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Figure 3-2: Nine S-CO2 compressor wheels have been fabricated. This image shows the compressor wheel blank, the finished wheel, and one of the tools (not the smallest) used to machine the wheel. 3.1.1 Rotor Cavity Figure 3-3 shows a detailed engineering drawing of the rotor, bearings, labyrinth seals, and compressor wheel. Frictional losses on the rotor are expected because the rotor is spinning at 75,000 rpm within the high density CO2 fluid. At the compressor inlet design temperature (305.3 K) and pressure (7687 kPa), the fluid has a density that is approximately 57% the density of water. At these very high shaft speeds and in this very dense fluid, substantial losses are expected. To keep the rotor windage losses manageable, the rotor cavity pressure must be reduced. The initial design sets a goal of 200 psia for the rotor cavity. Seals and separate pumps are required to lower the rotor cavity pressure For simplicity and cost reasons we initially selected labyrinth seals, and the use of Haskel gas booster pumps to lower the cavity pressure. The labyrinth seal is illustrated in Figure 3-4 A and B. The labyrinth seal uses four teeth that closely approach staggered steps in the compressor shaft to limit the flow through the seal. In the S-CO2 turbomachinery, the design clearance between the teeth and the root of the shaft is 0.0015”. Technologies other than stepped labyrinth seals were also considered and tested. Dry-liftoff seals, which will likely have about one order of magnitude less leakage than the labyrinth seals, are the preferred choice. However, commercially available dry-liftoff seals are much more expensive, relatively large compared to the shaft diameters being used in these designs, and do not normally operate at the high shaft speed that we are using in the turbomachinery. Thus, their use would require more development than labyrinth seals. Fortunately, because the turbomachinery uses a modular design it can easily be modified to add in components that would allow for the inclusion of dry-liftoff seals at a later date. Overall, it appears that the leakage flow rate through the labyrinth seals is on the order of 1-2% of the total mass flow rate per seal. 26PDF Image | Operation and Analysis of a Supercritical CO2 Brayton Cycle
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