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Apparent violations of the Rankine-Hugoniot equation in porous materials
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Low-Cost Scroll Organic Rankine Cycle (Final Report)
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Supercritical Carbon Dioxide Primary Power Large-Scale Pilot Plant
The United States electrical power generation fleet encompasses a wide range of technologies, ranging from traditional combustion-based power generation, to nuclear power, to renewable energy. While the distribution of these assets continues to shift due to economic and regulatory influences, coal combustion continues to be a key part of the US energy portfolio. Despite the relative maturity of coal combustion technology, improvements in overall fuel-to-power efficiency and generation flexibility are still possible and will improve both the economic and environmental factors of coal combustion. Echogen Power Systems proposes to lead a world-class team including the University of Missouri, Electric Power Research Institute and Louis Perry Associates in the design, construction and operation of a 10MWe coal-fired supercritical carbon dioxide (sCO 2 ) large-scale pilot. This transformational technology uses sCO 2 as a working fluid instead of water to achieve high thermodynamic efficiencies that can significantly exceed advanced steam-Rankine cycles. Further, the compact nature of sCO 2 turbomachinery offers capital cost and footprint advantages, and the low maintenance of a water-free power cycle can significantly reduce operation and maintenance (O&M) costs over conventional steam-Rankine systems. Recent integration studies of sCO 2 with coal combustion power plants highlight the significant improvements in plant efficiency that sCO 2 can offer relative to even advanced steam Rankine cycles. At commercial scales, coal-sCO 2 plant net efficiency is predicted to be 39-44.0% (HHV), or 10-20% higher output than conventional steam-Rankine systems, which will significantly improve the competitiveness of coal-fired generation. This proposal builds upon projects previously funded by the Department of Energy, including DE-FE0025959 (High-Efficiency Thermal Integration of Closed Supercritical CO 2 Brayton Power Cycles with Oxy-Fired Heaters) and DE-NE0008470 (Conceptual Design for sCO 2 Power Cycle Test Facility). An appropriately-scaled and properly designed and operated pilot project is essential to overcome the natural risk-aversion of the power generation industry and project financing community. The 10 MWe coal-fired sCO 2 pilot power plant proposed herein will reduce the technical and economic risk of this transformational technology, enabling commercial deployment at the conclusion of the project. For the second phase of this project, Echogen lead a team that completed and refined the pilot system conceptual system and key component designs resulting in the completion of a front-end-engineering-design (FEED) study, completed the NEPA review process, completed the permitting process for construction and operation, refined the techno-economic analysis of the proposed system at commercial scale and received commitments for Phase III cost share. The end result of the program will be to demonstrate the technical and economic superiority of the sCO 2 power cycle for coal-fired operation. Major risk elements will have been retired with sufficient operation at high power to enable the power generation industry to move forward with the first commercial deployment of this transformational system.
Advanced Steam-Electric Power Cycle for Advanced Reactor Concepts
This report presents improvements made to RELAP-7 for modeling Rankine power cycles, which are used on the secondary side of some advanced reactor concepts. For example, for a High-Temperature gas-cooled Reactor Pebble bed Module (HTR-PM), in the primary loop, helium transfers heat from the fuel to a steam generator, and on the secondary side, dry steam from the steam generator applies work to a turbine, which is converted into electrical power by a generator. After passing through the turbine, the steam passes through a condenser and pumped to the steam generator inlet, completing a Rankine cycle on the secondary side. This HTR-PM concept is used as an example to demonstrate a steam-electric power cycle capability in RELAP-7. This power cycle requires a number of different physical components, including a pump, compressor, turbine, steam generator, and condenser. The steam generator is modeled using a heat exchange between primary and secondary loops, and the condenser is modeled using a cooling source term. Recent efforts demonstrated preliminary models for the turbomachinery components (pump/compressor and turbine), but more physical models were required. Furthermore, several improvements were made for the robustness of mixed single-phase/two-phase flow present in a Rankine cycle.
Equipment List Comparing Balance of Plant Containing a Heat Pump against a Reference Electricity Generating Plant
Approximately two-thirds of U.S. energy consumption in the industrial and transportation sectors relies on fossil fuels. These sectors require high-quality heat, i.e., thermal energy at very high temperatures, for molecular transformation processes. The Integrated Energy Systems (IES) program aims to assess the economic potential of utilizing nuclear-grade heat from Advanced Reactors (ARs) to meet the high-quality heat demands. By having industrial processes (IPs) supplied with nuclear-generated heat, manufacturers could benefit from more stable and potentially lower energy costs, reducing reliance on volatile fossil fuel markets. The main outcome of the FY24 research was the thermodynamic assessment and gap analysis of steam generation for IP applications. The study completed in June 2024 demonstrated that the required steam temperatures could be achieved by integrating a heat pump into an AR power plant. After identifying the thermal demands of target IPs, multiple balance of plant configurations for the Xe-100 reactor by X-energy, incorporating a heat pump, were analyzed. Their technical feasibilities were assessed, including the design of suitable axial compressors for these applications. Comparative performance analysis showed that thermal efficiency alone is insufficient to evaluate system suitability. To address this, a new indicator (heat factor) was introduced in the report released in September 2024 to quantify the low-quality thermal power needed to produce one unit of high-quality heat for the IP. Results showed that integrating heat pumps into Rankine cycles enables higher steam temperatures, though at the expense of increased thermal energy input. This report builds upon and completes the foundational work previously undertaken. It focuses on the design of two Balance of Plant (BOP) configurations, both based on Rankine energy conversion cycles: “Case 1”, which involves electricity generation only, and “Case 2”, which combines electricity and high-temperature heat generation for industrial use. For each configuration, a comprehensive equipment list was developed, detailing all major components such as turbines, compressors, heat exchangers, pumps, and control systems. These lists will serve as the basis for future comparative cost analyses, with the goal of assessing the number and type of components required to integrate a heat pump into the Rankine cycle and to establish a heat transport system capable of delivering thermal energy from the nuclear plant to an industrial facility. Using the constitutive equations presented in the June 2024 milestone, the operating conditions of all BOP components for both “Case 1” and “Case 2” were evaluated. These parameters—such as temperature, pressure, mass flow rate, and steam quality—served as the basis for calculating the associated thermal and mechanical power flows. The net power required from the heat pump to raise the steam temperature to the target level was also determined. The thermodynamic performance of the configuration was then assessed using the heat factor metric. The key outcome of this analysis is a comparative table that presents the equipment that was used in the “Case 1” and “Case 2” configurations. This study offers a preliminary comparison of the two designs, providing insight into the impact of integrating a heat pump in terms of component requirements and thermal efficiency. This equipment list, together with the evaluated operating conditions, also serves as a foundation for the economic analyses scheduled for the current fiscal year.
Performance and Economic Evaluation of sCO2 Bottoming Cycles for Natural Gas Combined Cycle Plants with Capture
Natural gas combined cycles (NGCCs) with carbon capture are expected to play a significant role in decarbonization of the power generation sector. NGCC plants generally use triple pressure reheat steam Rankine power cycles for the bottoming cycle. Some studies in the literature have investigated the application of recompression and cascade style supercritical CO2 (sCO2) cycles for NGCC bottoming cycle applications but these studies have focused on power plants without carbon capture. However, NGCC plants fitted with post-combustion solvent-based CO2 capture systems will require a significant amount of steam for solvent regeneration and this can have a major impact on the optimal sCO2 bottoming cycle design. This study investigates the performance and economic potential of sCO2 bottoming cycles for H-class gas turbine based NGCC plants with a post-combustion capture system. A portion of the gas turbine exhaust heat is used for generation of steam required for solvent-based capture system while the rest of the waste heat is utilized in an sCO2 bottoming cycle for power generation. Overall, the performance and LCOE of investigated sCO2 bottoming cycles is similar to that of a state-of-the-art triple pressure reheat steam Rankine cycle. As the gas turbine exhaust temperature increases (beyond 630oC), sCO2 bottoming cycles begin to show greater performance and economic benefits compared to a steam Rankine cycle.
Real-time dispatch optimization for concentrating solar power with thermal energy storage
Concentrating solar power (CSP) plants present a promising path towards utility-scale renewable energy. The power tower, or central receiver, configuration can achieve higher operating temperatures than other forms of CSP, and, like all forms of CSP, naturally pairs with comparatively inexpensive thermal energy storage, which allows CSP plants to dispatch electricity according to market price incentives and outside the hours of solar resource availability. Currently, CSP plants commonly include a steam Rankine power cycle and several heat exchange components to generate high-pressure steam using stored thermal energy. The efficiency of the steam Rankine cycle depends on the temperature of the plant's operating fluid, and so is a main concern of plant operators. However, the variable nature of the solar resource and the conservatism with which the receiver is operated prevent perfect control over the receiver outlet temperature. Therefore, during periods of solar variability, collection occurs at lower-than-design temperature. To support operator decisions in a real-time setting, we develop a revenue-maximizing non-convex mixed-integer, quadradically-constrained program which determines a dispatch schedule with sub-hourly time fidelity and considers temperature-dependent power cycle efficiency. The exact nonlinear formulation proves intractable for real-time decision support. Here we present exact and inexact techniques to improve problem tractability that include a hybrid nonlinear and linear formulation. Our approach admits solutions within approximately 3% of optimality, on average, within a five-minute time limit, demonstrating its usability for decision support in a real-time setting.
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.
Expanded Accident Scenarios and Frequency Characteristics for a Fast Spectrum Molten Salt Reactor in an Integrated Energy System
Integration of advanced nuclear reactors to industrial processes in an integrated energy system (IES) has many potential advantages. The coupling of nuclear power to varied industrial processes introduces additional accident scenarios unique to the specific systems included in the IES. Similarly, noise in one system of the IES could potentially create negative effects in the other systems. Because of the limited amount of comparable nuclear IES operating experience, there is added value in scoping the inherent behavior of these systems in response to these transients. Here, this paper investigates the safety-related behavior of an open-source IES dynamic model of a fast spectrum molten salt reactor (MSR) powering a regenerative Rankine cycle for electricity production and a hybrid sulfur (HyS) cycle for hydrogen production. The simulations include a loss of cooling water to the Rankine cycle, a loss of sulfur in the HyS cycle, and the frequency characteristics of the entire IES across six orders of magnitude of frequency. The results show safe behavior in response to the two accident scenarios, wherein a disruption in heat transfer leads to increased salt temperatures and a decrease in reactor power. The frequency analysis shows that at higher frequencies, temperature changes propagating through an IES are increasingly damped to the point of negligibility.
Performance of a Natural Gas Solid Oxide Fuel Cell System With and Without Carbon Capture
The fuel cell program at the United States Department of Energy (DOE) National Energy Technology Laboratory (NETL) is focused on the development of low-cost, highly efficient, and reliable fossil-fuel-based solid oxide fuel cell (SOFC) power systems that can generate environmentally-friendly electric power with at least 90 percent carbon capture. NETL’s SOFC technology development roadmap is aligned with near-term market opportunities in the distributed generation sector to validate and advance the technology while paving the way for utility-scale natural gas (NG)- and coal-derived synthesis gas-fueled applications via progressively larger system demonstrations. The present study represents a part of a series of system evaluations being carried out at NETL to aid in prioritizing technological advances along research pathways to the realization of utility-scale SOFC systems, a transformational goal of the fuel cell program. In particular, the system performance of utility-scale NG fuel cell (NGFC) systems with and without carbon dioxide (CO2) capture is presented. The NGFC system analyzed features an external auto-thermal reformer (ATR) feeding the fuel to the SOFC system consisting of planar anode-supported SOFC with separated anode and cathode off-gas streams. In systems with CO2 capture, an air separation unit (ASU) is used to provide the oxygen for the ATR and for the combustion of unutilized fuel in the SOFC anode exhaust along with a CO2 purification unit to provide a nearly pure CO2 stream suitable for transport for usage in enhanced oil recovery operations or for storage in underground saline formations. Remaining thermal energy in the exhaust gases is recovered in a bottoming steam Rankine cycle while supplying any process heat requirements. A reduced order model (ROM) developed at the Pacific Northwest National Laboratory (PNNL) is used to predict the SOFC performance. The ROM, while being computationally effective for system studies, provides other detailed information about the state of the stack, such as the internal temperature gradient, generally not available from simple performance models often used to represent the SOFC. Such additional information can be important in system optimization studies to preclude operation under off-design conditions that can adversely impact overall system reliability. The NGFC system performance was analyzed by varying salient system parameters, including the percent of internal (to the SOFC module) NG reformation—ranging from 0 to 100 percent—fuel utilization, and current density. The impact of advances in underlying SOFC technology on electrical performance was also explored.
Performance and Cost Potential of sCO2 Bottoming Cycle for Gas Turbines with Carbon Capture – Paper 32
This study investigates the performance and economic potential of sCO2 bottoming cycles for H-class gas turbine-based NGCC plants with a post-combustion capture system. A portion of the gas turbine exhaust heat is used for the generation of steam required for a solvent-based capture system while the rest of the waste heat is utilized in an sCO2 bottoming cycle for power generation. Overall, the performance and LCOE of investigated sCO2 bottoming cycles are similar to those of a state-of-the-art triple-pressure reheat steam Rankine cycle. As the gas turbine exhaust temperature increases (beyond 630oC), sCO2 bottoming cycles begin to show greater performance and economic benefits compared to a steam Rankine cycle with ~0.7 percentage point higher plant efficiency and 1.4% lower LCOE.
Low-temperature solar thermal-power systems for residential electricity supply under various seasonal and climate conditions
In this work, the performance of low-temperature (<100 degrees C) solar thermal-power systems to satisfy residential electric loads was analyzed. The solar-driven system was designed to provide a fraction of the total electricity demand in a complementary operation with the electric grid. The analysis was conducted for an coperation during seven days each season, considering real solar and climate variables and residential loads at different climate zones in the United States. The efficiency of the system strongly depends on the solar radiation profile and the ambient temperature. Maximum efficiencies of around 9.5% were obtained in the cold and marine climate zones due to the high solar energy input and low heat dissipation temperatures. In these two zones, the system could supply more than 98% of the electricity demand all seasons. At mixed-humid and hot-humid regions, the system supplied around 50% of the electric load in three of the four seasons, but it only supplies about 27% of the electricity needs in the mixed-humid zone during summer and hot-humid zone during winter. The effect of the solar collector field area and the tank volume was also analyzed. In general, larger solar fields positively impact the efficiency. However, the impact of the tank volume varies depending on the solar radiation profile and the load requirements. Average efficiencies for the seven-day operation can be larger than 6% with a proper selection of the solar collector area and tank volume for an Organic Rankine Cycle with a capacity of about 2.6 kW. Finally, an economic analysis of the system was conducted, and the results were compared with a solar PV + battery system of similar capacity. It is expected that the cost for the analyzed solar-thermal system decreases in the coming years with the increased interest on low temperature applications.
Technoeconomic Benefits of Film-Forming Amine Products Applied to Steam Surface Condensers
In a conventional Rankine cycle, the majority of power plants employ surface condensers that use pumped cooling water to reject heat from the cycle. In such cases, heat rejection occurs in a shell and tube heat exchanger by film-wise condensation of low-pressure steam on stainless steel, titanium, brass, or copper-nickel tubing. To improve the thermal performance of steam surface condensers, a replenishable film-forming substance (FFS) can be ap-plied to the condenser tubing to promote efficient dropwise condensation. Conventionally, film-forming amine prod-uct (FFAP) coatings protect boiler surfaces from oxidative corrosion, which substantially reduces the operation and maintenance costs. To quantify the technical and economic benefits of FFAP coatings applied to condenser tubing due to the promotion of dropwise condensation, a thermal resistance network model was established. Using a rep-resentative steam surface condenser, the improvements in thermal performance (overall heat transfer coefficient) and process parameters (net plant efficiency, cooling water flowrate, and turbine backpressure) were determined due to the enhancement in the condensation heat transfer coefficient. Experimentally measured condensation heat transfer coefficients for common condenser materials were compared with the modeling results and were found to be within attainable bounds. Lastly, the trend in total heat exchanger cost reduction is generalized to understand the trade-off between reduced surface area for heat rejection and increase in coating application costs for a re-plenishable coating system.
Resource Characterization to Estimate Potential for Electricity Co-Production at Blackburn Oil Field, Nevada
The U.S. Department of Energy estimates that an annual average of 25 billion barrels of hot water are produced from oil and gas wells within the United States. The thermal energy available in the co-produced water stream is usually discarded, as the produced waters are considered an inconvenience by the operators and are disposed of using injection wells. However, utilizing organic Rankine cycle (ORC) generators, a vast amount of thermal energy can be captured and converted into electricity (albeit at relatively low efficiency due to the low temperatures). The National Renewable Energy Laboratory (NREL), in collaboration with Transitional Energy and Grant Canyon Oil & Gas, evaluated the feasibility of geothermal co-production of electricity by utilizing existing oil wells in Blackburn oil field in Nevada. The once prolific Blackburn oil field is located in Pine Valley, approximately 45 miles east-southeast of Elko, Nevada. Currently, the wells targeting the highly fractured Devonian Nevada dolomite reservoir are operating at a water cut ratio of more than 99%, with individual fluid (oil and water) production rates reaching 7.4 L/s (4,021 BBL/day). Analysis of publicly available data showed that the combination of the suitable wells' maximum historical production rates reached 22.90 L/s. The production from these wells occurs naturally and the wells are choked (and even shut down) by the operator to mitigate excessive water production, indicating a strong reservoir recharge and future opportunity to increase the water production for geothermal electricity generation. The main goal of this study was to evaluate the productivity of the existing wells, the performance of the reservoir, the surface network, and the operational constraints in order to achieve 1 MWe of electricity production from the field's water production. Utilizing the GEOPHIRES tool, we have determined that a twofold to threefold increase in the total fluid production, compared to the historical production under artificial restraint (choke), is required to reach a 1-MWe net target output for a low-temperature ORC system with air-cooled condensers. Lower flow rates would be required when utilizing water-based condensers instead of air-cooled condensers. However, that would require a constant supply of cold water, which may be challenging given the arid environment of the project site.
Geothermal Reservoir Simulation Analysis in Support of Electricity Co-Production Feasibility Study at the Blackburn Oil Field, Nevada: Preprint
Geothermal electricity co-production is a viable option for oil reservoirs producing large water cuts with elevated wellhead-observed temperatures. Repurposing existing oil wells significantly reduces initial investment costs historically associated with geothermal resource utilization. The National Renewable Energy Laboratory (NREL), partnering with Gradient Geothermal, Inc. (formerly known as Transitional Energy) and Grant Canyon Oil and Gas, has been tasked to evaluate the feasibility of geothermal electricity co-production at the Blackburn Oil Field with Organic Rankine Cycle (ORC) generators. The Devonian steady-state reservoir has historically been producing high water cuts of 240 degrees F (115.6 degrees C) observed at the wellhead without documented pressure drawdown or thermal breakthrough. An estimated initial reservoir temperature of approx. 260degreesF (126.7 degrees C) has been observed in the field and history-matched in a wellbore production analysis and reservoir simulation. Our objective was to develop a conceptual geological model of the subsurface, simulate a natural-state reservoir, model production scenarios, and complete a technical feasibility analysis to accomplish this task. Through extensive modeling and the use of available proprietary and public data, it was possible simulate three scenarios that indicated minimal thermal decline over the duration of a simulated ten-year production and re-injection scheme.
Geothermal Reservoir Simulation Analysis in Support of Electricity Co-Production Feasibility Study at the Blackburn Oil Field, Nevada
Geothermal electricity co-production is a viable option for oil reservoirs producing large water cuts with elevated wellhead temperatures. Repurposing existing oil wells significantly reduces initial investment costs historically associated with geothermal resource utilization. The National Renewable Energy Laboratory (NREL), partnering with Gradient Geothermal, Inc. (formerly known as Transitional Energy) and Grant Canyon Oil and Gas, has been tasked to evaluate the feasibility of geothermal electricity co-production at the Blackburn Oil Field with Organic Rankine Cycle (ORC) generators. The Devonian steady-state reservoir has historically been producing high water cuts of 240 degrees F (115.6 degrees C) observed at the wellhead without documented pressure drawdown or thermal breakthrough. An estimated initial reservoir temperature of approx. 260 degrees F (126.7 degrees C) has been observed in the field and history-matched in a wellbore production analysis and reservoir simulation. Our objective was to develop a conceptual geological model of the subsurface, simulate a natural-state reservoir, model production scenarios, and complete a technical feasibility analysis to accomplish this task. Through extensive modeling and the use of available proprietary and public data, it was possible simulate three scenarios that indicated minimal thermal decline over the duration of a simulated ten-year production and re-injection scheme.