Jason C. Wilkes, Kyle Robinson, Karl D. Wygant, Rob Pelton, Jonathan Bygrave
{"title":"Design and Testing of a 275 Bar 700 Degree Celsius Expander for an Integrally Geared Supercritical CO2 Compander","authors":"Jason C. Wilkes, Kyle Robinson, Karl D. Wygant, Rob Pelton, Jonathan Bygrave","doi":"10.1115/gt2022-83284","DOIUrl":"https://doi.org/10.1115/gt2022-83284","url":null,"abstract":"\u0000 An integrally-geared (IG) compressor-expander (compander) for use in a nominal 10 MW-scale concentrated solar power (CSP) supercritical carbon dioxide (sCO2) plant application was designed, manufactured, and tested. The integrally-geared compander (IGC) developed for this application comprises multiple pinion shafts interacting through a single bull gear to create a compact package and utilize a low-cost, low-speed driver.\u0000 The present work will detail the design of the high-pressure high-temperature expander casing on an integrally geared frame, and illustrate how the project successfully mitigated the risk of fatigue and creep while allowing for rapid thermal transients in the design. Furthermore, test data from the test campaign will be presented supporting the analysis. Test results also show temperature profiles during operation exceeding 720° Celsius.","PeriodicalId":105703,"journal":{"name":"Volume 9: Supercritical CO2","volume":"101 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121696243","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Rob Pelton, Jonathan Bygrave, Karl D. Wygant, Jason C. Wilkes, Thomas Revak, K. Kim
{"title":"Near Critical Point Testing and Performance Results of a sCO2 Compressor for a 10MWe Brayton Cycle","authors":"Rob Pelton, Jonathan Bygrave, Karl D. Wygant, Jason C. Wilkes, Thomas Revak, K. Kim","doi":"10.1115/gt2022-83503","DOIUrl":"https://doi.org/10.1115/gt2022-83503","url":null,"abstract":"\u0000 Development and commercial acceptance of sCO2 Brayton cycles for power generation applications are growing rapidly as they offer performance advantages over other cycles. To maximize the cycle performance, the compressors are designed to operate near the critical point of the working fluid. At the critical point the fluid properties change rapidly with variations in inlet conditions. This makes it challenging to both accurately predict the performance and guarantee the operability of the compressor, as the behavior is affected by these slight variations in inlet conditions. A full scale 1st stage main compressor for a 10MWe-Class recompression Brayton cycle was built and tested to validate performance and operability in this unique operating range.\u0000 The compressor was tested in a laboratory environment with additional instrumentation, beyond what is required by PTC-10, to minimize the uncertainty in the measured performance. Complete constant speed characteristics were collected at multiple supercritical points, operating at constant inlet conditions for each speed line covering a range of compressor inlet densities from 400 to 600 kg/m3. Variations in the compressor stage efficiency and choke margin were observed, and the overall operability and stability of the compressor in response to changes in operating condition were also monitored. The compressor was shown to have excellent performance that closely matched the original design prediction. The performance at various inlet conditions showed minimal change in isentropic head coefficient at the design flow, but did show some variation in efficiency and choke margin across the map. These changes in performance were observed to be minimal, and did not affect the stable operation of the compressor. The results demonstrate that a commercial scale sCO2 compressor can operate near the critical point and achieve the high levels of performance and stability required for power generation applications.","PeriodicalId":105703,"journal":{"name":"Volume 9: Supercritical CO2","volume":"48 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128201248","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Numerical Investigation on Mitigation of Heat Transfer Deterioration of Supercritical CO2 Flow by Introducing Multiple Turbulators Along Helices in a Circular Tube","authors":"Hangfei Duan, G. Xie, Yuan Ma, Shulei Li","doi":"10.1115/gt2022-83501","DOIUrl":"https://doi.org/10.1115/gt2022-83501","url":null,"abstract":"In order to effectively alleviate the heat transfer deterioration phenomenon of supercritical CO2 (S-CO2) in a vertical circular tube, explores the fluid hydraulic and thermal performance of multiple turbulator distributed along helices through a verified standard k-ω model. The effects of the pitch and the height of turbulators on flow characteristic and heat transfer are observed and analyzed in detail. With the increase of the height of turbulators, the heat transfer coefficient increases significantly. Besides, as the pitch decreases, the fluid re-circulation area behind each turbulator decreases, resulting in stronger mixing of swirling flow, which enhances turbulent kinetic energy of downstream fluid and weakens buoyancy force, thus mitigating heat transfer deterioration. The present results suggest that introducing multiple turbulators distributed along helices into circular tube can be a beneficial way to alleviate heat transfer deterioration and to enhance heat transfer of supercritical CO2 flow.","PeriodicalId":105703,"journal":{"name":"Volume 9: Supercritical CO2","volume":"01 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129782713","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Design and Operability Challenges for Supercritical CO2 Plants: The sCO2-Flex Centrifugal Compressor Test Experience","authors":"Bigi Manuele, Bisio Valentina, Evangelisti Silvia, Giancotti Marco, Milani Alberto, Pellegrini Tiziano","doi":"10.1115/gt2022-80658","DOIUrl":"https://doi.org/10.1115/gt2022-80658","url":null,"abstract":"\u0000 Interest in supercritical carbon dioxide (sCO2) cycles has grown significantly in recent years. The peculiar properties of the fluid open unique opportunities but also poses several challenges. Here we aim at narrowing the knowledge gap in operating such plants, leveraging the test experience of a full-scale 5 MW Centrifugal Compressor prototype designed for the sCO2-flex project (H2020 funded program, grant agreement #764690). The test rig replicated a complete recycle loop for the compressor. In addition to validating the compressor’s performances in its design condition, a larger envelope of operation and transients was explored. The paper describes engineering groundwork and design choices regarding: i) transient operation such as pressurized startups and emergency shutdowns; ii) safety relief valves and discharge lines, with possible CO2 solidification; and iii) vibrations due to extremely high density. For all these topics, specific challenges brought by the sCO2 are described. We show the most meaningful results, in excellent agreement with predictions, and discuss key learnings from the test experience. We highlight how important it was to anticipate risks during the design phase and we give recommendations for future installations. We conclude with hints on testing severe off-design conditions, with two-phase flow at compressor suction.","PeriodicalId":105703,"journal":{"name":"Volume 9: Supercritical CO2","volume":"8 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122594118","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Impact of Inlet Conditions on Performance of a Supercritical CO2 Centrifugal Compressor","authors":"Xueguang Jiang, Zhiheng Wang, G. Xi","doi":"10.1115/gt2022-84278","DOIUrl":"https://doi.org/10.1115/gt2022-84278","url":null,"abstract":"\u0000 The centrifugal compressor is one of the core components in a supercritical carbon dioxide (SCO2) Brayton cycle, in which the inlet state is near the critical point of CO2 to reduce the compression work. However, the thermodynamic properties of CO2 change dramatically near the critical point. Therefore, the performance and flow in a SCO2 compressor will be sensitive to the variation of inlet conditions. In this paper, a centrifugal compressor stage designed by the in-house code for a 20MW supercritical CO2 Brayton cycle is numerically investigated with the variation of considered inlet state point. Firstly, to take account of the nonlinear variation of the properties near the critical point, the accuracy of look-up table of CO2 properties is evaluated and implemented into the commercial CFD software. Then, the effect of small change in inlet temperature or pressure near the critical point on the compression process and performance is investigated, and the flow fields in compressor with different inlet states are compared. It is shown that the CFD-predicted compressor performance is highly sensitive to the resolution of look-up table as well as the inlet conditions. Slight increase in inlet temperature or inlet pressure will cause a significant decrease in pressure ratio. The impact of small change of inlet state on the flow structures are mainly concentrated on the first half of impeller blade passage.","PeriodicalId":105703,"journal":{"name":"Volume 9: Supercritical CO2","volume":"168 10 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125985309","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}