-1] [6-2]
Geothermal
Concentrated
Fossil Fuel
Solar Power

[6-5]

[6-4]
Ship-board
Nuclear Propulsion
127
Geothermal
 Low Temperature Heat Source
• T ≈ 210°C, P ≈ 100 bar

Pruess (May 19, 2010)

128
Other S-CO2 Power Cycle Applications

Image source: [6-11]

Waste Heat
Recovery

Zhang (2005)

Non-Concentrated
Solar Power

129
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 turbo-
alternator producing power
4. Expanded S-CO2 is cooled at recuperator and
condensed to a liquid at condenser

1
4

3
Image source: [6-11]
Image source: [6-12]
130
S-CO2 Rankine Cycle in Non-
Concentrated Solar Power
 NCSP (Trans-critical Rankine) Tt = 180°C
• ηe,exp = 8.75%-9.45%
 Photovoltaic
• ηe,exp = 8.2%

Zhang (2005)

Zhang (2007)

131
S-CO2 as a Refrigerant

Image source: [6-13]

Image source: [6-14]

132
S-CO2 vs R-22 in Refrigeration

 Employed MCHEs
 Summary
• CO2 COP vs. R-22
− 42% Lower at 27.8°C
− 57% Lower at 40.6°C
• Majority of entropy
generation in CO2
cycle was in the
expansion device

Brown (2002) 133

S-CO2 in Heat Pumps

 S-CO2 replaced as a
refrigerant in domestic heat
pump hot water heater in
Japan.
• COP = 8, 90°C (194°F)
• Compared to COPtyp=4-5

 Qh + We 
 COP = 
 We 
Image source: [6-14]

EcoCute Heat Pump (2007)

134
S-CO2 Power Cycle
Research Efforts
Development of a High Efficiency Hot Gas Turbo-expander and Low
Cost Heat Exchangers for Optimized CSP SCO2 Operation

J. Jeffrey Moore, Ph.D.

Klaus Brun, Ph.D.
Pablo Bueno, Ph.D.
Stefan Cich
Neal Evans
Kevin Hoopes
Southwest Research Institute
C.J. Kalra, Ph.D.,
Doug Hofer, Ph.D.
Thomas Farineau
General Electric
John Davis
Lalit Chordia
Thar Energy
Brian Morris
Joseph McDonald
Ken Kimball Taken from SunShot Subprogram
Bechtel Marine
Review: Concentrating Solar Power
(Sunshot Grand Challenge Summit
Anaheim, CA, May 19-22, 2014)

136
 Project Objectives
 To develop a novel, high-efficiency supercritical sCO2 turbo-expander
optimized for the highly transient solar power plant duty cycle profile.
– This MW-scale design advances the state-of-the-art of sCO2 turbo-expanders
from TRL3 to TRL6.
 To optimize compact heat exchangers for sCO2 applications to drastically
reduce their manufacturing costs.
 The turbo-expander and heat exchanger will be tested in a 1-MWe test
loop fabricated to demonstrate component performance and endurance.
 Turbine is designed for 10 MW output in order to achieve industrial scale
 The scalable sCO2 expander design and improved heat exchanger address
and close two critical technology gaps required for an optimized CSP
sCO2 power plant
 Provide a major stepping stone on the pathway to achieving CSP power at
$0.06/kW-hr levelized cost of electricity (LCOE), increasing energy
conversion efficiency to greater than 50% and reducing total power block
cost to below $1,200/kW installed.

137
 Project Approach
 Work has been divided into three phases that
emulate development process from TRL3 to
TRL6
 Phase I – Turbomachinery, HX, and flow loop
design (17 months)
 Phase II – Component fabrication and test
loop commissioning (12 months)
 Phase III – Performance and endurance testing
(6 months)
138
 Recuperator Prototypes – 5 and
50 kW
DMLS:
• Expensive and slow to build
• Highly automated
• High pressure drop
• Tested to 5000 psi

Laser Welded Construction:

• Undergoing flow tests
• Exceeded design predictions for
HTC
• Held 2500 psi @ 600°F
141
 TURBOEXPANDER DESIGN
 A novel turboexpander has been designed to meet the
requirements of the sCO2 power with these targets:
• ~14MW shaft power
DGS Face Pressure Distribution from CFD
• >700C inlet temp
• >85% aero efficiency

Multi-stage Axial Turbine

CFD Analysis
10 MW SCO2 Turbine Concept
 Test Loop Design
SwRI B278

Heater
Compressor

sCO2 Pump

Cooler

145
Mechanical Test Configuration
Pipe Section Color
Pump to heater Dark blue
LT heater to recuperator Yellow
Recuperator to HT heater Orange
HT heater to expander Red
Dark
Expander to recuperator
green
Light
Recuperator to existing
green
Existing facility piping White
Existing facility piping
Dark gray
(unused)
Existing piping to pump Light blue
Expander
Air dyno. Silencer

Recuperator

146
 Future Work
 Test heat exchanger prototypes
 Heat exchanger design nearing completion
 Complete Turbomachinery Design
 Procure long lead items for expander and test
loop
 Finalize test loop design

147
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

148
DOE S-CO2 Test Program
Turbomachinery

100 mm

Source: Wright (2011)

149
S-CO2 Brayton Cycle Test Loop

Source: Wright (2011)

150
S-CO2 Brayton Cycle Test Loop

Source: Wright (2011)

151
S-CO2 Brayton Cycle with Regeneration

Source: Conboy et al. (2012)

152
S-CO2 Brayton Cycle with Regeneration

Source: Conboy et al. (2012)

153
S-CO2 Brayton Cycle with Regen. + Recomp.

Source: Wright (2011)

154
S-CO2 Brayton Cycle Performance
with Regeneration Config.
Maximum Case: Improve with larger scale:
Total Turbine Work, 92 kW • Windage losses
• Thermal losses
• Seal leakage

Source: Conboy et al. (2012)

155
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

156
Printed Circuit Heat Exchanger (PCHE)

S-CO2 test loop used by Sandia/ Barber-Nicholls

Heatric PCHE Le Pierres (2011)
157
Heat Exchanger Testing (Bechtel)
 150 kW
 8000 lbm/hr S-CO2
 2500 psi

Nehrbauer (2011)
158
Tokyo Institute of Technology (TIT)

(Kato et al., 2007)

159
TIT, New Micro-Channel Heat
Exchanger

(Kato et al., 2007)

160
TIT, Heat Exchanger Testing (Kato et al., 2007)

3kW

19,21 kW

TokyoTech, HEATRIC
(S-Shaped Fins) (Zigzag Fins)
161
TIT, Heat Transfer Rate vs. Pressure
Drop

Kato et al. (2007)

162
Corrosion Loop at Tokyo Institute of
Technology

316 SS, 12% Cr alloy, 200-600°C, 10 Mpa CO2, Kato et al. (2007)
163
Other S-CO2 Corrosion Test Facilities
 MIT - 650°C, 22 MPa
• Steels
 UW - 650°C, 27 MPa
• Steels Guoping (2009)

 French Alternative Energies and Atomic

Energy Commission - 550°C, 25 MPa
• Steels
 MDO Labs – 54.4°C, 12.4 MPa
• Elastomers, engineering plastics, rubbers,
etc.

164
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 ≈ 210°C, P ≈ 100 bar)
• LBNL: model reactive chemistry induced by brine-CO2 injection

Schematic of EGS with S-CO2 Ogachi, Japan – HDR Site

Pruess (May 19, 2010) Pruess (May 18, 2010)
165
S-CO2 Critical Flow (Univ. Wisconsin)

(Anderson, 2009)
166
S-CO2 High Pressure Compression
(Dresser-Rand)

Tupi - I Tupi - III

(GT2012-70137)
167
 Future Trends for
S-CO2 Power Cycles
Future trends and research needs
Intermediate-scale is needed to demonstrate commercial viability of full-
scale 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

169
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%)

170
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

172
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
Fossil Fuel
Solar Power

Ship-board
Nuclear Propulsion

The combination of favorable property variation and high fluid density of S-

CO2 allows small footprint of machinery
1.50
PR = 1.4 PR = 2.0
Air Air
1.25
S-CO2 S-CO2

1.00

Impeller Dia.
0.75
[m]

0.50

0.25

0.00
0 10000 20000 30000
Shaft Speed [rpm] 173
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? 174
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