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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

NEAR CRITICAL POINT TESTING AND PERFORMANCE RESULTS OF A SCO2 COMPRESSOR FOR A 10MWE BRAYTON CYCLE

Development and commercial acceptance of sCO2 Brayton cycles for power generation applications are growing rapidly as they offer performance advantages over other cycles. To maximize the cycle performance, the compressors are designed to operate near the critical point of the working fluid. At the critical point the fluid properties change rapidly with variations in inlet conditions. This makes it challenging to both accurately predict the performance and guarantee the operability of the compressor, as the behavior is affected by these slight variations in inlet conditions. A full scale 1st stage main compressor for a 10MWe-Class recompression Brayton cycle was built and tested to validate performance and operability in this unique operating range. The compressor was tested in a laboratory environment with additional instrumentation, beyond what is required by PTC-10, to minimize the uncertainty in the measured performance. Complete constant speed characteristics were collected at multiple supercritical points, operating at constant inlet conditions for each speed line covering a range of compressor inlet densities from 400 to 600 kg/m3. Variations in the compressor stage efficiency and choke margin were observed, and the overall operability and stability of the compressor in response to changes in operating condition were also monitored. The compressor was shown to have excellent performance that closely matched the original design prediction. The performance at various inlet conditions showed minimal change in isentropic head coefficient at the design flow, but did show some variation in efficiency and choke margin across the map. These changes in performance were observed to be minimal, and did not affect the stable operation of the compressor. The results demonstrate that a commercial scale sCO2 compressor can operate near the critical point and achieve the high levels of performance and stability required for power generation applications.

pelton, rob↗
DOE OSTI2025

Design Assessment of Brayton Cycles for Combined Heat and Power from Nuclear Power Plants

Brayton cycles (BCs) are gaining renewed interest for use in high-temperature nuclear reactors for power production. This study explores the potential of nuclear Brayton systems in industrial combined heat and power (CHP) production. After a review of the historical deployment and technical development of BC systems for nuclear and cogeneration applications several BCs in CHP configurations are assessed when applied to representative high-temperature reactor types. The analysis emphasizes process heat delivery options, electrical efficiency, and component performance for the case of a direct cycle—Helium BC in a high temperature gas reactor, and an open-air Brayton cycle with a high temperature gas reactor. The results highlight thermodynamic trade-offs in cogeneration operation, particularly in recuperated configurations, and compare BC-based CHP with conventional Rankine cycle (RC) performance. Key findings suggest Helium BCs offer viable CHP performance primarily at lower process heat temperatures, with open air cycles being less efficient. The work also demonstrates trade-off between CHP performance and power production performance with a detailed comparison to where steam RC has better performance. The work is designed to be used as a reference work when cogeneration is proposed from high temperature reactors alongside the use of BCs.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Integrated Thermal Energy Storage and Brayton Cycle Equipment Demonstration (Integrated TESTBED) Project Design Basis

The Integrated Thermal Energy Storage and Brayton cycle Equipment Demonstration (Integrated TESTBED) project seeks to retire commercial-scale risks associated with the design, integration,and operation of a supercritical carbon dioxide (sCO2) power cycle and concentrating solar power (CSP) thermal energy storage (TES) system. This requires an understanding of commercial-scale collector system transient impacts on the TES system, the dynamics of heat exchange from theTES to the power cycle, and the control and operation of the power cycle to accommodate various dispatch strategies. In order to retire these risks, Heliogen has proposed to construct a 5 MWe CSP demonstration facility based on directly heated particle and sCO2 technology. The receivers, primary heat exchanger, and power cycle will be deployed at a full commercial scale based on Heliogen’s modular plant architecture to ensure actual system integration risks are validated during design, construction, and operation. This work summarizes the design basis for the Integrated TESTBED project demonstration facility including a design target for capacity factor to support test operations, hours of storage, particle silo arrangement, centrifugal article receivers, a diffusion bonded particle-sCO2 heat exchanger, and a 5 MWe (net) integrally geared sCO2 recompression Brayton cycle.

14 SOLAR ENERGY↗
DOE OSTI2021

Application of Refractory High-Entropy Alloys for Higher-Reliability and Higher-Efficiency Brayton Cycles and Advanced Nuclear Reactors

An exceptional set of newly-discovered advanced superalloys known as refractory high-entropy alloys (RHEAs) can provide near-term solutions for wear, erosion, corrosion, high-temperature strength, creep, and radiation issues associated with supercritical carbon dioxide (sCO2) Brayton Cycles and advanced nuclear reactors. In particular, these superalloys can significantly extend their durability, reliability, and thermal efficiency, thereby making them more cost-competitive, safer, and reliable. For this project, it was endeavored to manufacture and test certain RHEAs, to solve technical issues impacting the Brayton Cycle and advanced nuclear reactors. This was achieved by leveraging Sandia’s patents, technical advances, and previous experience working with RHEAs. Herein, three RHEA manufacturing methods were applied: laser engineered net shaping, spark plasma sintering, and spray coating. Two promising RHEAs were selected, HfNbTaZr and MoNbTaVW. To demonstrate their performance, erosion, structural, radiation, and hightemperature experiments were conducted on the RHEAs, stainless steel (SS) 316 L, SS 1020, and Inconel 718 test coupons, as well as bench-top components. The experimental data is presented, analyzed, and confirms the superior performance of the HfNbTaZr and MoNbTaVW RHEAs vs. SS 316 L, SS 1020, and Inconel 718. In addition, to gain more insights for larger-scale RHEA applications, the erosion and structural capabilities for the two RHEAs were simulated and compared with the experimental data. The experimental data confirm the superior performance of the HfNbTaZr and MoNbTaVW RHEAs vs. SS and Inconel. Most importantly, the erosion and the coating material experimental data show that erosion in sCO2 Brayton Cycles can be eliminated completely if RHEAs are used. The experimental suite and validations confirm that HfNbTaZr is suitable for harsh environments that do not include nuclear radiation, while MoNbTaVW is suitable for harsh environments that include radiation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Dynamic Model of a supercritical CO2 10MW Recompression Closed Brayton Cycle

This model of the 10MW recompression closed Brayton cycle (RCBC) was developed in conjunction with the DOE’s Supercritical Transformational Electric Power (STEP) project. A high-fidelity dynamic model was used extensively to study the dynamic characteristics of the cycle and develop the process control architecture and strategies for start-up and shutdown procedures. This version of the model has been simplified from the original version to be more accessible for a variety of applications and research. The controllers developed for the original model have been maintained for this version and tuned to give a similar performance to the original model. This model can be used to perform similar studies as those performed in Liese et al (2020). The overall cycle performance will not be identical but will perform similarly.

Controls,Power Cycles,Process Systems Engineering,↗
DOE OSTI2022

PDC Modifications for Analysis of Gas-Cooled Reactors with Direct Helium Brayton Cycle

Capabilities of the Plant Dynamics Code (PDC) have been extended to allow steady-state and transient simulation of graphite-cooled reactors with direct helium Brayton cycle. On the cycle side, the most significant code modification is the addition of helium properties, in the format required by the code’s equations. Since the code was already formulated to handle more complex real gas properties, adding helium as working fluid that behaves like ideal gas was fairly straightforward. A reactor module was added to PDC to simulate a reactor cooled by the working fluid of the Brayton cycle. Two options are supported: channel type, typical for graphite gas-cooled reactors, and pin type, typical for light-water and liquid metal-cooled reactors. The reactor module is an extension of the electrical heater model and simulates heat deposition in the fuel and transfer of this heat from the fuel to the coolant through the matrix and tube materials. The new reactor module becomes the third option in PDC for modeling heat addition to the cycle, besides previously modeled heat addition heat exchanger and electrical heater. In addition to those changes, other minor code modifications and improvements were introduced during the work of expanding PDC to modeling of gas-cooled reactors. These modifications are summarized in the last chapter of this report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Closed-loop brayton cycle system with turbine blade cooling

A closed-loop Brayton cycle system utilizes supercritical carbon dioxide as the working fluid for the system to achieve higher efficiencies than can be achieved with traditional open-loop gas turbine engines. A bleed channel is used to direct a flow of cooling fluid to cool the turbine blades during operation of the system, preventing damage to the turbine blades during operation of the system. The bleed channel includes a bleed inlet fluidly coupled between a first recuperator and a second recuperator and a bleed outlet fluidly coupled to the turbine blades. The bleed channel is configured to direct the flow of cooling fluid to the turbine blades at a desired temperature and pressure.

Taylor, Stephen H.↗
DOE OSTI2025

A Review of the Research and Development of Brayton Cycle Technology in Nuclear Power Applications with a Focus on Compressor Technology

This study reviews the integration of Brayton Cycle (BC) systems in nuclear power generation, emphasizing their potential to enhance thermal efficiency and operational flexibility over traditional Rankine Cycle (RC) systems. Key working fluids, such as helium (He), supercritical carbon dioxide (sCO 2 ), nitrogen (N 2 ), and air, are evaluated for their performance, efficiency, and compatibility with nuclear systems. He is recognized for its high thermal conductivity and inertness at elevated temperatures, while sCO 2 demonstrates advantages in compactness and efficiency in midrange temperatures. This article also highlights the importance of compressor designs in optimizing BC performance and reviews, available compressor technologies. Axial and centrifugal compressor designs enable efficient gas compression while managing the thermal and mechanical stresses associated with high-pressure operations in nuclear systems. Combined with variable geometry components and advanced materials, these technologies address the challenges posed by varying load conditions. Despite the promising features of BC systems, several challenges persist, including high leakage rates and material degradation under extreme conditions, which necessitate robust sealing technologies and thorough testing. The insights gained from operational experiences at facilities, such as the Oberhausen II plant and the High-Temperature He Test Facility (HHV), underscore the complexities involved in designing high-temperature gas turbines for nuclear applications. This review concludes that as the nuclear industry evolves, BC systems hold significant promise for contributing to a sustainable energy future, particularly in the context of small modular reactors (SMRs) and microreactors. Further exploration of combined cycle configurations that combine BCs with RCs may enhance overall efficiency and flexibility in power generation.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Pumped-Thermal Electricity Storage Based on Brayton Cycles

Pumped-thermal electricity storage (PTES) based on a reversible (Joule-)Brayton cycle is a promising grid-scale energy storage technology, whose working principle is to store electricity in the form of high-grade thermal energy. This chapter provides an overview of the inner workings, operating principle and current development status of the many PTES variants, as proposed to date in the scientific literature or by manufacturers. The potential and competitiveness of the various candidate designs is quantified by - and discussed thanks to the definition of - specific techno-economic indicators. Investment cost and thermodynamic performance estimates are reported and used to assess the value of this technology as a potential large-scale, long-duration and long-lifetime energy storage option with unique sector-coupling features and low geographical constraints.

electricity storage↗
DOE OSTI2022

Silicon Carbide Multilayer Piping for High Temperature sCO 2 Brayton Cycle

Efficiencies of greater than 50% in supercritical carbon dioxide (sCO 2 ) Brayton power cycle systems can be achieved only at turbine inlet temperatures of above 700°C. In support of the push to higher temperatures, a finite element model was developed by Materials Research & Design, Inc. (MR&D) with support from Ceramic Tubular Products, LLC. (CTP) to guide the refinement of CTP’s high temperature ceramic multilayer piping. The multilayer technology combines the advantages of a monolithic silicon carbide (SiC) tube and a SiOC f /SiOC ceramic matrix composite (CMC), the result of which is a material with high-temperature strength and stability, high mechanical and thermal shock resistance, and high corrosion resistance. In addition to fabricating test specimens to refine the finite element model, long-duration, high temperature CO 2 exposure tests were performed by Sandia National Laboratories (SNL) on two varieties of inner monolithic SiC.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

A Simple Program to Estimate the Fast Modular Reactor Steady-State Closed Brayton Cycle Operating Parameters

The Fast Modular Reactor (FMR) is a gas-cooled fast reactor (GFR) that produces a net electricity output of 50 MW with helium-driven closed Brayton cycle. The power plant includes reactor system and power conversion unit (PCU). The reactor system produces fission energy that is transferred by helium flow. The PCU consists of a turbine, two compressors, and three heat exchanges. More specifically, the recuperator is a counter-flow energy recovery heat exchanger. The precooler and intercooler are the heat sinks. To analyze and understand the sensitivity of plant performance to the design parameters, a numerical program was written to calculate the plant operating parameters represented by the helium temperature, pressure, mass flow, and the heat sink temperatures. The program was developed for the steady-state operating condition. etc.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Control methods for mitigating flow oscillations in a supercritical CO 2 recompression closed Brayton cycle

A dynamic model of a 10 MWe supercritical CO 2 (sCO 2 ) recompression closed Brayton power generation cycle is used to investigate control methods for mitigating oscillations in flow conditions and power demand load, especially as the load ramp rate is increased and the load setpoint is more closely tracked. The focus is on control of the main compressor inlet temperature (MCIT) since oscillations are prompted by the strong nonlinearities in sCO 2 fluid properties near the critical point and by changes in system inventory for efficient load management. In this study, the oscillatory behavior during load ramping is first shown and then two potential control solutions for substantially reducing oscillations are given: 1) the use of the main compressor inlet guide vanes (IGV) and 2) bypassing a portion of the sCO 2 around the cooler to maintain the MCIT. These control methods reduce the effect of cycle feedback from interactions between the MCIT and load. When implementing either control method, a load setpoint ramp of 7.5%/min was maintainable while achieving closer load setpoint tracking with limited oscillations. Finally, the impact of sensor noise on the control was examined since derivative action was used in the IGV and cooler sCO 2 bypass control. Finally, while some effect was evident, signal noise was not problematic to the control.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Development of Gas Bearings for Supercritical CO 2 Recompression Brayton Cycle (Final Technical Report)

During the period of performance from March 1 st , 2022 through December 31st, 2023 the University of Nevada, Las Vegas (UNLV) worked with New Way Air Bearings (NWAB) to design, fabricate, install, and test a set of non-contact Externally Pressurized Porous (EPP) gas bearings for a solar driven supercritical CO 2 Brayton system. This report summarizes the work performed for the entire project.

14 SOLAR ENERGY↗
DOE OSTI2021

Additive Manufacturing of Corrosion Resistant UHTC Materials for Chloride Salt-to-sCO2 Brayton Cycle Heat Exchangers

The objectives of the project include: (1) screen high-purity, high density ultra-high-temperature ceramics (UHTCs) for chloride salt corrosion resistance, (2) develop binder-jet additive manufacturing and sintering for ZrB 2 -MoSi 2 blends using literature and experiments to demonstrate feasibility, and (3) evaluate chloride salt corrosion resistance of additively manufactured ZrB 2 -MoSi 2 . These initial objectives support the development of a durable and reliable ultra-compact high-efficiency salt-to-sCO 2 heat exchanger for closed-loop Brayton power cycles based on corrosion resistant, high-strength, thermally conductive UHTC materials and novel designs enabled by additive manufacturing. The UHTC materials are also abrasion resistant so that they could be applicable to all three thermal carrier media pathways identified in the CSP Gen3 Roadmap.

36 MATERIALS SCIENCE↗