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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 OSTI2023

Extension of Argonne’s Plant Dynamics Code (PDC) Capabilities to TerraPower Direct-Cycle Supercritical CO2 (“Pascal”) Nuclear Reactor Concept. Final CRADA report

Argonne National Laboratory (the Contractor) and TerraPower, LLC, (the Participant), entered into a Cooperative Research and Development Agreement (CRADA) to extend the Plant Dynamics Code (PDC) to model the Pascal reactor plant. PDC is the system-level computer code developed at Argonne, primarily for design and transient analysis of supercritical carbon dioxide (sCO2) energy conversion systems for various power plants. Pascal is a supercritical carbon dioxide (sCO2)-cooled direct-cycle nuclear power reactor under development by TerraPower. New features were added to the code to model components and systems specific to the Pascal plant and to make the code readily available as a tool for design, control, and safety analysis for this and other direct-cycle power plants. TerraPower provided design information of the Pascal reactor and the requirements for the development of the new PDC features. Argonne modified the PDC capabilities to introduce the new features.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Exfoliation Propensity of Oxide Scale in Heat Exchangers Used for Supercritical CO2 Power Cycles

Supercritical CO2 (sCO2) Brayton cycle systems offer the possibility of improved efficiency in future fossil energy power generation plants operating at temperatures of 650 C and above. As there are few data on the oxidation/corrosion behavior of structural alloys in sCO2 at these temperatures, modeling to predict the propensity for oxide exfoliation is not well developed, thus hindering materials selection for these novel cycles. The ultimate goal of this effort is to provide needed data on scale exfoliation behavior in sCO2 for confident alloy selection. To date, a model developed by ORNL and EPRI for the exfoliation of oxide scales formed on boiler tubes in high-temperature, high-pressure steam has proven useful for managing exfoliation in conventional steam plants. A major input provided by the model is the ability to predict the likelihood of scale failure and loss based on understanding of the evolution of the oxide morphologies and the conditions that result in susceptibility to exfoliation. This paper describes initial steps taken to extend the existing model for exfoliation of steam-side oxide scales to sCO2 conditions. The main differences between high-temperature, high-pressure steam and sCO2 that impact the model involve (i) significant geometrical differences in the heat exchangers, ranging from standard pressurized tubes seen typically in steam-producing boilers to designs for sCO2 that employ variously-curved thin walls to create shaped flow paths for extended heat transfer area and small channel cross-sections to promote thermal convection and support pressure loads; (ii) changed operating characteristics with sCO2 due to the differences in physical and thermal properties compared to steam; and (iii) possible modification of the scale morphologies, hence properties that influence exfoliation behavior, due to reaction with carbon species from sCO2. The numerical simulations conducted were based on an assumed sCO2 operating schedule and several generic heat exchanger channel shapes and cross-sectional areas. Implications for the evolution of stresses in the oxide scales formed on sCO2 heat exchangers, and ensuing critical oxide thicknesses for exfoliation, were derived and compared with expectations for an equivalent conventional tubular heat exchanger in a steam cycle (for a given alloy).

Sabau, Adrian S↗
DOE OSTI2017

Enhancing power cycle efficiency for a supercritical Brayton cycle power system using tunable supercritical gas mixtures

Various technologies pertaining to tuning composition of a fluid mixture in a supercritical Brayton cycle power generation system are described herein. Compounds, such as Alkanes, are selectively added or removed from an operating fluid of the supercritical Brayton cycle power generation system to cause the critical temperature of the fluid to move up or down, depending upon environmental conditions. As efficiency of the supercritical Brayton cycle power generation system is substantially optimized when heat is rejected near the critical temperature of the fluid, dynamically modifying the critical temperature of the fluid based upon sensed environmental conditions improves efficiency of such a system.

42 ENGINEERING↗
DOE OSTI2019

Cogeneration using multi-effect distillation and a solar-powered supercritical carbon dioxide Brayton cycle

Supercritical carbon dioxide (sCO 2 ) Brayton cycles are considered to be a potentially viable option for reducing the cost of electricity generation from solar power tower plants, owing to theoretically high efficiency, low compressor work, and compact turbomachinery. These cycles have relatively high heat rejection temperatures (>70 degrees C), which are ideal for integration with multi-effect distillation (MED) for distillate generation from seawater, without being a parasitic load to the power plant as compared to cogeneration with steam Rankine cycle. The intermittency of solar radiation reduces the annual capacity factor of concentrating solar power (CSP) plants to about 50-60% even with a molten salt storage tank of 10-h. This reduces the annual distillate generation and increases the cost of the distillate. A novel concept to reduce distillate cost is introduced, whereby the waste heat from the sCO 2 Brayton cycle is stored. A two-tank demineralized water storage tank is selected and is shown to allow for the integration of a smaller MED system operating at an increased capacity factor. The optimal storage tank design reduces the distillate cost by 19% and increase the MED capacity factor from 46.4% to 75%. Different coastal locations with good solar resource are studied for cogeneration with the CSP-sCO 2 Brayton cycle. Techno-economic analysis shows the cost of distillate produced by MED is 16% cheaper than the distillate produced from reverse osmosis system for Yanbu, Saudi Arabia.

14 SOLAR ENERGY↗
DOE OSTI2020

A novel triple power cycle featuring a gas turbine cycle with supercritical carbon dioxide and organic Rankine cycles: Thermoeconomic analysis and optimization

In this study, a novel triple power cycle is proposed where waste heat from a gas turbine cycle is utilized to drive a supercritical carbon dioxide (s-CO 2 ) recompression cycle and a recuperative organic Rankine cycle (ORC) in sequence. A detailed thermoeconomic model is developed and implemented in MATLAB to evaluate the performance of the proposed cycle under different operating conditions. Optimization using a particle swarm optimization (PSO) algorithm is performed to minimize the levelized cost of electricity (LCOE) and determine the optimum design conditions of the cycle. The optimization results show that for a 100 MW cycle, the overall thermal efficiency and LCOE are 0.521 and $\$52.819$/MWh, respectively. The turbine inlet temperature of the gas turbine and s-CO 2 cycles are found as the most influential parameters on the thermoeconomic performance of the triple cycle. The proposed triple cycle shows an excellent waste energy recovery potential and superiority over a very thermodynamically efficient cycle from the literature, which included a gas turbine topping cycle and a complex cascade s-CO 2 power cycle used a bottoming cycle. As a result, the proposed triple cycle shows up to 0.9% points higher efficiency while it has fewer heat exchangers and turbomachinery than the cycle from the literature.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2019

Advanced supercritical carbon dioxide cycles

The supercritical carbon dioxide cycle (sCO2) has been chosen as the most promising cycle to meet the SunShot goals with a power block that has the potential to achieve thermal efficiencies of 50+% with a turbine inlet temperature of 720 o C. While this cycle has significant potential, it is a fairly new cycle and therefore the costs and performance of the cycle are not known to the level required for detailed economic analysis. There are also multiple cycle configurations that may be used and the choice of configuration could depend on size, cost constraints, efficiency, cooling mode, O&M costs, etc. Each of the variants has particular advantages and drawbacks that have to be understood. The most cost effective way to understand these variants is to use models that allow us to predict the performance of the cycles linked to the heat source (solar thermal energy). In order to do this these models, need to be developed and improved to better predict the costs and performance of the cycle. One of the issues identified with the supercritical Brayton cycle is the fact that a large amount of internal heat exchange is required in order for it to realize its efficiency potential. To address this, recuperators of the Printed Circuit Heat Exchanger (PCHE) design have been primarily considered. While PCHEs are fairly advanced technology and have significant potential there are several drawbacks associated with them. The first being their cost; it is estimated that the two recuperators in a recompression Brayton cycle will cost more than 30% of the entire power block. Another major issue is the in service performance and lack of ability to repair or easily clean the recuperators. If there is a defect in a diffusion bond, fouling or plugging of the channels or mechanical damage due to rapid thermal transient then the entire PCHE may need to be replaced. The third issue is the lack of data and information on the performance of PCHEs at the scale that would be required even for a small 10 MWe plant. To date PCHE heat exchangers have not been constructed at this size and it is necessary to have multiple modules headered together in order to be able to recuperate up to the 40 MWth required in even a small, 10 MWe plant.

14 SOLAR ENERGY↗
DOE OSTI2017

Evaluation of Property Methods for Modeling Direct-Supercritical CO2 Power Cycles

Direct supercritical CO2 (sCO2) power cycles combust natural gas or syngas with oxygen in a high pressure, heavily-diluted sCO2 environment, and are an efficient and potentially cost-effective method of capturing CO2 from fossil-fueled power plants. The cycle thermal efficiency varies with the proximity of the operating conditions to the CO2 critical point, as well as to the level of working fluid dilution by minor components, thus it is crucial to correctly model the thermo-physical properties of these sCO2 mixtures. This paper presents a quantitative evaluation of ten different property methods that can be used for modeling direct sCO2 cycles in Aspen Plus. These property methods are assessed against several mixture property measurements, and offer a relative comparison to the accuracy obtained with REFPROP, the standard for analyzing high purity indirect sCO2 systems. The Lee-Kessler-Plocker Equation of State is recommended if REFPROP cannot be used.

direct sCO2↗
DOE OSTI2017

Evaluation of Property Methods for Modeling Direct-Supercritical CO2 Power Cycles

Direct supercritical CO2 (sCO2) power cycles combust natural gas or syngas with oxygen in a high pressure, heavily diluted sCO2 environment, and are an efficient and potentially cost-effective method of capturing CO2 from fossil-fueled power plants. The cycle thermal efficiency varies with the proximity of the operating conditions to the CO2 critical point, as well as to the level of working fluid dilution by minor components, thus it is crucial to correctly model the thermo-physical properties of these sCO2 mixtures. This presentation includes a quantitative evaluation of ten different property methods that can be used for modeling direct sCO2 cycles in Aspen Plus. These property methods are assessed against several mixture property measurements and offer a relative comparison to the accuracy obtained with REFPROP, the standard for analyzing high purity indirect sCO2 systems. The Lee-Kessler-Plocker Equation of State is recommended if REFPROP cannot be used.

Weiland, Nathan↗
DOE OSTI2017

Materials and Manufacturing Challenges for Compact Heat Exchangers of Supercritical CO2 Power Cycles

The supercritical CO2 (sCO2) power cycles rely heavily on heat recuperation to increase efficiency. Compact heat exchangers are proposed to reduce equipment size and enhance heat transfer between heat source and sCO2. Microchannel architectures in these heat exchangers are typically formed by a lamination process wherein channels are formed in layers of sheet material, which are then stacked and joined together using diffusion bonding, brazing, or transient-liquid-phase bonding (TLPB). TLPB of Ni-based superalloy (Alloy 230) sheets into stacks was investigated. Electron microscopy identified solidification shrinkage porosity on the bond line as the most common defect in the TLP bonded stacks. Tensile yield strengths of 76-86 % of the base alloy strength were obtained on bonded stacks. Scanning electron microscopy on the fracture surfaces indicated ductile failure mode in the bonded zone. Environmental stability of joined regions in Alloy 230 stacks was investigated by exposing to CO2 at 700°C for 1500 hours. Mass change and post-exposure microscopic analysis showed a corrosion behavior similar to the base material.

14 SOLAR ENERGY↗
DOE OSTI2017

Cost comparison of printed circuit heat exchanger to low cost periodic flow regenerator for use as recuperator in a s-CO 2 Brayton cycle

Supercritical Carbon Dioxide (sCO 2 ) power cycles have the potential to deliver high efficiency at low cost. However, in order for an sCO 2 cycle to reach high efficiency, highly effective recuperators are needed. These recuperative heat exchangers must transfer heat at a rate that is substantially larger than the heat transfer to the cycle itself and can therefore represent a significant portion of the power block costs. Regenerators are proposed as a cost saving alternative to high cost printed circuit recuperators for this application. A regenerator is an indirect heat exchanger which periodically stores and releases heat to the working fluid. The simple design of a regenerator can be made more inexpensively compared to current options. The objective of this paper is a detailed evaluation of regenerators as a competing technology for recuperators within an sCO 2 Brayton cycle. The level of the analysis presented here is sufficient to identify issues with the regenerator system in order to direct future work and also to clarify the potential advantage of pursuing this technology. A reduced order model of a regenerator is implemented into a cycle model of an sCO 2 Brayton cycle. An economic analysis investigates the cost savings that is possible by switching from recuperative heat exchangers to switched-bed regenerators. The cost of the regenerators was estimated using the amount of material required if the pressure vessel is sized using ASME Boiler Pressure Vessel Code (BPVC) requirements. The cost of the associated valves is found to be substantial for the regenerator system and is estimated in collaboration with an industrial valve supplier. The result of this analysis suggests that a 21.2% reduction in the contribution to the Levelized Cost of Electricity (LCoE) from the power block can be realized by switching to a regenerator-based system.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2014

Analysis of Brayton Cycles Utilizing Supercritical Carbon Dioxide

This white paper documents a detailed and extensive Brayton cycle analysis that was performed to better understand at a fundamental level the dependence of the Brayton cycle performance on operating conditions, working fluid, supercritical fluid properties, and some cycle non-idealities. This work was performed to better understand the factors controlling Brayton cycle performance and optimal operating conditions, particularly for cycles utilizing supercritical CO 2 (sCO 2 ) as the working fluid. The focus of this study is on cycle performance, particularly efficiency. No cost estimates were performed. However, as a single indirect measure of cycle cost, some sensitivity analyses on specific power (net output divided by working fluid mass flow rate) were included.

42 ENGINEERING↗
DOE OSTI2016

Preheating of fluid in a supercritical Brayton cycle power generation system at cold startup

Various technologies pertaining to causing fluid in a supercritical Brayton cycle power generation system to flow in a desired direction at cold startup of the system are described herein. A sensor is positioned at an inlet of a turbine, wherein the sensor is configured to output sensed temperatures of fluid at the inlet of the turbine. If the sensed temperature surpasses a predefined threshold, at least one operating parameter of the power generation system is altered.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

PDC: Plant Dynamics Code for Design and Transient Analysis of Supercritical Brayton Cycles

The current report documents the Plant Dynamics Code developed at the Argonne National Laboratory for steady-state and transient analysis of supercritical Brayton cycles. The report consists of three major parts. Code Overview provides the general description of the code, including the purpose of the code development and the code’s main features. User’s Guide explains how to work with the code, including its user interface. Code Manual provides the detailed description of the code, including modeling, assumptions, and the solution schemes.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2014

Identified corrosion and erosion mechanisms in SCO2 Brayton Cycles.

Supercritical Carbon Dioxide (S-CO2) is an efficient and flexible working fluid for power production. Research to interface S-CO2 systems with nuclear, thermal solar, and fossil energy sources is currently underway. To proceed, we must address concerns regarding compatibility of materials, at high temperature, and compatibility between significantly different heat transfer fluids. Dry, pure S-CO2 is thought to be relatively inert [1], while the addition of ppm levels of water and oxygen result in formation of a protective chromia layer and iron oxide [2]. Thin oxides are favorable as diffusion barriers, and for their minimal impact on heat transfer. While S-CO2 is typically understood to be the secondary fluid, many varieties of primary fluids exist for nuclear applications. Molten salts, for use in the Molten Salt Reactor concept, are given as an example to contrast the materials requirements of primary and secondary fluids. Thin chromia layers are soluble in molten salt systems (nitrate, chloride, and fluoride based salts) [3-8], making materials selection for heat exchangers a precarious balancing act between high temperature oxidation (S-CO2) and metal dissolution (salt side of heat exchanger). Because concerns have been raised regarding component lifetimes, S-CO2 work has begun to characterize starting materials and to establish a baseline by analysis of 1) as-received stainless steel piping, and 2) piping exposed to S-CO2 under typical operating conditions with Sandia National Laboratories Brayton systems. A second issue discovered by SNL involves substantial erosion in the turbine blade and inlet nozzle. It is believed that this is caused by small particulates that originate from different materials around the loop that are entrained by the S-CO2 to the nozzle, where they impact the inlet nozzle vanes, causing erosion. We believe that, in some way, this is linked to the purity of the S-CO2, the corrosion contaminants, and the metal particulates that are present in the loop and its components.

Fleming, Darryn D.↗
DOE OSTI2021

A High-Fidelity Modeling Tool to Support the Design of Oxy-Combustors for Direct-Fired Supercritical CO2 Cycles

The challenge in the design of oxy-combustors for direct-fired supercritical CO 2 (sCO 2 ) cycles is in addressing disparate performance metrics and objectives. Key design parameters to consider include, among others, injector design for mixing and flame stability, split of recycled CO 2 diluent between injectors and cooling films, target flame temperatures to control noncondensable products, and strategies to inject the diluent CO 2 for film cooling and thermal control. In order to support novel oxy-combustor designs, a high-fidelity yet numerically efficient modeling framework based on the CRUNCH CFD® flow solver is presented, featuring key physics-based submodels relevant in this regime. For computational efficiency in modeling large kinetic sets, a flamelet/progress variable (FPV) based tabulated-chemistry approach is utilized featuring a three-stream extension to allow for the simulation of the CO 2 film cooling stream in addition to the fuel and oxidizer streams. Finite rate chemistry effects are modeled in terms of multiple progress variables for the primary flame as well as for slower-evolving chemical species such as NO x and SO x contaminants. Real fluid effects are modeled using advanced equations of states. The predictive capabilities of this computationally tractable design support tool are demonstrated on a conceptual injector design for an oxy-combustor operating near 30 MPa. Simulations results provide quantitative feedback on the effectiveness of the film cooling as well as the level of contaminants (CO, NO, and N) in the exhaust due to impurities entering from the injectors. These results indicate that this framework would be a useful tool for refining and optimizing the oxy-combustor designs as well as risk mitigation analyses.

Engineering↗
DOE OSTI2020

Measurements of Density and Sound Speed in Mixtures Relevant to Supercritical CO2 Cycles

Abstract The objective of this research is to validate properties of mixtures relevant to supercritical carbon dioxide (sCO2) power cycles. Direct-fired sCO2 cycles are a promising technology for the future power generation systems. The working fluid of sCO2 cycles will be near and above critical point of CO2. One of the challenges is that the simulation of mixtures should consider real gas behavior. Expected operating conditions of Allam cycles reach up to 300 bar and 1000 °C. Characterizing the mixtures at the extreme conditions is an important issue in current researches and industrial applications. Thermophysical properties of mixtures may be beyond the valid range of the widely used database such as NIST REFPROP. Experimental data of mixture properties in the literature are limited which is necessary to develop high-fidelity design tools for sCO2 power cycles. We measured the density and sound speed of several multi-component mixtures. A temperature-controlled high-pressure test cell was used for the density measurements. Sound speed was measured by resonant frequency detection using an external speaker and a piezoelectric pressure sensor. Mixtures studied in this work include carbon dioxide, methane, oxygen, and water vapor. Properties of pure CO2 were measured to show the validity of our technique. Compositions were selected to be close to frozen mixtures at the inlet, mid-progress, and exhaust conditions of a model sCO2 combustor in the previous numerical simulation work. Corresponding reaction progress variables (RPV) were RPV = 0, 0.5, and 1. Temperature and pressure conditions of experiments are 310–450 K and 0–150 bar. In our study, density and sound speed from the NIST REFPROP database agree with experimental measurements within the range of our measurement uncertainties.

Energy & Fuels↗
DOE OSTI2022

Combustion Kinetics Model Development & Fluid Property Experimental Investigation For Improved Design Of Supercritical CO 2 Power Cycle Components

Supercritical carbon dioxide (sCO 2 ) cycles are being investigated for the future of power generation and will contribute to a carbon-neutral future to combat the effects of climate change. These direct-fired closed cycles will produce power without adding significant pollutants to the atmosphere. For such cycles to be efficient, they will need to operate at significantly higher pressures (e.g., 300 atm for Allam Cycle) than existing systems (typically less than 40 atm). There is limited knowledge on combustion at these high pressures and with a high dilution of carbon dioxide. Also, various experimental and computational investigations and model developments have been performed by the University of Central Florida (UCF), Embry-Riddle Aeronautical University (ERAU), and Stanford University (S.U.) to improve the current knowledge base and support the design and development of sCO 2 combustors. This project's technical aspects include chemical kinetics development, fundamental sCO 2 combustion, combustion model and sub-model development, supercritical fluid injection characterization, and heat transfer characterization.

20 FOSSIL-FUELED POWER PLANTS↗