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At least 163 records · Page 9

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DOE OSTI2024

Understanding Environmental Barrier Coating Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. Here, the goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aeroturbine applications. To provide data for the lifetime model, laboratory testing used atmospheric plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air–steam environments and reaction kinetics were assessed from 700 °C to 1350 °C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

08 HYDROGEN↗

DOE OSTI2020

Off-design performance of molten salt-driven Rankine cycles and its impact on the optimal dispatch of concentrating solar power systems

This paper presents a model for improving off-design performance predictions for molten salt-driven Rankine power cycles, such as in concentrating solar power tower applications. The model predicts cycle off-design performance under various boundary conditions, including molten salt inlet temperature, mass flow rate, and ambient temperature. The model is validated using industry performance data and benchmarked with results from the literature. A complete concentrating solar power plant, inclusive of solar heliostat field and receiver, is then considered, by implementing the Rankine cycle off-design performance results into the National Renewable Energy Laboratory’s System Advisor Model software, which includes a tool that determines optimal power production schedules. The work improves upon the current System Advisor Model by updating off-design performance characteristics. A case study demonstrates the impact of cycle off-design behavior on annual performance for a stand-alone concentrating solar power system and a concentrating solar power-photovoltaic hybrid system. In addition, we demonstrate how cycle off-design performance influences optimal operator dispatch decisions and, thereby, overall system design and economics. We conclude that off-design cycle performance impacts “optimal” sub-system sizing, especially for a concentrating solar power-photovoltaic hybrid configuration in which concentrating solar power must dispatch in conjunction with photovoltaic generation.

14 SOLAR ENERGY↗

DOE OSTI2021

Impact on Cycle Efficiency of Small CHP Plants from Increasing Firing Temperature Enabled by AM of Turbine Blades

Combined Heat and Power (CHP) systems are gaining popularity because of their potential for high overall thermodynamic efficiency and increased need for distributed power generation. Most CHP systems include a gas turbine for electricity generation and a heat recovery steam generator (HRSG) for steam generation. The steam can be used to power a steam turbine for additional electricity generation or to drive rotating equipment, for space heating, for absorption chillers, etc. A CHP cycle configuration is often driven by the ‘principal’ utility for the facility that it services; steam or electricity. In either case, performance improvements in the gas turbine have the potential to increase the steam and power output from the cycle, which is a direct result of improvements in the gas turbine efficiency and power output. One possible opportunity to improve an existing gas turbine’s performance is to increase the firing temperature with improved turbine cooling and increased compression ratio.<br>In this study, the impact on CHP cycle performance from increasing the turbine firing temperature by 100 °C and improving the turbine blade cooling for a 6-MW scale gas turbine is estimated using an analytical cooled gas turbine model and a steam cycle model. A sensitivity analysis was performed to understand the impact of increasing the internal cooling effectiveness, thermal barrier coating performance and blade material upgrades on gas turbine and CHP cycle efficiency. The impacts of turbine blade cooling improvements were studied for three common CHP cycle configurations identified from the literature. Various definitions for CHP cycle efficiency from the literature are used in the comparisons. The results showed that a 100 °C increase in firing temperature can increase the gas turbine efficiency by 1 percentage point without improving cooling effectiveness and add 2 additional percentage points in efficiency by using advanced turbine blades with higher internal cooling efficiency. Studied engine upgrades showed potential for increasing the CHP cycle efficiency by 3 percentage points while increasing the steam generation rate by 8%.<br>

Uysal, Selcuk Can↗

NASA NTRS1972

Advanced spacecraft fuel cell systems

The development and characteristics of advanced spacecraft fuel cell systems are discussed. The system is designed to operate on low pressure, propulsion grade hydrogen and oxygen. The specific goals are 10,000 hours of operation with refurbishment, 20 pounds per kilowatt at a sustained power of 7 KW, and 21 KW peaking capability for durations of two hours. The system rejects waste heat to the spacecraft cooling system at power levels up to 7 KW. At higher powers, the system automatically transfers to open cycle operation with overboard steam venting.

Thaller, L. H.↗

NASA NTRS1979

Phase 1 of the First Small Power System Experiment (engineering Experiment No. 1). Volume 1: Executive Summary

The development of a modular solar thermal power system for application in the 1 to 10 MWe range is presented. The system is used in remote utility applications, small communities, rural areas, and for industrial uses. Investigations are performed on the energy storage requirements and type of energy storage, concentrator design and field optimization, energy transport, and power conversion subsystems. The system utilizes a Rankine cycle, an axial flow steam turbine for power conversion, and heat transfer sodium for collector fluid.

Holl, R. J.↗

NASA NTRS1979

Phase 1 of the First Small Power System Experiment (engineering Experiment No. 1). Volume 2: System Concept Selection

The development of a modular solar thermal power system for application in the 1 to 10 MWe range is presented. The system is used in remote utility applications, small communities, rural areas, and for industrial uses. Systems design and systems optimization studies are conducted which consider plant size, annual capacity factors, and startup time as variables. Investigations are performed on the energy storage requirements and type of energy storage, concentrator design and field optimization, energy transport, and power conversion subsystems. The system utilizes a Rankine cycle, an axial flow steam turbine for power conversion, and heat transfer sodium for collector fluid.

Holl, R. J.↗

NASA NTRS1978

Performance and economic risk evaluation of dispersed solar thermal power systems by Monte Carlo simulation

A preliminary comparative evaluation of dispersed solar thermal power plants utilizing advanced technologies available in 1985-2000 time frame is under way at JPL. The solar power plants of 50 KWe to 10 MWe size are equipped with two axis tracking parabolic dish concentrator systems operating at temperatures in excess of 1000 F. The energy conversion schemes under consideration include advanced steam, open and closed cycle gas turbines, stirling, and combined cycle. The energy storage systems include advanced batteries, liquid metal, and chemical. This paper outlines a simple methodology for a probabilistic assessment of such systems. Sources of uncertainty in the development of advanced systems are identified, and a computer Monte Carlo simulation is exercised to permit an analysis of the tradeoffs of the risk of failure versus the potential for large gains. Frequency distribution of energy cost for several alternatives are presented.

Manvi, R.↗

NASA NTRS1979

Survey of MHD plant applications

Open-cycle MHD is one of the major R&D efforts in the Department of Energy's program to meet the national goal of reducing U.S. dependence on oil through increased utilization of coal. MHD offers an effective way to use coal to produce electric power at low cost in a highly efficient and environmentally acceptable manner. Open-cycle MHD plants are categorized by the MHD combustor oxidizer, its temperature and the method of preheat. The paper discusses MHD baseline plant design, open-cycle MHD plant in the Energy Conversion Alternatives Study (ECAS), early commercial MHD plants, conceptual studies of the engineering test facility, retrofit (addition of an MHD topping cycle to an existing steam plant), and other potential applications and concepts. Emphasis is placed on a survey of both completed and ongoing studies to define both commercial and pilot plant design, cost, and performance.

Lynch, J. J.↗

NASA NTRS1978

Performance and economics of advanced energy conversion systems for coal and coal-derived fuels

The desire to establish an efficient Energy Conversion System to utilize the fossil fuel of the future - coal - has produced many candidate systems. A comparative technical/economic evaluation was performed on the seven most attractive advanced energy conversion systems. The evaluation maintains a cycle-to-cycle consistency in both performance and economic projections. The technical information base can be employed to make program decisions regarding the most attractive concept. A reference steam power plant was analyzed to the same detail and, under the same ground rules, was used as a comparison base. The power plants were all designed to utilize coal or coal-derived fuels and were targeted to meet an environmental standard. The systems evaluated were two advanced steam systems, a potassium topping cycle, a closed cycle helium system, two open cycle gas turbine combined cycles, and an open cycle MHD system.

Corman, J. C.↗

NASA NTRS1991

Mass budget for mining the moons of Mars

The mass budget is detailed for system architectures that use rocket fuels of propellants derived from Deimos and Phobos to transport 10000 ton payloads of exofuel (exoatmospheric fuels) or exomass (exoatmospheric mass) to earth orbits. A point design for the system architecture is used that includes a self-sustaining cycle, which requires no materials from earth, and an infrastructure, which must be emplaced to start the cycle. Both the use of steam rockets and the use of liquid oxygen and liquid hydrogen is examined. It is shown that a system delivering 10000 tons of payload to a highly elliptical earth orbit requires approximately 23000 tons of water for use by nuclear heated steam rockets to effect completely propulsive, round trip maneuvers. It is also shown that about 8000 tons will be available for sale at low earth orbit, each cycle, and that the number of cycles can number in the tens before critical components are replaced.

Zuppero, Anthony↗

NASA NTRS1977

Molten salt thermal energy storage for utility peaking loads

This paper considers the use of thermal energy storage (TES) in molten salts to increase the capacity of power plants. Five existing fossil and nuclear electric utility plants were selected as representative of current technology. A review of system load diagrams indicated that TES to meet loads over 95% of peak was a reasonable goal. Alternate TES heat exchanger locations were evaluated, showing that the stored energy should be used either for feedwater heating or to generate steam for an auxiliary power cycle. Specific salts for each concept are recommended. Design layouts were prepared for one plant, and it was shown that a TES tube/shell heat exchanger system could provide about 7% peaking capability at lower cost than adding steam generation capacity. Promising alternate heat exchanger concepts were also identified.

Ferrara, A.↗

NASA NTRS1978

Solar thermal power systems point-focusing distributed receiver /PFDR/ technology - A project description

The goal of the Project is to support the industrial development of PFDR technology that will provide favorable life-cycle costs per unit of electrical or thermal energy produced. The technology will be made available in the early 1980s for applications project experiments. PFDR systems utilize concentrator dishes to furnish energy to their own individual receivers and power conversion subsystems. Initial effort is with steam Rankine and gas Brayton cycles. Periodic assessments will be made to confirm or change the cycles initially selected. Subsystems will be designed, fabricated and tested together in modules as appropriate. This paper describes PFDR systems briefly, outlines the project goals and organization, discusses the plans and current status of the project, and lists the benefits of PFDR technology concepts.

Lucas, J. W.↗

DOE OSTI2024

Design and optimization of flexible decoupled high-temperature gas-cooled reactor plants with thermal energy storage

Advanced nuclear power plants are well-positioned for future zero-carbon grids, however, the need for flexible power generation will be required over the traditional emphasis on baseload generation for meeting historical demands. To achieve such flexibility, this work examines viable configurations for coupling nuclear energy production with thermal energy storage. Previous designs on nuclear-thermal energy storage configurations for advanced reactor designs, which utilized reactor steam as the heat source for charging the thermal energy storage, are restricted by the heat diversion ratio and efficiency losses, thus their impacts can be limited. In this context, this study proposes configurations for fully decoupling the nuclear reactor from the power cycle and positioning the storage as an intermediate loop, thereby achieving an unconstrained heat diversion ratio and improved efficiency. Compared with a standard high-temperature gas-cooled reactor’s power cycle, steady-state thermodynamic modeling and dispatch optimizations quantify the benefits of a steam reheat cycle within the fully decoupled thermal energy system to separate the plant cycle from the high-pressure primary side. These benefits are further detailed, compatible with required high-temperature and high-pressure conditions, through (1) open-source dynamic transient models that examine the impact of off-design operation on the systems, (2) the investigation of components design and costing and finally (3) sizing and dispatch optimization. The fully-decoupled design achieves a cycle efficiency of 43.1%, an enhancement over the vendor’s standard efficiency of 42.2% (Xe-100 design). Here, the proposed design offers strengthened physical barriers from the nuclear island as well as superior operational flexibility and power boosting. Dispatch optimization and market analysis reveal that thermal energy storage size is highly dependent on the peak patterns of electricity prices and the minimum generation level constraint imposed on the balance of plant. Evaluation of off-design operation demonstrates that the full decoupling design with the suggested fail-safe control mechanisms ensures a minimal impact on reactor parameters, even during rapid power ramping.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1976

Liquid-metal magnetohydrodynamic system evaluation

The present study emphasizes a direct coal-fired design using a bubbly two-component flow of sodium and argon in the MHD generator and a Rankine steam-bottoming plant. Two basic cycles were studied, corresponding to argon temperatures of 922 and 1089 K at the duct inlet. The MHD duct system consisted of multiple ducts arranged in clusters and separated by iron magnet pole pieces. The ducts, each with an output of about 100 MW, were parallel to the flow, but were connected in series electrically to provide a higher MHD voltage. With channel efficiencies of 80%, a pump efficiency of 90%, and a 45% efficient steam-bottoming plant, the overall efficiency of the 1089 K liquid-metal MHD power plant was 43%.

Holman, R. R.↗

DOE OSTI2021

sCO 2 Brayton Energy Conversion Customer Discovery

All energy production systems need efficient energy conversion systems. Current Rankine cycles use water to generate steam at temperatures where efficiency is limited to around 40%. As existing fossil and nuclear power plants are decommissioned due to end of effective life and/or societies’ desire for cleaner generation options, more efficient energy conversion is needed to keep up with increasing electricity demands. Modern energy generation technologies, such as advanced nuclear reactors and concentrated solar, coupled to high efficiency sCO 2 conversion systems provide a solution to efficient, clean energy systems. Leading R&D communities worldwide agree that the successful development of sCO 2 Brayton power cycle technology will eventually bring about large-scale changes to existing multi-billion-dollar global markets and enable power applications not currently possible or economically justifiable. However, all new technologies face challenges in the path to commercialization and the electricity sector is distinctively risk averse. The Sandia sCO 2 Brayton team needs to better understand what the electricity sector needs in terms of new technology risk mitigation, generation efficiency, reliability improvements above current technology, and cost requirements which would make new technology adoption worthwhile. Relying on the R&D community consensus that a sCO 2 power cycle will increase the revenue of the electrical industry, without addressing the electrical industry’s concerns, significantly decreases the potential for adoption at commercial scale. With a clear understanding of the market perspectives on technology adoption, including military, private sector, and utilities customers, the Sandia Brayton Team can resolve industry concerns for smoother development and faster transition to commercialization. An extensive customer discovery process, similar to that executed through the NSF’s I-Corp program, is necessary in order to understand the pain points of the market and articulate the value proposition of Brayton systems in terms that engage decision makers and facilitate commercialization of the technology.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Understanding EBC Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. The goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aero-turbine applications. To provide data for the lifetime model, laboratory testing used plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air-steam environments and reaction kinetics were assessed from 700°-1350°C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

Ridley, Mackenzie↗

DOE OSTI2021

Chapter 2: Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines

The global geothermal power market has shown significant growth since the last decade and is expected to reach a total installed capacity of 18.4 gigawatts electric (GWe) by the end of 2021 (GEA, 2016). The global geothermal power plant turbine market is dominated by a small number of manufacturers. Between 2005 and 2015, 82% of the geothermal steam turbines were manufactured in Japan, and 74% of the geothermal binary cycle turboexpanders were manufactured in Israel. During this period, the United States played an important role in the global trade flow of fully assembled turbine units and turbine parts, with a high volume of imports and exports. Another significant growth area was in Italian turbine/turboexpander manufacturers, who have increased their market share in the last couple of years. One other important change in the manufacturing market was in Turkey, where the bonus on feed-in-tariff (FIT) for domestic hardware components boosted the national manufacturing sector between 2010 and 2020. When planning geothermal power projects, developers customize their power plant size to fit the available geothermal resource capacity. The turbine is designed and sized to optimize the efficiency and utilization of resource and revenue production. The rest of the power plant components such as heat exchangers (HX), water-cooled cooling towers (WCCT), or air-cooled condensers (ACC) are then chosen to complement the turbine size and design. These one-off manufacturing custom design turbines have relatively higher manufacturing set-up costs, longer lead times, and higher capital costs than the standard design turbines manufactured in larger volumes. However, turbines produced in standard increments and in larger manufacturing volumes could result in lower costs per turbine, but potentially lower efficiency. Based on pipeline projects and resource assessments, there is significant potential value in creating standard turbine sizes that could offer an economic advantage, as is done for modular microturbines.

40 EE - Geothermal Technologies Office (EE-4G)↗

NASA NTRS2017

Flexural Fatigue Behavior of an EBC CMC Composite System In Air and Steam at High Temperature

Both coated and uncoated SiCSiC ceramic matrix composite (CMC) samples were tested in flexure under sustained peak low cycle fatigue (SPLCF) conditions in air or steam at elevated temperatures. The SiCSiC composites were reinforced with 2-D plies of boron nitride coated Hi-Nicalon Type-S SiC fibers which were woven as 5 harness satin (5HS) cloth. The composites were densified by chemical vapor infiltration (CVI) followed by slurry melt infiltration (SMI). A multilayer barium strontium aluminosilicate (BSAS) coating was applied to the samples by a plasma spray method. Fatigue loading limits were determined from monotonic flexure tests at room temperature and 1200oC. Stress levels under the proportional limit of the composite material were selected for the SPLCF tests. After cyclic testing, the composites were evaluated to determine crack propagation and failure modes in the coated and uncoated composites. Microstructural examination was used to identify coating degradation and failure modes of the EBCCMC system.

Steam testing↗