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Introduction Barber Nichols Inc. (BNI) has completed a preliminary power-generation Rankine cycle review for NREL. The review included: validation of the NREL cycle thermodynamic data, consultation on system issues, the economic feasibility of the proposed cycle, and estimated power output. The NREL cycle is a solar-heated power-generation Rankine cycle. Solar energy heats Caloria HT-43 (a heat-transfer fluid marketed by Exxon Corp.). The Caloria HT-43 then flow through a heat-exchanger where its thermal energy is transferred to normal-pentane (the working fluid used within the Rankine cycle). The Rankine cycle is super-critical and the cycle contains a recuperator and air-cooled condensers. The initial NREL cycle contained a two-stage turbine with reheat between stages. Subsequent analysis by BNI and discussion with NREL led to the adoption of a single-stage turbine with the corresponding elimination of reheat. The modified cycle also had a 3-fold increase in the n-pentane mass flow rate. Two distinct super-critical cycles were reviewed (600psia and 800psia max. turbine inlet pressure cycles). Feasibility study results led to the selection of the 600psia cycle as the preferred one. Cycle Thermodynamic Data NREL modeled the power-generation cycle with the ASPEN software package. BNI simulated the cycle using its proprietary software. The fluid property equation-of-state used in the BNI software is outlined in Kenneth E. Starlings book, “Fluid Thermodynamic Properties for Light Hydrocarbon Systems.” This equation-of-state is an enhancement of the Benedict-Webb-Rubin (BWR) equation (adding 3 additional equation parameters – bringing the total to 11 parameters). BNI calculated Caloria HT-43 specific heat using linear curve-fits to Exxon data sheets. The thermodynamic property equations used in the ASPEN software is unknown to BNI. Results generated by the ASPEN and BNI’s software compared favorably with temperature, pressure, and enthalpy deviations less than 2%. Some uncertainty remained in how recuperator effectiveness and overall cycle efficiency were modeled and calculated with ASPEN. System Issues and Cycle Modifications Upon review of the original NREL cycles, BNI suggested several cycle modifications that would result in a more practical cycle. A brief summary of these cycle modifications follows: Eliminate the two-stage turbine with reheat and use a simpler single-stage turbine (reheat N/A). This change reduces cycle power output slightly (approximately 3% reduction). High-rotational speed (particularly in the 1st turbine stage) also favored a single-stage turbine cycle. The resulting singe-stage turbine speed is 25% slower than the rotational speed of the 1st stage turbine in the original NREL 2-stage turbine cycle. The single-stage turbine speed was still unacceptably high at (26,000 rpm). Increasing the n-pentane mass flow rate to 66,000 lbm/hr reduced the turbine speed to 15,000 rpm (600psia turbine inlet pressure cycle). This speed will still require a 2-stage gear reduction (to 1800rpm) and fall into the category of a “high-speed” gearbox and a corresponding cost premium for it and the high-speed shaft coupling. If turbine speed could be reduced below 13,600rpm, a single- stage “high-speed” gear reduction is possible – which would lower the gearbox cost. Reducing turbine speed would lower turbine efficiency slightly. However, lower rotational speed typically improves system life. C-3PDF Image | Modular Trough Power Plant Cycle and Systems Analysis
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