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At least 271 records · Page 15

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DOE OSTI2020

Identifying geologic characteristics and operational decisions to meet global carbon sequestration goals

Geologic carbon sequestration is the process of injecting and storing CO 2 in subsurface reservoirs and is an essential technology for global environmental security (e.g., climate change mitigation) and economic security (e.g., CO 2 tax credits). To meet energy, economic, and environmental goals, society will have to identify vast volumes of high-capacity, low-cost, and viable storage reservoirs for sequestering CO 2 . In turn, this requires understanding how major geologic characteristics (such as reservoir depth, thickness, permeability, porosity, and temperature) and design and operational decisions (such as injection well spacing) impact CO 2 injection rates, storage capacity, and economics. Although many numerical simulation tools exist, they cannot repeat the required thousands or millions of simulations to identify ideal reservoir properties and the sensitivity and interaction between geologic parameters and operational decisions. Here, we use SCO 2 T—a fast-running, reduced-order modeling framework—to explore the sensitivity of major geologic parameters and operational decisions to engineering (CO 2 injection rates, plume dimensions, and storage capacities and effectiveness) and costs. Our results show, for the first time, benefits and impacts such as allowing CO 2 plumes to overlap, how different well spacing patterns affect CO 2 sequestration, the effects on costs of including brine treatment and disposal, and the effect of restricting injection rates to 1 MtCO 2 per y based on well limitations. We reveal multiple novel and unintuitive findings including: (i) deeper reservoirs have reduced carbon sequestration costs until injection rates reach 1 MtCO 2 per y, at which point deeper reservoirs become more expensive, (ii) thicker formations allow for increased injection rates and storage capacity, but thickness barely impacts plume areas, (iii) higher geothermal gradients result in reduced sequestration costs, unless brine treatment/disposal costs are included, at which point reservoirs having lower geothermal gradients are more economical because they produce less brine for each unit of injected CO 2 , and (iv) allowing plumes to overlap has a significantly positive impact of increasing storage capacities but has only a small influence on reducing sequestration costs. Altogether, our results illustrate new scientific conclusions to help identify suitable sites to inject and store CO 2 , to help understand the complex interaction between geology and resulting costs, and to help support the pursuit of meeting global sequestration targets.

58 GEOSCIENCES↗

DOE OSTI2021

CASPT2 molecular geometries of Fe( II ) spin-crossover complexes

Using fully internally contracted (FIC)-CASPT2 analytical gradients, geometry optimizations of spin-crossover complexes are reported. This approach is tested on a series of Fe(II) complexes with different sizes, ranging from 13 to 61 atoms. A combination of active space and basis set choices are employed to investigate their role in determining reliable molecular geometries. The reported strategy demonstrates that a wave function-based level of theory can be used to optimize the geometries of metal complexes in reasonable times and enables one to treat the molecular geometry and electronic structure of the complexes using the same level of theory. For a series of smaller Fe(II) SCO complexes, strong field ligands in the LS state result in geometries with the largest differences between DFT and CASPT2; however, good agreement overall is observed between DFT and CASPT2. For the larger complexes, moderate sized basis sets yield geometries that compare well with DFT and available experimental data. Here we recommend using the (10e,12o) active space since convergence to a minimum structure was more efficient than with truncated active spaces despite having similar Fe–ligand bond distances.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Self-assembly of a supramolecular spin-crossover tetrahedron

A new mononuclear iron(ii) SCO compound featuring H-bonding donor and acceptor units provides an entry to a purely supramolecular switchable {Fe 4 } tetrahedron that exhibits a singular magnetic behavior for each of the four Fe(ii) centers.

Chemistry↗

DOE OSTI2023

Defining a compact dry cooler design to reduce LCOE contribution in a CSP facility

Concentrating solar power (CSP), when coupled with a supercritical carbon dioxide (sCO 2 ) power cycle and sensible heat storage, presents a renewable and clean alternative for utility-scale power generation. However, in order to be competitive in the current and future markets, CSP facilities must limit their levelized cost of electricity (LCOE) by minimizing capital costs and reducing operating costs over the lifetime of the plant. Targeting this goal, this study investigates the LCOE impact of the power cycle pre-cooler. This study considers a compact dry cooler with micro-channel technology on the CO 2 side and formed fin geometry on the air side, using directly-coupled centrifugal fans and a transition duct to improve air distribution across the fins as well as protect the fins from contaminants which may cause blockage, soiling, fouling, and damage. In an effort to better understand the dry cooler impact on LCOE, a sensitivity study was conducted using various combinations of end-to-end approach temperatures, air-side pressure drop values, CO 2 -side pressure drop values, fan types, cooler turndown control schemes, cooler module sizes, and design-point ambient temperatures. Furthemore, off-design cycle performance data was calculated for each dry cooler design using NPSS simulation software; cycle performance data were then input to System Advisor Model (SAM) along with the associated capital costs for LCOE prediction of a 100 MW system over a 30 year plant lifetime. Results of this study show the LCOE is most sensitive to air-side performance, followed by heat transfer effectiveness and capital cost. It was found that a power cycle with a mid- to high-performance dry cooler will produce the most competitive power-production costs. Designing at the extreme ends for approach temperature (or effectiveness), design-point ambient temperature, and compactness (footprint) produce higher LCOE values; mid-range values for these parameters balance performance, operating costs, and associated capital cost to optimize LCOE.

14 SOLAR ENERGY↗

DOE OSTI2023

Direct observation of the magnetic anisotropy of an Fe(II) spin crossover molecular thin film

Abstract In this work, we provide clear evidence of magnetic anisotropy in the local orbital moment of a molecular thin film based on the SCO complex [Fe(H 2 B(pz) 2 ) 2 (bipy)] (pz = pyrazol−1−yl, bipy = 2,2′−bipyridine). Field dependent x-ray magnetic circular dichroism measurements indicate that the magnetic easy axis for the orbital moment is along the surface normal direction. Along with the presence of a critical field, our observation points to the existence of an anisotropic energy barrier in the high-spin state. The estimated nonzero coupling constant of ∼2.47 × 10 −5 eV molecule −1 indicates that the observed magnetocrystalline anisotropy is mostly due to spin–orbit coupling. The spin- and orbital-component anisotropies are determined to be 30.9 and 5.04 meV molecule −1 , respectively. Furthermore, the estimated g factor in the range of 2.2–2.45 is consistent with the expected values. This work has paved the way for an understanding of the spin-state-switching mechanism in the presence of magnetic perturbations.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2020

High-precision mass measurements of the isomeric and ground states of 44 V: Improving constraints on the isobaric multiplet mass equation parameters of the A=44, 0 + quintet

Background: The quadratic isobaric multiplet mass equation (IMME) has been very successful at predicting the masses of isobaric analog states in the same multiplet, while its coefficients are known to follow specific trends as functions of mass number. The Atomic Mass Evaluation 2016 [Chin. Phys. C 41, 030003 (2017)] 44 V mass value results in an anomalous negative c coefficient for the IMME quadratic term; a consequence of large uncertainty and an unresolved isomeric state. The b and c coefficients can provide useful constraints for construction of the isospin-nonconserving Hamiltonians for the pf shell. In addition, the excitation energy of the 0 + , T = 2 level in 44 V is currently unknown. This state can be used to constrain the mass of the more exotic 44 Cr. Purpose: The aim of the experimental campaign was to perform high-precision mass measurements to resolve the difference between 44 V isomeric and ground states, to test the IMME using the new ground state mass value and to provide necessary ingredients for the future identification of the 0 + , T = 2 state in 44 V. Method: High-precision Penning trap mass spectrometry was performed at LEBIT, located at the National Superconducting Cyclotron Laboratory, to measure the cyclotron frequency ratios of [ 44g,m VO] + versus [ 32 SCO] + , a well-known reference mass, to extract both the isomeric and ground state masses of 44 V. Results: The mass excess of the ground and isomeric states in 44 V were measured to be -23 804.9(80) keV/c 2 and -23 537.0(55) keV/c 2 , respectively. This yielded a new proton separation energy of S p = 1 773(10) keV. Conclusion: The new values of the ground state and isomeric state masses of 44 V have been used to deduce the IMME b and c coefficients of the lowest 2 + and 6 + triplets in A = 44. The 2 + c coefficient is now verified with the IMME trend for lowest multiplets and is in good agreement with the shell-model predictions using charge-dependent Hamiltonians. The mirror energy differences were determined between 44 V and 44 Sc, in line with isospin-symmetry for this multiplet. Finally, the new value of the proton separation energy determined, to an uncertainty of 10 keV, will be important for the determination of the 0 + , T = 2 state in 44 V and, consequently, for prediction of the mass excess of 44 Cr.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2020

Probing the Effects of NO x and SO x Impurities on Oxy-Fuel Combustion in Supercritical CO 2 : Shock Tube Experiments and Chemical Kinetic Modeling

The direct-fired supercritical carbon dioxide cycles are one of the most promising power generation methods in terms of their efficiency and environmental friendliness. Two important challenges in implementing these cycles are the high pressure (300 bar) and high CO 2 dilution (>80%) in the combustor. The design and development of supercritical oxy-combustors for natural gas require accurate reaction kinetic models to predict the combustion outcomes. The presence of a small amount of impurities in natural gas and other feed streams to oxy-combustors makes these predictions even more complex. During oxy-combustion, trace amounts of nitrogen present in the oxidizer is converted to NO x and gets into the combustion chamber along with the recirculated CO 2 . Similarly, natural gas can contain a trace amount of ammonia and sulfurous impurities that get converted to NO x and SO x and get back into the combustion chamber with recirculated CO 2 . In this work, a reaction model is developed for predicting the effect of impurities such as NO x and SO x on supercritical methane combustion. The base mechanism used in this work is GRI Mech 3.0. H 2 S combustion chemistry is obtained from Bongartz et al. while NOx chemistry is from Konnov. The reaction model is then optimized for a pressure range of 30–300 bar using high-pressure shock tube data from the literature. It is then validated with data obtained from the literature for methane combustion, H 2 S oxidation, and NO x effects on ignition delay. The effect of impurities on CH 4 combustion up to 16 atm is validated using NO x -doped methane studies obtained from the literature. In order to validate the model for high-pressure conditions, experiments are conducted at the UCF shock tube facility using natural gas identical mixtures with N 2 O as an impurity at ~100 bar. Current results show that there is a significant change in ignition delay with the presence of impurities. A comparison is made with experimental data using the developed model and predictions are found to be in good agreement. The model developed was used to study the effect of impurities on CO formation from sCO 2 combustors. It was found that NO x helps in reducing CO formation while the presence of H 2 S results in the formation of more CO. The reaction mechanism developed herein can also be used as a base mechanism to develop reduced mechanisms for use in CFD simulations.

Energy & Fuels↗

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 OSTI2022

Investigation of Gas Turbine Internal Cooling Using Supercritical CO 2 —Effect of Surface Roughness and Channel Aspect Ratio

In this paper, an experimental and numerical investigation of internal cooling channels with rib turbulators is presented with sCO 2 as the working fluid at process conditions (pressure-20.7 MPa and temperature up to 150 °C). The effect of channel aspect ratio up to 2:1 on thermal-hydraulic performance is explored in additively manufactured rectangular channels and square channels, both with and without 60 deg ribs on the top and bottom sides. The Wilson-plot method is employed to experimentally measure channel-averaged Nusselt number over a Reynolds number range up to 370,000. The friction factor is calculated from pressure drop and mass flow rate and additionally, the overall thermal performance factor (TPF) is reported. A companion computational fluid dynamics (CFD) simulation is performed for the rib turbulated cooling configurations reported in the experiments using the Reynolds average Navier–Stokes-based turbulence model. The objective of the numerical study is to gain insight into the local heat transfer augmentation in the ribbed channels as a result of varying the aspect ratio, channel configuration (square versus rectangular), operating conditions (Reynolds number) and the surface roughness, an inherent outcome of the additive manufacturing process. Surface roughness is simulated using sand grain roughness height (K S ) calculated from the experimental data, and a comparison is presented with the corresponding channel configuration with varying surface roughness heights starting from smooth surfaces (K S = 0). Experimental results indicate that the heat transfer augmentation is negligible in the rectangular channels with ribs on the long side compared to the square channel. However, it is enhanced by 60% in comparison to placing ribs on the shorter side. The TPF remains constant at around 1 for the entire range of Reynolds numbers consistent with prior work at the National Energy Technology Laboratory (NETL). Here, the simulation results highlight that increased surface roughness can have a favorable considerable influence on Nusselt number and overall thermal performance enhancement.

42 ENGINEERING↗

DOE OSTI2023

Helical Fins for Concentrated Solar Receivers: Design Optimization and Entropy Analysis

Concentrated solar power (CSP) with thermal energy storage (TES) has the potential to achieve grid parity. This can be realized by operating CSP systems at temperatures above 700 °C with high-efficiency sCO 2 power cycles. However, operating CSP systems at such temperatures poses several challenges, among which the design of solar receivers to accommodate increased thermal loads is critical. To this end, this work explores and optimizes various swirl-inducing internal fin designs for solar receiver tubes. These fin designs not only improve the thermal performance of receiver tubes but also levelize temperature unevenness caused by non-uniform thermal loading. In this work, the geometric parameters of the fin designs are optimized to maximize the Nusselt number with a constraint on the friction factor. This optimization, however, is computationally intensive, requiring hundreds of simulation calls to computational fluid dynamics (CFD) models. Here, to circumvent this problem, surrogate models are used to approximate the simulation outputs needed during the optimization. In addition, this study also examines the fin designs from an entropy generation perspective. To this end, the entropy contributions from thermal and viscous effects are quantitatively compared while varying the operational Reynolds number.

14 SOLAR ENERGY↗

DOE OSTI2024

Leveraging Additive Manufacturing to Fabricate High Temperature Alloys With Co-Designed Mechanical Properties and Environmental Resistance

A paradigm shift in the traditional sequential design approaches is critically essential to create application-specific hierarchical and multifunctional materials with superior long-term performance for next-generation energy technologies involving extreme environments. In the current work, we aim to leverage the flexibility and geometric/compositional complexity offered by additive manufacturing to demonstrate this new approach by codesigning a compositionally graded Ni-based alloy for molten salts\sCO 2 heat exchangers to enable mitigation of environmental degradation of surfaces exposed to molten halide salts, while simultaneously suppressing the consequent deterioration in mechanical stability. Further, thermokinetic modeling describing the underlying physics of thermally- and environmentally induced spatiotemporal compositional and microstructural evolution will be employed to predict the parameter space of material deposition processes and precisely identify the required composition gradient. Preliminary corrosion and mechanical testing of the dual material demonstrated the potential of the material to replace existing solid solution strengthened materials for this application.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Experimental Validation of a High-Temperature Test Facility for Future Additive Manufactured Supercritical Carbon Dioxide Turbine Testing

For next-generation power plants to achieve high cycle efficiencies consistent with the Department of Energy's 65% efficiency target, turbomachinery capable of operating within high-temperature power cycles must be demonstrated. Pairing additively manufactured superalloy turbines with the supercritical carbon dioxide (sCO 2 ) power cycle could enable turbine inlet temperatures approaching 1300 °C while providing flexibility in turbine cooling strategies. Development of test facilities to characterize and validate such systems is crucial. In this study, a turbine test facility capable of achieving inlet conditions of 800 °C, 11 MPa, and 0.43 kg/s while accommodating complex auxiliary cooling flow requirements has been designed and constructed to support future testing of a Haynes 282 additively manufactured 30 kW turbine-generator system with advanced cooling channels. This facility enables characterization of aerodynamic performance, leakage, and windage losses. Details of the facility's construction and operation are presented, along with experimental validation tests using an orifice as an expansion device in place of the turbine. These tests confirm that the facility can reach the required conditions, distinguish regions of achievable steady and pseudo-steady conditions, and identify the heater power required for each point in the upcoming turbine campaign. The campaign confirmed that ISO 5167-2 can reliably predict orifice mass flow rates in extreme supercritical carbon dioxide conditions with deviations of 0.5–7.5%.

42 ENGINEERING↗

DOE OSTI2020

Evaluation of Ceramic Heat Exchanger for Next-Generation Concentrated Solar Power

The U.S. Department of Energy has identified a third generation of concentrated solar power (Gen3 CSP) technologies to minimize cost of CSP produced electricity. By developing these technologies further, it is forecasted that Gen3 CSP will meet the levelized cost of electricity (LCOE) SunShot target of 6 cents/kWh to compete with dominant, conventional nonrenewable energy sources (1). The focus for advancing CSP systems for Gen3 is to increase overall system efficiency. Thus, reevaluating second-generation systems, superheated steam-turbine power cycles, and implementing more advanced power cycles is essential. Specifically, it has been identified that a supercritical carbon dioxide (sCO 2 ) Brayton cycle can increase the net thermal-to-electric efficiency to over 50% for CSP power tower configurations (2). Compared to conventional superheated steam Rankine cycle systems, more extreme operating conditions are required and pose critical barriers to overcome in the field of materials and manufacturing for Gen3 CSP.

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↗

DOE OSTI2021

CSP Gen3: Liquid-Phase Pathway to SunShot

The United States Department of Energy (DOE) established the Concentrating Solar Power Generation 3 (CSP Gen3) program to promote the development of advanced CSP systems capable of producing electricity at a levelized cost of energy (LCOE) less than $60/MWh, based on criteria published in the CSP Gen3 Roadmap and a subsequent funding opportunity announcement (Gen3 FOA). This report documents the progress and potential of the “Liquid Pathway” to meet these objectives. The Liquid Pathway proposes the use of low-cost molten chloride salts for energy storage, mated with an operationally flexible solar receiver that employs liquid-metal sodium for heat capture and transfer to the storage salt. This approach leverages molten-salt technology from the current state-of-the-art CSP power towers embodied by plants such as Gemasolar, Crescent Dunes, Noor III, and the DEWA 700 CSP project. Furthermore, the design builds on the knowledge gained over decades of use of liquid-metal sodium as a high-temperature heat transfer fluid (HTF) in solar tests and nuclear-power applications. The commercial representation of the proposed Gen3 design incorporates a high-efficiency sodium receiver operating at ~740°C, with a liquid-liquid heat exchanger feeding a two-tank, molten-chloride salt storage system. Chloride salt is dispatched to a supercritical CO 2 (sCO 2 ) power cycle to provide electric power to the grid. The design integration is a conceptual match for the current sodium receiver → solar salt storage → steam-Rankine power cycle promoted by developer Vast Solar, which may facilitate commercial acceptance and development.

14 SOLAR ENERGY↗

DOE OSTI2021

Review and Analysis of Heat Transfer Correlations For Horizontal Pseudocritical CO 2 Heat Exchanger Applications

There is significant interest in the development of supercritical carbon dioxide (sCO 2 ) power cycles because of the potential for smaller and more energy efficient systems than a steam Rankine cycle. Heat exchanger designs typically use empirical correlations, but the applicability of these correlations near the CO 2 critical point is a potential issue. Though numerous correlations have been proposed in the literature, there are some disagreements when it comes to the accuracy. The current work recognizes the role of thermophysical properties, and its impacts on the heat transfer correlations and cycle efficiency. Heat transfer correlations proposed for horizontal flow inside circular pipes were analyzed with the help of numerical simulations. Steady state RANS simulations were performed using SST k-w turbulence model to evaluate the Nusselt number empirical correlations. It was found that the most of correlations (except Yoon) produced a Nusselt number that differed significantly with the one predicted numerically. Some of the correlations were developed for pure forced convection regime and as mentioned in Lin et al. do not account for mixed convection or free convection effects. Based on the limited observation, it appears that Yoon et al. predictions match well with the numerically predicted Nusselt Numbers. However, further analysis is required understand the applicability of various correlations and is contingent on accurate measurements or predictions of wall temperature profiles in the axial and the circumferential directions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Measuring Heat Transfer Coefficients for Supercritical Carbon Dioxide Cycle Recuperators

This paper describes the measurement of convective heat transfer coefficients and friction factors for sCO 2 flowing in pin-fin patterned pipes at the US DoE’s National Energy Technology Laboratory (NETL) in Morgantown, WV. The measurement procedures were validated by conducting benchmark tests with smooth stainless-steel tube and comparing the results with published correlations for Nusselt number (𝑁𝑢) and friction factor. Over Reynolds numbers (Re D ) ranging from 5×104 to 2.5×105 , measured 𝑁𝑢 was within 5% of the Dittus-Boelter correlation and measured friction factors were within 5% of the McAdams correlation for smooth tube flow.

42 ENGINEERING↗

DOE OSTI2022

Ultra High-Temperature Magnetic Bearing System for s-CO 2 Turbines/Expanders. Phase II Final Report

The goal of this project is to design and construct of a prototype of ultra-high temperature permanent magnet (UHT–PM), which provides the force to pull the spinning shaft towards the target position in the magnetic bearing (MB) clearance circle. This project will develop a PM biased MB system, that is actively cooled to the 550°C maximum operating temperature limit of PMs. The MB test environment will include 700°C, 40krpm and 4,000 psi requirements to advance the supercritical carbon dioxide (sCO 2 ) and other types of Brayton power cycle systems. The proposed novel MBs combine PMs for supplying the bias field and electromagnets for supplying the control field, both in UHT conditions. The choice of material is the UHT Sm-Co PMs (US patent 6,451,132) due to their significantly better thermal stability. The 6-pole homopolar design permits uninterrupted force delivery via a redundant control capability (US patent 7,429,811) even if 3 poles were to fail. The Phase I efforts was to focus on development and demonstration of component technologies and detailed design of full scale components and a demonstrator test rig for use in Phase II. UHT–PMs were produced and used in the MB actuator. The operating environment of the EEC-T550 Sm-Co magnet material could be extended by implementing active cooling. Electromagnetic coils imbedded in the MB provide forces to stabilize the shaft position at the target via sensing and control stages. Shaft position sensors enable to identify the present position of the spinning shaft relative to its desired target position in the MB clearance circle (air gap). Auxiliary bearings will be installed to provide a backup support system in the event that power to the MB fails or there is a fault in a device providing current to the MB coils. For control, reliability and safety reasons the sensors and auxiliary bearings are typically located as close as possible to the MBs, which exposes them to the same environmental conditions. Development of only the actuator for the UHT environment is an inadequate approach to complete integration of the MB system in the turbine/expander. Therefore the UHT sensor and auxiliary bearing were designed and developed along with the actively cooled, UHT-PM actuator development. Although shaft position sensors are commercially available (Kaman) they may cost up to $10k per channel, and a full 5 axis magnetic suspension is best implemented with up to 20 sensors. Once successfully completed, this project will significantly extend the operating environment capability for turbomachinery applications such as nuclear power, concentrated solar thermal, fossil fuel, geothermal, and shipboard propulsion. The further advancement of UHT-PM-MB will also strengthen the US position in PM technology, which is presently heavily dominated by China. The UHT Sm-Co magnet material that will be utilized in the proposed work has been developed exclusively by the project proposer. Many actuators, motors, generators and other MB applications will greatly benefit from the proposed work.

24 POWER TRANSMISSION AND DISTRIBUTION↗