SAND2014-16828D

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Supercritical CO2 Brayton Cycles

NP-NE Workshop #2 August 4, 2014
Gary E. Rochau, Manager 6221
Jim J. Pasch, Brayton Cycle Principle Investigator
Glenn Cannon, Matt Carlson*, Darryn Fleming,
Alan Kruizenga (8223), Rob Sharpe, Mollye Wilson
Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin
Corporation, for the U.S. Department of Energys National Nuclear Security Administration under contract DE-AC04-94AL85000. SAND NO. 2011-XXXXP
Executive Summary SCO2 Brayton
Key Challenges for Electrical Energy Generation
Capital and operating cost of power plants, including NGNP
Growing use and demand for water; the Energy-Water nexus
Increasing emissions control requirements

Potential for SCO2 Brayton Cycle Technologies

Reduced capital and operating costs from compactness and efficiency
Reduced fan power and high efficiency under dry cooling operation
Reduced emissions and potential for direct CO2 sequestration

Critical Activities for SCO2 Brayton Power

Research to reduce component cost
Demonstrate a scalable system to retire industrial risks
Investigate plant-level designs for NGNPs
Current Electrical Generation
Electrical Generation
Dominated by fossil
Nuclear is a critical part
Expected that natural
gas and nuclear will
grow; coal will shrink
Two main technologies
Steam Rankine cycle U.S. 2000 Water Withdrawals by Market

Coal, Nuclear, CCNG

Gas Brayton cycle
Natural gas
Supercritical CO2 Brayton Cycle
The turbomachinery industry
has been here before
Turbomachinery housing of the 12 MW Nippon Kokan
Escher Wyss (EW) was the first plant, built by Fuji Electric, based on EW design.
company known to develop the
turbomachinery for CBC systems
starting in 1939
24 systems built, with EW designing
the power conversion cycles and
building the turbomachinery for all
but 3.
Plants installed in Germany,
Switzerland, Vienna, Paris, England,
Russia, Japan, Los Angeles, and
Phoenix.

Fluid: Air @ 28 kg/s Reliability factor

Tur. Inlet Temp >95%
600-660C
Intercooling
Net Eff. =23-25% Availability factor
> 90% 5
Supercritical CO2 (sCO2) Brayton Cycle

Key Advantages over Steam

Smaller turbomachinery
Single-phase fluid (no quality issues)
Recuperation becomes practical

Key Advantages over Gas

High efficiency at low temperatures
Lower compression work
Smaller turbomachinery
Many SCO2 Cycle Applications

DOE-NE Nuclear
Solar (Gas, Sodium, Water)
Advanced
Reactors

Supercritical CO2
SunShot Power Cycle Brayton Cycle
5 1

Military Turbine Compressors Alternator Waste Heat

CONUS Chiller

Marine 6
2

3
Mobile?
CO2 7 8
ARRA
4 HT Recup LT Recup
Geothermal
Fossil
Solar Sequestration Ready

Elec.
Prop.
7
Some applications push existing technology

Size Temp Pressure

Application Organization Motivation [MWe] [C] [MPa]
Nuclear DOE-NE Efficiency, Size, Water 10 350 20 35
Reduction 300 700
Fossil Fuel (Indirect DOE-FE, Efficiency, Water 300 550 15 35
heating) DOE-NETL Reduction 600 900
Fossil Fuel (Direct DOE-FE, Efficiency, Water 300 1100 35
heating) DOE-NETL Reduction, 600 1500
Facilitates CO2
Capture
Concentrating DOE-EE, Efficiency, Size, Water 10 500 35
Solar Power DOE-NREL Reduction 100 1000
Waste Heat DOE-EERE Efficiency, Size, 1 10 < 230 15 35
Recovery Simple Cycles 650
Geothermal DOE-EERE Efficiency 1 50 100 15
300

Nominal Application-Specific Conditions for sCO2 Turbo Machinery

(Ref. sCO2 Power Cycle Technology Road mapping Workshop, February 2013, SwRI San Antonio, TX)

8
Office of Nuclear Energy Roadmap
Objective #3 - Develop improvements in the affordability of new
reactors to enable nuclear energy to help meet the
Administrations energy security and climate change goals

Maturing this technology promotes the Administrations all

of the above clean energy strategy;
Contributes towards meeting national and energy goals
Promotes domestic industry growth
Facilitates industrial competitiveness

10 MWe Turbine ~ 30 in
Courtesy EchoGen
Pathway to High Conversion Efficiency

At What Cost?

Goal:
1/10th the cost
1/100th the volume
Of conventional
steam Rankine

10
Recompression Closed Brayton Cycle
(RCBC)Test Article (TA)
TA under test since 4/2010
Over 100 kW-hrs of power
generated
Operated in 3 configurations
Simple Brayton
GE Waste Heat Cycle
Recompression
Verified cycle performance
Developed Cycle Controls
Developing maintenance
procedures

TA Description:
Heater 750 kW, 550C Load Bank 0.75 MWe
Max Pressure - 14 MPa Gas Compressor to scavenge TAC gas
TACs 2 ea, 125 kWe @ 75 kRPM, Inventory Control
2 power turbines, 2 compressors Turbine Bypass(Remote controlled)
High Temp Recuperator - 2.3 MW duty ASME B31.1 Coded Pipe, 6 Kg/s flow rate
Low Temp Recuperator 1.7 MW duty Engineered Safety Controlling Hazards
Gas Chiller 0.6 MW duty Remotely Operated 11
The Turbine-Alternator-Compressor (TAC)

~24 Long by 12 diameter

12
 Key Technology
Turbo- Alternator-Compressor Design
Permanent Magnet Generator with Gas Foil Bearings

Tie Bolts (Pre-stressed) Low Pressure Rotor Cavity

Chamber (150 psia)

Turbine Laby Seals

Gas-Foil Bearings

Compressor
Journal Bearing Stator
Water Cooling PM Motor Generator Thrust Bearing

125 kWe (max) at 75,000 rpm 13

Pathway to High Conversion Efficiency
Advanced SMR Energy Conversion
Heat Exchanger Development

Na HeatX Freeze/Thaw/Plug Na/CO2 Interaction

Diffusion Bonding Furnace U.S. mfg Bonded Fuel Diff. Prototype Na/CO2 PCHE 15
Whats Next?
Commercialize a RCBC system scalable to 1000 MWe.
Stronger emphasis on industry collaboration through CRADAs to provide
equipment infrastructure resources.
Improve the technology readiness and move toward power on the grid
demonstration.
Move from TRL 3 to TRL 7 with the help of DOE and Turbomachinery Industry
Follow a systems engineering approach (ex. DOE 413)
A demonstration RCBC system must be built and extensively tested.
Must be directly scalable to power plant levels and put power on the grid
Performance must be well understood, modeled and benchmarked.
Availability and Reliability
Start-up and Shut-down
Heat source transients
Commercialization objective achieved when industry begins to mature
sCO2 Recompression Closed Brayton Cycles with order books indicating
commercial production of systems.
16
Scaling Rules and Ranges of Application for
Components
Power (MWe)
TM Feature
0.3 1.0 3.0 10 30 100 300

TM Speed/Size 75,000 / 5 cm 30,000 / 14 cm 10,000 / 40cm 3600 / 1.2 m

Single stage Radial multi stage

Axial multi stage

Turbine type
Single stage Radial multi stage
single stage Axial multi stage

Gas Foil Hydrodynamic oil

Bearings
Magnetic Hydrostatic

Adv labyrinth
Seals
Dry lift off

Frequency/ Permanent Magnet Wound, Synchronous

alternator Gearbox, Synchronous

Dual/Multiple
Shaft
Configuration Single Shaft

High Technology Commercial Technology

High $/kWe Lower $/kWe

10 MWe allows use of primarily commercial technologies

 High Temperature Materials Needs
125 kWe sCO2 turbine rotor
550C, INCONEL 718
(proposed for 700C service not in code)
High temperature-high pressure
boundaries for Primary Heat
Exchangers and Piping
The goal is high nickel sCO2
corrosion resistant alloy in large
diameter pipe that can handle 850C
at 30 Mpa
Current temperature limit is 650C
Slabs of such materials exist, but no
manufacturer produces affordable
material in less than years of lead
time
18
Advanced Heat Exchangers
For High Efficiency And Small Volume

Low Temperature Recuperator

High Temperature Recuperator

Gas Water Chiller Prototype Sodium/CO2 PCHE 19

Scalable Demonstration System
Necessary to spur commercial development.
Accelerate the commercial deployment of high efficiency
electrical generation technologies using supercritical fluids
heated by various sources (e.g. fossil, solar, nuclear, and
geothermal).
This program will be accomplished in two phases:
1.) Demonstration of supercritical carbon dioxide Brayton cycles with
minimal economic and technical risk at a marketable level, and
2.) Demonstrate Brayton cycles at the highest conversion efficiency
for future markets (high temperatures and scalable to large power
levels).