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second rotor shaft (see Figure 2-5) was built to work with the gas-foil bearings. Both journal bearings and thrust load bearings are required. Photos of the bearings that were installed in the turbo-compressor are illustrated in Figure 5-21. The left image shows the thrust bearings. These are standard bump foil supported Inconel pads. It is estimated that these thrust bearings can support up to 225 lbs of thrust at the design speed of 75,000 rpm. In the thrust load testing performed in the single compression loop, thrust loads were always less than 80 lbs, so the expectation is that these bearings will function properly. The right image in Figure 5-21 shows the Capstone journal bearings. Barber Nichols has an agreement with Capstone Microturbine that allows them to use the Capstone journal and thrust bearings. Barber Nichols has elected to use only the Capstone journal bearings because the thrust load capacity of the BNI bump- foil gas bearings shown in Figure 5-21 is greater than the capacity of those in the Capstone design. Figure 5-21: Photos of the gas foil bearings for use in the GenIV turbomachinery. The left image shows the bump-foil thrust bearings which were designed and manufactured by Barber Nichols Inc. The right image shows the journal gas foil bearings. These bearings were purchased from Capstone Microturbines. The theory and models for gas foil bearing operation are complicated and not widely applied beyond a few experts in the field. Our analysis of the gas foil bearings is largely based on data reported by NASA Glenn Research Center by C. DellaCorte and Bruckner (DellaCorte, 2006 and Bruckner, 2009). This data suggests that the bearings are capable of withstanding 1 lb/in2 of load per 1000 rpm. Thus, the thrust bearing which has about 3 in2 of surface area can withstand loads of 3 in2 x 75,000 krpm or about 225 lbs of thrust. These correlations were developed for gases at low pressure and not for high pressure CO2. Windage power loss models indicate that the bearing heating will be proportional to the fluid density. For this reason we have placed the gas foil bearings in the rotor cavity region where the pressure and density can be reduced to 200-300 psia (16 kg/m3) by using scavenging pumps. At the current time we are using gas booster pumps manufactured by Haskel to reduce the rotor cavity pressure. Unfortunately, these pumps together with the labyrinth seal technology are only capable of reducing the pressure to 650-700 psia. This means that the rotor cavity has a density of about 100 kg/m^3 or 6-7 lb/ft3 which is about 5 - 7 times more dense than desired. This also means that the frictional heating power will also be about 5-7 times greater than the design goal. Still these arguments have led us to explore the use of advanced seals 70PDF Image | Operation and Analysis of a Supercritical CO2 Brayton Cycle
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