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Organic Rankine cycle receiver development
The selected receiver concept is a direct-heated, once-through, monotube boiler operated at supercritical pressure. The cavity is formed by a cylindrical copper shell and backwall, with stainless steel tubing brazed to the outside surface. This core is surrounded by lightweight refractory insulation, load-bearing struts, and an outer case. The aperture plate is made of copper to provide long life by conduction and reradiation of heat away from the aperture lip. The receiver thermal efficiency is estimated to be 97 percent at rated conditions (energy transferred to toluene divided by energy incident on aperture opening). Development of the core manufacturing and corrosion protection methods is complete.
Control system development for an organic Rankine cycle engine
The development of a control logic to govern the toluene throttle valve and verify the stability of the speed control approach for multiple engines connected to a 1 MWe point focus solar generator installation for distributed applications is presented. The toluene is is pumped by booster and main feed pumps through a regenerator to the parabolic focus receiver, with the flow rate controlled by a valve to remain at critical level of 4.1 MPa. The valve changes the inlet pressure at the turbine nozzle block. Each concentrator would produce 76 kWth and 20 kWe. Dynamic variables in the logic account for insolation variation, fluid temperature, ac grid voltage, the thermal dynamics of the regenerator, and variations in the head supplied by the feed pump. Separate analyses are presented for the turbine shaft speed and toluene loop dynamics. The resulting logic is considered preliminary and suitable only in full insolation conditions. Extension of the model to nonlinear perturbations is indicated.
Optimization of organic Rankine cycles for space station applications
The purpose of the current program is to investigate the tradeoffs between solar dynamic and nuclear powered systems for the space station. This research is based on a typical Rankine cycle using toluene as the working fluid. The first objective is to produce an adequate thermodynamic cycle model and calculate its efficiency. The next step is to implement a sizing algorithm that calculates the capacity of the various elements of the system, such as the radiator and regenerator, for a given electrical output. Then, the mass of each component must be calculated to give the overall total system mass. Likewise, the space for each component can be determined, giving an estimate of what volume must be available to place the system into orbit.
Low-Cost Scroll Organic Rankine Cycle (Final Report)
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Techno-Economic Analysis of Greenfield Geothermal Hybrid Power Plants using a Solar or Natural Gas Steam Topping Cycle
The relatively low generation costs associated with wind, solar photovoltaic (PV), and natural-gas power plants make it challenging for geothermal power plants to produce and sell the power that has the reliability and sustainability characteristics that are greatly needed in U.S. power markets. This is especially true for geothermal resources with low-to-medium temperatures, which results in relatively low-thermal efficiency and generation costs that are higher than those for wind, solar PV, and natural gas. This analysis evaluates solar thermal- and natural-gas combustion waste heat recovery-based topping cycle hybridization of geothermal binary power plants. This approach provides several benefits that may allow geothermal power plants to generate power at more competitive costs. First, the addition of solar thermal energy or natural-gas combustion waste heat input to a geothermal power plant provides additional heat input that can be converted to electrical power. Second, the temperature level of the heat obtained from concentrating solar collectors or natural-gas combustion exhaust is higher than that of geothermal heat, which provides opportunities for improving the efficiency of the conversion of thermal energy to electrical power. Third, the ease with which solar thermal systems integrate with energy storage and the flexibility of natural gas means power generation can occur during peak demand periods. The hybrid cycles are compared to equivalently sized, co-located, independent geothermal, concentrating solar, and/or natural-gas power plants. The hybrid cycle tends to produce slightly more power than the standalone plants combined. However, the hybrid plant Levelized Cost of Energy (LCOE) is slightly higher than the LCOE of the combined standalone power plants for each of the case study locations investigated. Using the steam-topping cycle, organic Rankine cycle (ORC)-bottoming cycle hybrid plant design to combine a solar thermal resource and low- temperature geothermal resource (<120 degrees C) leads to a hybrid plant with a lower LCOE than a standalone geothermal-only system. Thus, hybrid plants may enable the economic development of geothermal resources in locations with low geothermal resource temperatures. However, in areas with higher geothermal resource temperatures (>120 degrees C), the geothermal-only plant has a lower LCOE than the hybrid cycle and thus could be developed without the need for solar heat addition. iv A geothermal-natural-gas reciprocating engine hybrid plant was evaluated for an Elk Hills, California case study location. The Elk Hills case study analysis indicates that when the natural-gas engine operates for more than 12 hours per day the hybrid plant can produce power at an LCOE lower than a standalone geothermal plant, and comparable to that of the standalone natural-gas reciprocating engine, while also reducing the carbon intensity of the power generated relative to the standalone natural-gas engine. This may represent a scenario in which the hybrid plant provides an opportunity for the deployment of a low-temperature geothermal resource that otherwise may have an LCOE too high to develop and operate as a standalone resource, while also reducing the carbon intensity of natural-gas generation sources. A "triple-hybrid" plant that combines natural gas, solar thermal, thermal energy storage, and geothermal was also investigated. A natural-gas combustion turbine (NGCT) is added to the geothermal-solar hybrid such that the hot exhaust gas from the gas turbine provides an alternative source of heat to the steam turbine of the hybrid cycle. Analysis results suggest that the triple-hybrid plant has a significantly higher energy generation and revenue than a standalone NGCT or the original geothermal-solar hybrid. The triple-hybrid design benefits most from using a smaller solar field so that the solar energy can be dispatched at the most valuable times available. The triple-hybrid plant also has a lower LCOE than the standalone NGCT. The triple-hybrid plant was evaluated making simple assumptions about the dispatch profile of the gas cycle, and more nuanced and realistic dispatching schedules should be analyzed in future work.
Development of an Organic Rankine-Cycle power module for a small community solar thermal power experiment
An organic Rankine-cycle (ORC) power module was developed for use in a multimodule solar power plant to be built and operated in a small community. Many successful components and subsystems, including the reciever, power conversion subsystem, energy transport subsystem, and control subsystem, were tested. Tests were performed on a complete power module using a test bed concentrator in place of the proposed concentrator. All major single-module program functional objectives were met and the multimodule operation presented no apparent problems. The hermetically sealed, self-contained, ORC power conversion unit subsequently successfully completed a 300-hour endurance run with no evidence of wear or operating problems.
Test results of an organic Rankine-cycle power module for a small community solar thermal power experiment
The organic Rankine-cycle (ORC) power conversion assembly was tested. Qualification testing of the electrical transport subsystem was also completed. Test objectives were to verify compatibility of all system elements with emphasis on control of the power conversion assembly, to evaluate the performance and efficiency of the components, and to validate operating procedures. After 34 hours of power generation under a wide range of conditions, the net module efficiency exceeded 18% after accounting for all parasitic losses.
An RC-1 organic Rankine bottoming cycle for an adiabatic diesel engine
A system analysis and preliminary design were conducted for an organic Rankine-cycle system to bottom the high-temperature waste heat of an adiabatic diesel engine. The bottoming cycle is a compact package that includes a cylindrical air cooled condenser regenerator module and other unique features. The bottoming cycle output is 56 horsepower at design point conditions when compounding the reference 317 horsepower turbocharged diesel engine with a resulting brake specific fuel consumption of 0.268 lb/hp-hr for the compound engine. The bottoming cycle when applied to a turbocompound diesel delivers a compound engine brake specific fuel consumption of 0.258 lb/hp-hr. This system for heavy duty transport applications uses the organic working fluid RC-1, which is a mixture of 60 mole percent pentafluorobenzene and 40 mole percent hexafluorobenzene. The thermal stability of the RC-1 organic fluid was tested in a dynamic fluid test loop that simulates the operation of Rankine-cycle. More than 1600 hours of operation were completed with results showing that the RC-1 is thermally stable up to 900 F.
Thermoeconomic analysis of a multigeneration system using waste heat from a triple power cycle
Multigeneration systems represent an appealing concept, due to their multiple benefits compared to standalone systems, which has motivated researchers to develop different types of multigeneration systems for several applications. Considering their significance, in this study, a novel multigeneration is proposed that uses the waste heat of a thermodynamically efficient triple power cycle with a 100 MWe capacity. The proposed system, which can generate power, freshwater, cooling, and domestic hot water concurrently, is evaluated using detailed thermodynamic and economic analyses. The triple cycle includes a simple Brayton cycle coupled with a supercritical carbon dioxide recompression cycle and a high-temperature organic Rankine cycle. The waste energy of the recompression and organic Rankine cycles is recovered by a half effect absorption chiller, a multi-effect distillation unit, and two heat exchangers. The results show that for an optimized triple cycle, up to 1,804 kW cooling and 8,472 m 3 /day of hot water can be generated from the hot supercritical carbon dioxide stream with a levelized cost of cooling and hot water of 0.0362/ton-hr and $0.6823/MWth, respectively. The integration of a multi-effect distillation unit with 7 effects can generate 4,167 m 3 /day freshwater with a levelized cost of water of $1.142/m 3 . Finally, the proposed multigeneration system offers a very promising application and a number of benefits such as a generating multiple useful products with no adverse effect on the thermodynamic efficiency of the triple power cycle.
Bearing development program for a 25 kWe solar-powered organic Rankine-cycle engine
The bearing development program is summarized for a 25-kWe power conversion subsystem (PCS) consisting of an organic Rankine-cycle engine, and permanent magnetic alternator (PMA) and rectifier to be used in a 100-kWe point-focusing distributed receiver solar power plant. The engine and alternator were hermetically sealed and used toluene as the working fluid. The turbine, alternator, and feed pump (TAP) were mounted on a single shaft operating at speeds up to 60,000 rev/min. Net thermal-to-electric efficiencies in the range of 21 to 23% were demonstrated at the maximum working fluid temperature of 400 C (750 F). A chronological summary of the bearing development program is presented. The primary causes of bearing wear problems were traced to a combination of rotordynamic instability and electrodynamic discharge across the bearing surfaces caused by recirculating currents from the PMA. These problems were resolved by implementing an externally supplied, flooded-bearing lubrication system and by electrically insulating all bearings from the TAP housing. This program resulted in the successful development of a stable, high-speed, toluene-lubricated five-pad tilting-pad journal bearing and Rayleigh step thrust bearing system capable of operating at all inclinations between horizontal and vertical.
Preliminary design of reactor power systems for the manned space base.
The results of design integration studies of uranium-zirconium hydride (UZr-Hx) reactor power systems for the NASA space base study program are presented. The power conversion systems investigated include the Brayton cycle, the organic Rankine cycle, the SNAP-8 mercury Rankine cycle, and thermoelectric (PbTe). The proposed space base has a 10-year life and requires 100 kWe of power. Two 50-kWe power systems with a nominal replacement life of 5 years are utilized. Parametric design data such as life, weight, radiator area, reactor outlet-temperature, reactor thermal power, and power conversion system efficiency are presented and used for the design and integration of the system with the space base.
Control system development for an organic Ranking cycle engine
An organic Rankine cycle engine is used as part of a solar thermal power conversion assembly (PCA). The PCA, including a direct-heated cavity receiver and a shaft-mounted alternator, is mounted at the focal point of a parabolic dish concentrator. The engine controls are required to maintain approximately constant values of turbine inlet temperature and shaft speed, despite variation in the concentrated solar power input to the receiver. The controls design approach, system models, and initial stability and performance analysis results are presented herein.
Radiator selection for Space Station Solar Dynamic Power Systems
A study was conducted to define the best radiator for heat rejection of the Space Station Solar Dynamic Power System. Included in the study were radiators for both the Organic Rankine Cycle and Closed Brayton Cycle heat engines. A number of potential approaches were considered for the Organic Rankine Cycle and a constructable radiator was chosen. Detailed optimizations of this concept were conducted resulting in a baseline for inclusion into the ORC Preliminary Design. A number of approaches were also considered for the CBC radiator. For this application a deployed pumped liquid radiator was selected which was also refined resulting in a baseline for the CBC preliminary design. This paper reports the results and methodology of these studies and describes the preliminary designs of the Space Station Solar Dynamic Power System radiators for both of the candidate heat engine cycles.
Hybrid Natural Gas Geothermal Combined Cycle Power Plant Analysis
Low temperature geothermal resources, including those associated with oil and gas production, are an underutilized source of low carbon energy. The present work investigates coupling of low-temperature geothermal resources with concentrating solar and/or natural gas energy sources to increase the number of locations at which power generation from low temperature geothermal resources would be technically and economically viable. Stand-alone and hybrid geothermal power cycles are simulated using SimTech IPSEpro process modeling software. Design point strategies for a hybrid power cycle that may operate with either a single heat source or two simultaneous heat input sources are considered. Additionally, off-design power plant operation is investigated to consider the impacts of the heat source availability and ambient temperature variations. The off-design analysis utilizes a modeling tool that predicts power plant performance at each time step as a function of topping cycle heat input (from gas or solar), bottoming cycle heat input (from geothermal), and ambient temperature. Addition of a steam topping cycle to an organic Rankine cycle geothermal power plant provides opportunities to increase the efficiency and power output relative to a stand-alone geothermal power plant. Additionally, use of the waste heat from gas turbine power generation in a geothermal bottoming cycle provides opportunities to increase the amount of power generation associated with each unit of carbon dioxide emitted. This paper will describe the hybrid plant configuration evaluated, discuss the predicted power cycle performance, and compare with stand-alone natural gas and geothermal power generation cases. The power cycle investigated is expected to be applicable for use with conventional hydrothermal resources as well as with geologic thermal energy storage applications and/or enhanced geothermal systems. The steam topping cycle could use a concentrated solar heat source for fully renewable hybrid plant configuration. A plant initially constructed with a natural gas topping cycle heat source could be converted to a solar heat source part way though the power cycle operational life to achieve life cycle carbon emission reductions.
Thermal energy storage for a space solar dynamic power system
In the past, NASA has employed solar photovoltaic devices for long-duration missions. Thus, the Skylab system has operated with a silicon photovoltaic array and a nickel-cadmium electrochemical system energy storage system. Difficulties regarding the employment of such a system for the larger power requirements of the Space Station are related to a low orbit system efficiency and the large weight of the battery. For this reason the employment of a solar dynamic power system (SDPS) has been considered. The primary components of an SDPS include a concentrating mirror, a heat receiver, a thermal energy storage (TES) system, a thermodynamic heat engine, an alternator, and a heat rejection system. The heat-engine types under consideration are a Brayton cycle engine, an organic Rankine cycle engine, and a free-piston/linear-alternator Stirling cycle engine. Attention is given to a system description, TES integration concepts, and a TES technology assessment.
Preliminary operational results from the Willard solar power system
The solar powered system located near Willard, New Mexico, generates mechanical or electrical power at a capacity of 19 kW (25 HP). The solar collection system incorporates east/west tracking parabolic trough collectors with a total aperture area of 1275 sq m (13,720 sq ft). The hot oil type thermal energy storage is sufficient for approximately 20 hours of power system operation. The system utilizes a reaction type turbine in conjunction with an organic Rankine cycle engine. Total collector field efficiency reaches a maximum of 20 percent near the winter solstice and about 50 percent during the summer. During the month of July, 1979, the system pumped 60 percent of the 35,300 cu m (28.6 acre-feet) of water delivered. Operating efficiencies for the turbine component, organic Rankine cycle engine and the complete power system are respectively 65 to 75 percent, 12 to 15 percent and 5 to 6 percent. Significant maintenance time was expended on both the collector and power systems throughout the operational period.