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The high shaft speed also makes the shaft seal difficult from a longevity standpoint. Therefore, a lower shaft speed would be desirable to reduce maintenance. To operate the Rankine cycle in a controllable / sustainable fashion requires the inclusion of additional components and their resultant pressure drops. Added components: Feed pump flow control valve, check-valve and filter (15psid, 20psid max. – at filter replacement) Turbine inlet control valve (1psid), high-pressure leg of recuperator (5psid), low-pressure leg of recuperator (2psid), super-critical HX (20psid), air-cooled condenser (n-pentane side) (2psid). Note: pressure drop estimates include the small minor piping pressure losses between components. Increase condensing temperature. Though not done in the cycles analyzed, the following cycle feasibility section indicates a high cost and large parasitic load for an air-cooled condenser sized for an 80°F ambient and 102°F condensing temperature. BNI recommends a design condensing temperature of 115°F, but this may not be optimal. The 600psi turbine inlet temperature cycle is favored. The 800psi-cycle operates at a pressure in excess of the maximum allowable housing pressure for common vertical centrifugal pumps. Also, the additional pressure probably would require two pumps in series due to the large number of stages (28-stages). The 800psi cycle will generate only an additional 2% power over the 600psi cycle – due mainly to the large 34% increase in feed pump power. Maximum temperature of n-pentane (563°F) may cause thermal decomposition. BNI advises NREL to research this important point before further cycle optimizations are conducted. Cycle Feasibility and Cost For the feasibility / cost analysis, one “design-point” cycle was chosen. This cycle had 600psia, 563°F turbine inlet conditions, a recuperator with 75% effectiveness, and a condensing temperature of 102°F. BNI gathered preliminary ROM estimates of major cycle components. BNI scope was restricted to the Rankine cycle only and includes none of the solar energy collection circuit except for the super-critical HX where the solar-collected heat energy is transferred to the n-pentane. The super-critical HX is likely to be a shell-and-tube design. A welded plate design is a remote possibility. The high pressure difference between the heat-transfer fluid and the n-pentane (+550psi – I assume a high-pressure solar loop with thermal storage is not practical) do not work well with the flat “sheet-like” geometry of a plate HX. Also, plate collectors does not work well with large increases in volumetric flow through the HX (shell-and-tube HX address this point by requiring multiple units in series with different baffle spacing and/or tube numbers). The BNI cycle simulation software predicts an air-cooled condenser fan parasitic loss of 125hp. The normal BNI approach is to run condenser fans slower than standard commercial practice. This lowers fan power, but has the impact of increasing condenser size and cost. Hudson Products returned a budgetary quote of $260,000 for an induced draft design using six 13-ft diameter fans fitted with 30hp motors. The actual fan parasitic power is estimated at 150hp. The C-4PDF Image | Modular Trough Power Plant Cycle and Systems Analysis
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