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diameter) compressor would have small parasitic losses and use bearings, seals, and other components that are widely available in industry. A supercritical carbon dioxide power system on that scale with a pressure ratio of 3.3 would run at 25,000 rpm and have a turbine that is 11 inches in its outer diameter. It would, however, produce 10 MW of electricity (enough for 8,000 homes), require about 40 MW of recu- perators, a 26 MW CO2 heater, and 15 MW of heat rejection. That’s a rather large power plant for a “proof-of-concept” experiment. The hardware alone is estimated to cost between $O20 million and $30 million. ur development approach at Sandia was to compro- mise a bit on the performance, but we selected a size that could fit within the Department of Energy’s nuclear energy budget. We currently have two supercritical CO2 test loops. (The term “loop” derives from the shape taken by the working fluid as it completes each circuit.) A power production loop is located at the Arvada, Colo., site of contractor Barber Nichols Inc., where it has been running and producing electricity dur- ing the developmental phase. It is now being upgraded and is expected to be shipped to Sandia in Winter 2012. The loop has the design capabili- ties to produce 240 kilowatts of electricity. The turbo-alternator-com- pressor designed by Barber Nichols relies on such key en- abling technologies as gas-foil bearings (both journal and thrust), a permanent magnet motor/generator, advanced labyrinth seals, the use of seal leakage for bearing cooling, and a reduced rotor cavity region to manage and control frictional power losses. In addition to the turbomachinery, the other enabling tech- nologyfortheS-CO2 powercycleistheuseofprintedcircuit heat exchangers that are manufactured by Heatric. Those heat exchangers are composed of sheets of steel with flow passages etched into them. The parts are diffusion bonded to provide a core-block that can have heat transfer areas exceed- ing 1,000 square meters per cubic meter. The heat exchangers are very compact and can withstand very high pressure and high temperatures. The high-temperature recuperator and gas chiller also use this technology. Those technologies and the advanced high power switching electronics that made it possible to build a small proof-of- conceptS-CO2 powerloophaveonlyrecentlybecomecom- mercially available. In this cycle the peak inlet temperature was selected to be 538°C,andthepressureratiowaslimitedto1.8.Thelower pressure ratio increased the volumetric flow rate through the compressor, which increased its diameter and lowered the shaft speed to something that is within the range of gas foil bearings or magnetic bearings. Other changes to the system were to use two 125 kWe mo- tor/generators rather than one. This choice was made be- cause the high-speed permanent magnet generator power level was limited by rotor dynamics. The final modification we selected was the use of a re-com- pression Brayton cycle, which uses two recuperators and splits a fraction of the flow. Part of the flow is sent to a re- compressor that increases the temperature rise in the high- pressure leg of the recuperators to assure that the tempera- ture rise there nearly equals the temperature drop in the low-pressure leg. It also reduces the likelihood of a pinch point, which occurs when there is little or no temperature difference between the hot- and low-temperature legs in the recuperator, so no heat flows from one to the other. The re- compression cycle has large amounts of recuperation (note that the recuperators transfer 2.8 MW while the heater only supplies 0.78 MW). A second loop, located at Sandia, is used to research the unusual issues of compres- sion, bearings, seals, and fric- tion that exist near the critical point, where the carbon diox- ide has the density of liquid but otherwise has many of the properties of a gas. Immediate plans call for Sandia to continue to develop and operate the two small test loops to identify key fea- tures and technologies. Test results will illustrate the ca- pability of the concept, par- ticularly its compactness and efficiency; confirm models; and demonstrate the scalabil- ity to larger systems. Down the line, we want to commercialize the technology. That would entail the development of an industrial demon- strationplantat10MWofelectricity,perhapsinpartnership with industry. Sandia would use or modify its loops to study the behavior of various types of components not previously tested (for example, other types of seals or bearings). Alter- natively, our Brayton loop could be reconfigured to test the behavior for other types of power cycles that may more opti- mally couple to gas turbines, solar plants, or fossil plants. Brayton-cycle turbines using supercritical carbon dioxide would make a great replacement for steam-driven Rankine- cycle turbines currently deployed. Rankine-cycle turbines generally have lower efficiency, are more corrosive at high temperature,andoccupy30timesasmuchturbomachinery volume because of the need for very large turbines and con- densers to handle the low-density, low-pressure steam. An S-CO2 Brayton-cycleturbinecouldyield10megawattsof electricity from a package with a volume as small as four to six cubic meters. This low-temperature recuperator – one of two in the loop – is designed to transfer 1.6 MW of heat. 42 mechAnIcAl engIneerIng | January 2012 BarBer Nichols iNc.PDF Image | A turbine that uses supercritical carbon dioxide can deliver great power from a small package.
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