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Appl. Sci. 2020, 10, 4168 22 of 26 shaft speed of 40,000 rpm [51]. In the case of the operating temperature of the modified NET Power cycle, Joule-Thomson or throttle cooling will need to be provided at that shaft end from compressor discharge to decrease the temperature to around 700 ◦C and allow safe and effective seal operation. Commercially-ready dry gas seals are limited to shaft sizes in the range of 37.5 mm for high rotational speeds (near 50,000 rpm) and for slower speeds, they can reach up to 10 times bigger shaft diameters [45]. Looking back at the conditions of the designed turbine in terms of temperature (900 ◦C), pressure (297 bar), rotational speed (≈20,000 rpm) and shaft diameter (≈120 mm), dry gas lift off seals are not a far measure from use for a 60–70 MWe supercritical CO2 radial turbine. 4.4. Electrical Configuration The turbine shaft rotational speed is in the range of 20,000 rpm which would require an appropriate choice of a step-down gearbox to speeds of 1800 rpm or 3600 rpm for coupling the turbine to a synchronous generator or for the requirement of separating the unknown speed of the compressor which is not designed yet. Not only is the selection of the gearing configuration dependant on shaft speed but also on the power scale; McClung et al. [45] report that General Electric (GE) has gearing configuration for power ratings reaching 60 MW. The availability of a gearbox providing a speed reduction from 12,000 rpm to 3600 rpm for a 50 MW turbine scale is also disclosed by Bidkar et al. [52]. Geared turbine generator sets are widely available for steam turbines with power output up to 40 MWe as reported by GE and Mitsubishi Hitachi [53,54]. Gearbox manufacturers can provide information on the applicability of having a speed reduction ratio of around 6 from near 20,000 rpm for a 60–70 MWe turbine. Besides the mentioned technologies which need to be developed for successful use of the radial turbine, there are some operational design considerations reported for sCO2 turbines which require careful attention. Transient operation of the turbine might induce an overspeed risk and loss of electrical load due to the small size of the rotor. The necessitated temperature reduction near the turbine inlet, to safe margins tolerated by seals and bearings, incurs high thermal stresses in that region that needs addressing via further stress analysis. 5. Conclusions This paper outlines the design procedure of a radial turbine for a cycle size of ≈100 MW starting with cycle modelling and moving towards preliminary design, performance analysis, CFD simulations, and mechanical assessment. Key findings include the identification of the areas within the turbine passage that require careful readjustment due to the presence of losses that diminish the performance. The final observation is that a radial turbine configuration is suitable for use in a utility-scale (100 MW) supercritical CO2 power cycle at the pressure and temperature levels of 297 bar and 900 ◦C. The advantage of using a radial turbine is its compactness and its ability to endure a high pressure ratio in a single stage, about 5 for the designed turbine. The flow behaviour in the turbine design aligns well with results from other works on high fluid density radial turbines. However, the current design requires re-visitation to improve the overall turbine efficiency especially through optimising the design of the nozzle vanes through different stacking, or changing the number of blades to deliver better incidence to the rotor, and to reduce the exit Mach number, and thus the associated losses. The approach towards achieving the goal of employing a radial turbine in a mid-scale power plant requires further work. Future research should include, but is not limited to: • Incorporation of the fluid mixture in the design processes to account for the influence on performance • Optimisation of the blade profiles • Additional stress analyses including modal, harmonic, and hot-to-cold simulations • Experimental testing and validation • Investigation of the relevant technologies such as seals, bearings, gearing • Research on suitable material advancementsPDF Image | Radial Turbine Design for a Utility-Scale Supercritical CO2 Power
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