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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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14 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Design and Analysis of a 25 MWe Supercritical CO2 Turbo Machine

This paper presents the design and analysis of a turbo machine operating with supercritical carbon dioxide (sCO2) in a 25 MWe Recompression Brayton Cycle (RCBC). The work was performed under US Department of Energy (DoE) program DE-EE-0010318. The design process involves the aerodynamic design of the compressor and turbine, including the initial layout of flowpaths and stage configurations to achieve high efficiency and performance. Additionally, a comprehensive rotodynamic analysis is performed to ensure the stability and reliability of the system. Conceptual designs for a high-speed motor and synchronous generator that match turbomachinery requirements are also developed from first principles.

42 ENGINEERING↗
DOE OSTI2023

AN OVERVIEW OF THE DESIGN AND PERFORMANCE TESTING OF A 275 BAR INTEGRALLY GEARED SUPERCRITICAL CO2 COMPRESSOR FOR POWER GENERATION

An integrally geared compressor-expander (compander) for supercritical CO2 (sCO2) was developed to convert thermal energy to electricity. With operating pressures of 275 bar, this turbomachine represents the state of the art in integrally geared machine architecture, hitting compressor inlet densities of 600 kg/m3 and discharge pressures of 275 bar. The product development was funded by the Department of Energy’s Energy Efficiency and Renewable Energy Office under EE0007114 to advance the state of the art in concentrated solar power applications; however, the technology itself is agnostic to heat source, and is predicted to achieve a thermal-to-electric conversion efficiency of 50% for any indirect heat source capable of providing turbine inlet temperatures of 700°C or greater. While the program encompassed the design and testing for the compressor and turbine elements, this paper will focus on the compressor design and operation. The paper will begin with an introduction to the cycle design and analysis of an indirectly heated integrally geared sCO2 compander, a discussion of the mechanical and aerodynamic design of the compressor that is a two stage radial compressor operating subcritically at 27,512 rpm, and will then proceed to describe the test facility and measured data to characterize the performance and robustness of the machine. The paper will conclude with a discussion on lessons learned throughout the course of commissioning and testing. Practical aspects of testing a compressor operating near the dome including complications relating to obtaining an accurate compressor flow map, efficiency calculations, flow unsteadiness, and associated measurement uncertainties will be discussed.

wilkes, jason↗
DOE OSTI2022

NUMERICAL PREDICTIONS OF MEAN PERFORMANCE AND DYNAMIC BEHAVIOR OF A 10 MWe SCO2 COMPRESSOR WITH TEST DATA VALIDATION

High-fidelity aerodynamic analysis has been demonstrated for mean performance and unsteady dynamics in a sCO2 compressor designed by Hanwha Power Systems Americas for a 10 MWe Concentrating Solar Power plant. Simulations were performed with CRUNCH CFD® software tool that was matured to accurately model near critical real fluid effects in sCO2. Pre-test predictions for mean performance were validated with test data collected later. Performance predictions were accurate and captured sensitivity of the efficiency to inlet temperature of CO2 as well as steep drop-off at high flow rates due to condensation in the inlet throat. Detailed analysis was performed to understand the source of these performance losses at near critical conditions. Unsteady dynamic effects in the compressor at off-design conditions were also identified and quantified. In particular a system wide “condensation surge” condition was detected at high flow coefficients that results in large amplitude pulsations with accompanying mass flow fluctuations at low frequencies and has potential to cause damage in closed loop systems.

hosangadi, ashvin↗
DOE OSTI2020

High-Temperature Heat Transfer Fluid Circulator for Concentrating Solar Power Systems

A high temperature Heat Transfer Fluid circulator compressor with wide turn down ratio aerodynamic performance was designed, fabricated and tested for application with high pressure super Critical CO2 fluid capable of temperatures and pressures to >750°C and 25 MPa respectively. The modular system decoupled the drive motor system from an independent compressor shaft to provide thermal isolation between the high temperature compressor shaft and the lower temperature capable motor elements. While the thermal management approach appears to be viable there are potential losses in the secondary cooling flows that need to be taken into account and fine-tuned during operation in order to achieve desired overall system efficiencies. The system was also shown to be viable and dynamically stable throughout the entire operating speed range, thereby validating the overall system configuration and structural design approach used. Finally, while it was not possible to achieve specific PTC-10 test points, the compressor performance tests provide sufficient data to indicate that the compressor has the ability to achieve the required performance in practice. The two key factors affecting compressor design and cost are the maximum expected temperature and pressure. The maximum allowable temperatures for current state-of-the-art (SOA) motor driven compressor technology is limited to of approximately 150-200°C, but inlet temperatures >750 °C may be encountered. While the optimal efficiency of compression is in the transcritical region, some concepts require inlet pressures to 225 bar.

14 SOLAR ENERGY↗
DOE OSTI2021

High-Temperature Heat Transfer Fluid Circulator for Concentrating Solar Power Systems How Mohawk and Velo3Dare Printing the Future of Energy

A high temperature Heat Transfer Fluid circulator compressor with wide turn down ratio aerodynamic performance was designed, fabricated and tested for application with high pressure super Critical CO2 fluid capable of temperatures and pressures to >750°C and 25 MPa respectively. The modular system decoupled the drive motor system from an independent compressor shaft to provide thermal isolation between the high temperature compressor shaft and the lower temperature capable motor elements. While the thermal management approach appears to be viable there are potential losses in the secondary cooling flows that need to be taken into account and fine-tuned during operation in order to achieve desired overall system efficiencies. The system was also shown to be viable and dynamically stable throughout the entire operating speed range, thereby validating the overall system configuration and structural design approach used. Finally, while it was not possible to achieve specific PTC-10 test points, the compressor performance tests provide sufficient data to indicate that the compressor has the ability to achieve the required performance in practice. The two key factors affecting compressor design and cost are the maximum expected temperature and pressure. The maximum allowable temperatures for current state-of-the-art (SOA) motor driven compressor technology is limited to of approximately 150-200°C, but inlet temperatures >750 °C may be encountered. While the optimal efficiency of compression is in the transcritical region, some concepts require inlet pressures to 225 bar.

14 SOLAR ENERGY↗
DOE OSTI2023

Detailed Simulations of a Three-Stage Supercritical Carbon Dioxide Axial Compressor with a Focus on the Shrouded Stator Cavities Flow

This paper describes the findings of detailed simulations performed to investigate the impact of seal teeth cavity leakage flow on the aerodynamic and thermal performance of a three-stage supercritical CO 2 axial compressor. The study compares a shrouded stator configuration (with cavities) to a cantilevered stator configuration (without cavities) to highlight their differences. High-fidelity computational fluid dynamics simulations were performed using non-linear harmonic (NLH) and mixing plane assumptions, considering various possible rotor/stator interface configurations for mixing plane calculations. The key performance parameters for each case were compared, and the best-performing configuration selected for further analysis. The individual stage performance parameters are also examined and compared between the cantilevered and shrouded configurations. It was observed that in the shrouded case, the leakage flow enters the cavity downstream of the stator trailing edge and gets entrained into the primary flow upstream of the stator, leading to boundary layer changes at the hub and degradation of stator and downstream rotor performance. Vortical flow structures were also observed in the stator wells, which tended to change the flow angles around the region, thereby affecting mixing and velocity distribution, resulting in a slight deterioration of compressor performance. Additionally, the study examines windage heating due to shear work from rotating walls, including the seal teeth surface. The amount of shear work done on the leakage flow and the corresponding rise in fluid temperature were quantified, tabulated, and further compared with a simple analytical model, showing good agreement between them and, hence, validating the numerical approach used.

42 ENGINEERING↗
DOE OSTI2022

LEAKAGE CHARACTERISTICS OF A STEPPED BALANCE PISTON LABYRINTH SEAL IN SUPERCRITICAL CO2

In an integrally geared compressor, there is a net thrust load on the pinion shaft from gear loads and aerodynamic forces. The net thrust on the pinion is resolved with either a thrust bearing or a thrust collar (rider ring). As the pressure increases, this increases the aerodynamic force proportionally. In highpressure systems this can overwhelm the thrust bearing or thrust collar if thrust is mismanaged. In a recent test program for an sCO2 integrally geared compander (compressor/turbine), a balance piston was created on the opposite end of the turbine to provide an equalizing thrust; while this is not novel, the balance piston provided a test apparatus for measuring the leakage on a 20 tooth stepped labyrinth seal operating at pressures in excess of 250 bar (3600 psi). The stepped balance piston seal is a 20 tooth tooth-onrotor balance piston seal. This type of seal was selected since it was predicted to have substantially less leakage than a comparably sized straight through labyrinth seal. Comparisons between the two designs will be made, showing that the leakage of the stepped balance piston seal is considerably lower. The tooth clearance on the seal was selected to be 30 mils radial. While this seems large, a stack-up tolerance assessment showed that this magnitude of clearance was appropriate to prevent rotor stator contact. During the testing campaign, data was recorded showing the leakage across this stepped balance piston seal at pressures in excess of 250 bar (3600 psi) with a pressure ratio of 2. This leakage data was measured, and will be compared to leakage data predicted with CFD. Two measurement methods are presented for the stepped balance piston seal: an orifice plate and valve. The predicted seal leakage from a straight through seal was four times that of the predicted stepped labyrinth seal. The measured flow from the stepped seal was on the same order as the CFD prediction and offered adequate rotordynamic performance

wilkes, jason↗
DOE OSTI2022

Attributes of Bi-Directional Turbomachinery for Pumped Thermal Energy Storage

Abstract In this paper, we (i) present a methodology for determining the aerodynamic performance of bi-directional turbomachines for pumped thermal energy storage, i.e., turbomachines designed to operate as a compressor in one direction, and then as a turbine in the opposite direction, (ii) carry out performance computations for such turbomachines, and (iii) propose principles for conceptual design of these devices. Focus is placed on using the energy storage cycle not only to identify the novel requirements placed on bi-directional turbomachines but also to estimate the effect of these requirements on the efficiency of the energy storage process. In particular, the difference between aerodynamic loading in forward and in backward operation causes the blading to work at incidences leading to the performance below maximum efficiency, resulting in a lower round-trip efficiency. The description of the design principles includes determination of the number of stages, definition of nondimensional parameters for blading selection, and optimization of two-dimensional blading for bi-directional operation. The assessment of stage count shows the relationship between relative Mach number, pressure ratio, and round-trip efficiency. The nondimensional parameters are assessed through a bi-directional analogue to existing “Smith charts,” for the efficiency of single-direction turbomachines, as a function of camber and stagger. The blade shape evaluation and optimization show how the blade profile can be modified to address the requirements of a bi-directional turbomachine, enabling an increase in round-trip efficiency of two percentage points compared to a baseline double circular arc configuration.

Engineering↗
DOE OSTI2022

OPEN2018 (continuation of GENSETS effort)

This project has demonstrated the key components and engineering principles to support a residential scale (1 to 2 kWe) recuperated Brayton cycle generator based upon a screw compressor and screw expander. This technical work is a continuation of the previously awarded ‘GENSETS’ program. The product goal has been to achieve a 40% fuel-to-electric LHV efficiency, an 80% overall CHP efficiency, emissions qualified to the California Air Resources Board standards, and at noise levels of 55 dB or less at 1 meter. Further, the product must operate with 8,000 hour service intervals and achieve a mean-time to overhaul of 90,000 hours. Lastly, and possibly most importantly, the product must meet demanding cost targets, exhibiting a factory cost well below $1,500/kWe. After extensive aerodynamic studies under the ‘GENSETS’ program, Brayton concluded that miniature turbomachinery could not achieve an efficiency consistent with the product’s system performance goal. Given compressor and turbine efficiency targets in the range of 78 to 81%, Brayton turned to the rotary screw machines. While the justification for a screw compressor over a conventional centrifugal compressor is well supported by industry experience, the high temperature expander represented the core technology advancement. To meet the extremely high efficiency goals, an all-ceramic rotary screw expander hot section was developed and has now been tested in the laboratory. This first-of-its-kind ceramic screw expander prototype was able to demonstrate aerodynamic efficiency in line with predictions. The test article was successfully run to full stress conditions so has also validated the mechanical design of such a unit. This has opened new avenues for the commercialization of high efficiency, small scale power generation. Interest in the technology has sparked several requests for alternate uses, an invitation to present at a screw machine conference, and continued interest from parties looking to develop a product in the spirit of the original ‘GENSETS’ goals.

42 ENGINEERING↗
DOE OSTI2024

MULTI-LEADER: MULTI-source LEarning-Accelerated Design of high-Efficiency multi-stage compRessor (Final Technical Report)

The objective of MULTI-LEADER is to cut design costs by 80% while generating more energy-efficient designs of multi-stage compressors by developing and implementing novel machine learning (ML) techniques, which enable faster and fewer design iterations, improved solver performance, and concurrent multi-disciplinary design. Current industrial practices for the design of multi-stage compressors involve simulation-based design optimization with successive levels of model fidelity, iteratively evaluated between distinct disciplines, one stage at a time to tackle the high dimensional design variations. This project addresses these key design challenges: (1) concurrent optimization of multiple stages under many non-linear constraints; (2) multitude of evaluation of high-fidelity and expensive solvers and their gradients during optimization convergence in high-dimensional design; (3) multi-disciplinary design to maximize aerodynamic performance while guaranteeing structural integrity and additive manufacturability; (4) utilization of multiple fidelity of solvers with disparate parameterization and modeling assumptions. MULTI-LEADER achieved more than 5x speed up in detailed design of more energy-efficient compressors via these machine learning (ML) innovations: (i) rapid design surrogates by multi-source learning from diverse fidelities across multiple disciplines, (ii) physics-constrained data-augmented modeling for improved empiricism, (iii) generative manifold embedding for high dimensional concurrent design without gradient information; (iv) budget-constrained fidelity-adaptive sampling towards fewer design iterations.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Passive Ultrasonic Deterrents to Reduce Bat Mortality in Wind Farms (Final Report)

The overall objective of this project was to develop active and passive ultrasonic deterrent concepts to mitigate bat mortality at wind turbines. The research was supported by the US Department of Energy under the contract DE-EE0008731. Novel ultrasonic bat deterrents are investigated in this study. The deterrents are based on the idea of aerodynamic whistles wherein flow-acoustic resonance is used to produce high-amplitude tonal sound at desired ultrasonic frequencies. The deterrents can be grouped into active and passive. The active deterrents/whistles are driven by pressurized air supplied by an external source (e.g., an air compressor). The passive deterrents/whistles are designed to be mounted on wind turbine blades and are “powered” by the energy in the air moving past the rotor blades. Multiple active and passive deterrent ideas are proposed and investigated numerically and experimentally. The computational analysis involves solving the compressible unsteady Reynolds-averaged Navier-Stokes (URANS) equations and coupling the near-field aerodynamic solution with an integral method based on the Ffowcs Williams-Hawkings acoustic analogy to predict ultrasound in the farfield. Experiments are performed in the anechoic chamber at ISU (for the active whistles) and in the Stability wind tunnel at Virginia Tech (for the passive whistles).

17 WIND ENERGY↗
DOE OSTI2026

Scaling considerations for supercritical carbon dioxide cycles including turbomachinery loss models

A modeling framework for the supercritical carbon dioxide recompressed closed Brayton cycle was developed. Unlike typical models, this effort incorporated generalized empirical turbomachinery loss models. Aerodynamic, windage, and leakage losses were considered in order to address the limitations of conventional constant-efficiency turbomachinery assumptions without relying on machine-specific or computationally expensive simulations. The model enables system-level exploration of optimal cycle design across a range of power scales, including smaller scales that are relevant to microreactors and extraterrestrial power applications. Parametric studies and multi-objective optimizations are used to evaluate the trade-offs between thermal efficiency and system compactness based on an analytical heat exchanger scaling model, yielding Pareto-optimal fronts across a range of operating pressures. Results reveal that at small power scales, the Pareto-optimal compressor inlet pressure becomes subcritical due to the increasing influence of density-dependent turbomachinery losses. Here, the relative contributions of each loss mechanism are quantified, and design recommendations are provided for key parameters such as recompression split ratio and generator cavity pressure across varying power scales.

Multi-objective optimization↗
DOE OSTI2022

Advanced Hydrogen Compressor for Hydrogen Storage Integrated with a Powerplant

This report summarizes work performed by Siemens Energy (SE) to design, build and test an advanced hydrogen compressor stage suitable for use in a hydrogen electrolysis system integrated with a powerplant to achieve energy storage in the form of compressed hydrogen. As hydrogen utilization increases to achieve energy storage and decarbonization of a variety of industries, the need is growing for improved and more cost-effective hydrogen compression technologies. The counter-rotating compression stage concept demonstrated under this contract and presented in this report offers a novel approach to achieve significantly more head rise per stage of compression, resulting in the potential for decreased capital cost and footprint compared to current state of the art centrifugal compression technologies. This report includes details of the design, testing, results, and subsequent validation of aerodynamic performance predictions.

08 HYDROGEN↗
DOE OSTI2025

Temperature Measurements in Hypersonic Wind Tunnels via Femtosecond Coherent Anti-Stokes Raman Scattering

A femtosecond coherent anti-Stokes Raman scattering (fs CARS) instrument is developed to perform gas-phase thermometry in cold-flow hypersonic wind tunnels. Measurements are reported for Mach 8 and 14 pure-nitrogen flows. The fs CARS instrument includes a 100 fs pump/Stokes pulse and a spectrally narrow probe pulse from a second harmonic bandwidth compressor. Important experimental considerations such as limits on the pump/Stokes pulse energy are discussed. The fs CARS focusing and collimating optics are mounted on a two-axis translation stage system to scan the measurement location during a 30 second wind tunnel run. Single-laser-shot rotational CARS spectra are recorded at the laser repetition rate of 1 kHz in the wind tunnel freestream and near simple cone models. Spectral fitting is used to determine quantitative gas temperatures. Freestream temperatures at Mach 8 and 14 spanned ranges of 40–75 and 35–50 K, respectively, depending on tunnel operating conditions. Temperature variations across the central 100 mm span of the wind tunnel were quantified. Measured temperature jumps across conical bow shocks from various models varied by less than 1% from predicted values. Hypersonic boundary layer measurements were demonstrated. In conclusion, these measurements illustrate the utility and robustness of this instrument for the study of complex fluid flow phenomena in challenging ground test facilities.

Aerodynamics↗