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Problems related to: (1) high helium outlet temperature of the reactor, and (2) gas generator design used in hydrogen production are studied. Special attention was given to the use of Oklahoma coal in the gasification process. Plant performance, operation, and environmental considerations are covered.
ComTest is a $27M Department of Energy-funded project. Phase I, which began in November 2015, served to identify the technology gaps, as well as the scope and cost of required testing. Phase II, which was awarded in December 2018, includes an advanced manufacturing effort to complete U.S. based supply chain development for full commercial scale (800-850 MWe) AUSC components made of nickel-based alloys, components operating at up to 760°C. Completion of Phase II scheduled for September 30, 2021. Strategic Objectives of U.S. AUSC Project include: Power Plant Efficiency Improvements –Develop cost-effective, reliable technologies to improve the efficiency of new and existing high-temperature advanced generation power plants. Close gaps to achieve readiness for commercial scale demonstration of Advanced Ultra-Supercritical (AUSC) technology. Fabricate full-scale versions of key nickel-based alloy components. Validate capabilities of US supply chain for cost certainty. Support cross-cutting high-temperature generation technologies. Obtain ASME Code approval for new materials, components and processes. Increase power plant steam temperatures for higher cycle efficiency (Note: Average efficiency of US coal-fired fleet = 33% HHV; A-USC plant efficiency over 47% HHV at 1,400°F (760°C) steam temperature).
Results were arrived at by utilizing and expanding on information presented in the literature. The results were analyzed and compared with those for simple gas turbine and combined cycles for both utility power generation and industrial cogeneration applications. The efficiency and specific power of simple gas turbine cycles can be increased as much as 30 and 50 percent, respectively, by the injection of steam into the combustor. Steam-injected gas turbines appear to be economically competitive with both simple gas turbine and combined cycles for small, clean-fuel-fired utility power generation and industrial cogeneration applications. For large powerplants with integrated coal gasifiers, the economic advantages appear to be marginal.
In this paper, preliminary studies on two turbine engine applications relevant to the tilt-rotor rotary wing aircraft are performed. The first case-study is the application of variable pitch turbine for the turbine performance improvement when operating at a substantially lower shaft speed. The calculations are made on the 75 percent speed and the 50 percent speed of operations. Our results indicate that with the use of the variable pitch turbines, a nominal (3 percent (probable) to 5 percent (hypothetical)) efficiency improvement at the 75 percent speed, and a notable (6 percent (probable) to 12 percent (hypothetical)) efficiency improvement at the 50 percent speed, without sacrificing the turbine power productions, are achievable if the technical difficulty of turning the turbine vanes and blades can be circumvented. The second casestudy is the contingency turbine power generation for the tilt-rotor aircraft in the One Engine Inoperative (OEI) scenario. For this study, calculations are performed on two promising methods: throttle push and steam injection. By isolating the power turbine and limiting its air mass flow rate to be no more than the air flow intake of the take-off operation, while increasing the turbine inlet total temperature (simulating the throttle push) or increasing the air-steam mixture flow rate (simulating the steam injection condition), our results show that an amount of 30 to 45 percent extra power, to the nominal take-off power, can be generated by either of the two methods. The methods of approach, the results, and discussions of these studies are presented in this paper.
A sputtering system was developed to deposit aluminum and aluminum alloys by the dc sputtering technique. This system is designed for a high level of cleanliness and for monitoring the deposition parameters during film preparation. This system is now ready for studying the deposition and annealing parameters upon double-level metal preparation. A technique recently applied for semiconductor analysis, the finite element method, was studied for use in the computer modeling of two dimensional MOS transistor structures. It was concluded that the method has not been sufficiently well developed for confident use at this time. An algorithm was developed for confident use at this time. An algorithm was developed for implementing a computer study which is based upon the finite difference method. The program which was developed was modified and used to calculate redistribution data for boron and phosphorous which had been predeposited by ion implantation with range and straggle conditions. Data were generated for 111 oriented SOS films with redistribution in N2, dry O2 and steam ambients.
A system was developed for depositing aluminum and aluminum alloys by the D.C. sputtering technique. This system which was designed for a high level of cleanliness and ion monitoring the deposition parameters during film preparation is ready for studying the deposition and annealing parameters upon double level metal preparation. The finite element method was studied for use in the computer modeling of two dimensional MOS transistor structures. An algorithm was developed for implementing a computer study which is based upon the finite difference method. The program was modified and used to calculate redistribution data for boron and phosphorous which had been predeposited by ion implantation with range and straggle conditions typical of those used at MSFC. Data were generated for 111 oriented SOS films with redistribution in N2, dry O2 and steam ambients. Data are given showing both two dimensional effects and the evolution of the junction depth, sheet resistance and integrated dose with redistribution time.
Instrument is adaptation of hot-wire anemometer. Hot-wire anemometer detects liquid droplets entrained in flowing gas. Droplets impinge on probe and carry away heat as vaporized. Power required to maintain probe at constant resistance and elevated temperature gives measure of amount of liquid present. Instrument used in steam turbines to check for condensation and detect fog at airports and highways, generating control signal to turn on fog lights.
Kuljian Corporation provides design engineering and construction management services for power generating plants in more than 20 countries. They used WASP (Calculating Water and Steam Properties), a COSMIC program to optimize power station design. This enabled the company to substantially reduce lead time and software cost in a recent design project.
The extensive evidence for sulfate deposits on Mars provided by analyses of MER and Mars Express data shows that the sulfur played an essential role in the geochemical cycles of the planet, including reservoirs in the atmosphere, hydro-sphere and geosphere. Overall the data are consistent with a fluvial/lacustrine-evaporative origin of at least some of the sulfate deposits, with mineral precipitation through oversaturation of salty acidic fluids enriched in sulfates. This scenario requires reservoirs of sulfur and associated cations, as well as an acidic and oxidizing hydrochemistry which could be provided by surface and subsurface catching of meteoric waters resulting in the presence of sulfur-bearing gases and steam photochemistry. In this work we suggest a new scenario for the extensive generation of sulfates in Mars based on the observation of seasonal changes in the redox and pH of subsurface waters enriched in sulfur that supply the acidic Mars process analog of Rio Tinto. This model considers the long-term subsurface storage of sulfur during most of Noachian and its release from the late Noachian to Hesperian time through weathering by meteoric fluids that would acidify and oxidize the sulfur bearing compounds stored in the subsurface.
Many plants experience multiple failure events each year, and while none of these events result in core damage further consideration for nuclear power plant (NPP) type and its role in an event needs to be considered. Specifically herein initiating events (IE) are considered these are unplanned events that occur while a nuclear plant is in critical operation, and requires that the plant be shut down to achieve a stable state. Breaking IE failure events into groups results in the classification of functional impact (FI) groups. A FI group is a risk-significant event category that could impact the ability of a NPP to remove decay heat from the reactor. For an event to be considered a FI, it must be associated with a manual or automatic reactor trip, irrespective of the order of events. In addition, the plant must be at or above the point of adding heat and the event must happen before or shortly after a reactor trip. One or more FIs may be identified in any individual reactor trip sequence. An example of a FIs is the loss of offsite power (LOOP) from a bird interaction with the power lines. This results in a failure to transfer power to an emergency source, such as a generator, producing a turbine and reactor trip and then a closure of main steam isolation valves (MSIVS). The FI applicable to this reactor trip sequence would be loss of offsite power and closure of at least one MSIV in each main steam line. The results presented are focused on the analysis and evaluation of FI event categories that can be found in IE studies [1], [2] and the Initialing Events Spreadsheet [3] and is a historical review of Licensee.
FeCrAl alloys are promising candidate materials for the accident tolerant fuel (ATF) cladding application due to their exceptional resistance to oxidation in elevated temperature steam environments. Currently, limited fracture toughness data are available for the FeCrAl alloys, including the FeCrAl alloys newly developed at Oak Ridge National Laboratory (ORNL) under the U.S. Department of Energy’s Advanced Fuels Campaign (AFC) program. In this study, two Generation II candidate FeCrAl alloys, i.e., C06M (81.8Fe-10Cr-6Al-0.03Y-2Mo-0.2Si) and C36M (78.8Fe-13Cr-6Al-0.03Y-2Mo-0.2Si), were irradiated in the High Flux Isotope Reactor (HFIR) at ORNL to assess the fracture characteristics of these alloys after neutron irradiation. A total of six rabbit capsules were irradiated in HFIR at target temperatures of 200°C, 330°C, and 500°C up to target damage doses of 8 displacements per atom (dpa) and 16 dpa. Post-irradiation fracture toughness testing was performed following the Master Curve method in the ASTM E1921 standard. The main findings of this study are:1) Both the C06M and C36M alloys exhibited a similar response to irradiation concerning irradiation hardening and embrittlement.2) The irradiation temperature played different roles in terms of irradiation hardening and embrittlement for both C06M and C36M: after irradiation between 166°C and 204°C, both materials exhibited significant irradiation hardening and embrittlement; after irradiation between 315°C and 343°C, both materials showed small irradiation hardening without irradiation embrittlement. After irradiation between 501°C and 507°C, however, the irradiation softening without irradiation embrittlement was observed in both materials.3) Comparing the microhardness and Master Curve reference temperature T0q before and after neutron irradiation, we did not observe a linear correlation between the two parameters for both C06M and C36M steels. This should be mainly due to a flat response of the Master Curve reference temperature T0q to the irradiations at 166–204°C and 315–343°C ranges4) C06M showed a lower T0q, meaning better toughness, than C36M at the unirradiated condition, and such trend was kept even after neutron irradiation except for the 166–204°C irradiation after which both materials had similar T0q.5) In terms of hardening and embrittlement, the irradiation effect on both C06M and C36M appeared to saturate after an irradiation dose of 7 dpa.
Advanced power-generation systems using coal-derived fuels are evaluated in two-volume report. Report considers fuel cells, combined gas- and steam-turbine cycles, and magnetohydrodynamic (MHD) energy conversion. Presents technological status of each type of system and analyzes performance of each operating on medium-Btu fuel gas, either delivered via pipeline to powerplant or generated by coal-gasification process at plantsite.
The U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) have sponsored a project aimed at identifying, evaluating, and qualifying the materials needed for the construction of the critical components of coal-fired power plants capable of operating at much higher efficiencies than the current generation of supercritical plants. This increased efficiency is expected to be achieved principally through the use of advanced ultrasupercritical (A-USC) steam conditions. A limiting factor in this can be the materials of construction for boilers and for steam turbines. The overall project goal is to assess/develop materials technology that will enable achieving turbine throttle steam conditions of 760°C (1400°F)/35MPa (5000 psi). This final technical report covers the research completed by the General Electric Company (GE) and Electric Power Research Institute (EPRI), with support from Oak Ridge National Laboratory (ORNL) and the National Energy Technology Laboratory (NETL) – Albany Research Center, to develop the A-USC steam turbine materials technology to meet the overall project goals. Specifically, this report summarizes the industrial scale-up and materials property database development for non-welded rotors (disc forgings), buckets (blades), bolting, castings (needed for casing and valve bodies), casting weld repair, and casting to pipe welding. Additionally, the report provides an engineering and economic assessment of an A-USC power plant without and with partial carbon capture and storage. This research project successfully demonstrated the materials technology at a sufficient scale and with corresponding materials property data to enable the design of an A-USC steam turbine. The key accomplishments included the development of a triple-melt and forged Haynes 282 disc for bolted rotor construction, long-term property development for Nimonic 105 for blading and bolting, successful scale-up of Haynes 282 and Nimonic 263 castings using traditional sand foundry practices, and a techno-economic study of an A-USC plant including cost estimates for an A-USC turbine which showed A-USC to be economically attractive for partial carbon and capture compared to today’s USC technology. Based on this successful materials research and a review with U.S. utility stakeholders, a new project to develop a component test facility (ComTest) including the world’s first A-USC turbine has been proposed to continue the technology development.
An analytical technique is presented with the goal of measuring reaction kinetics during steam oxidation reactions for three cases in which obtaining kinetics information often requires a prohibitive amount of time and cost. The technique presented relies on coupling thermogravimetric analysis (TGA) with a quantitative hydrogen measurement technique using quadrupole mass spectrometry (QMS). The first case considered is in differentiating between the kinetics of steam oxidation reactions and those for simultaneously reacting gaseous impurities such as nitrogen or oxygen. The second case allows one to independently measure the kinetics of oxide and hydride formation for systems in which both of these reactions are known to take place during steam oxidation. The third case deals with measuring the kinetics of formation for competing volatile and non-volatile oxides during certain steam oxidation reactions. In order to meet the requirements of the coupled technique, a methodology is presented which attempts to provide quantitative measurement of hydrogen generation using QMS in the presence of an interfering fragmentation species, namely water vapor. This is achieved such that all calibrations and corrections are performed during the TGA baseline and steam oxidation programs, making system operation virtually identical to standard TGA. Benchmarking results showed a relative error in hydrogen measurement of 5.7–8.4% following the application of a correction factor. Lastly, suggestions are made for possible improvements to the presented technique so that it may be better applied to the three cases presented.
Some energy consumers require power on an anytime, all-year-round basis with a high level of certainty, including defense installations, isolated communities, and some industrial processes. For these customers, interruptions in electricity or heat can mean substantial financial loss or even loss of life. In the absence of grid-scale energy storage, a high level of power availability can be accomplished only through the robustness and redundancy of power generators. The NuScale small modular reactor design is well suited to provide highly available power because of several features related to both the nuclear steam supply system and the overall plant design. In analogy to Redundant Array of Independent Disks (RAID) systems used to provide highly reliable data storage, a NuScale plant can assure sustained power generation by virtue of its Redundant Array of Integral Reactors (RAIR).This paper describes the NuScale RAIR plant features and summarizes the results of a rigorous analysis of RAIR availability as a function of power or, conversely, the RAIR plant output power as a function of power availability. The analysis utilized the Matrix Laboratory code (MATLAB) and included probability distributions for the frequency and duration of module outages due to planned and unplanned events. Further, the study evaluated the impact of implementing turbine bypass rather than module shutdown and using one or more modules to supply house loads in the case of loss of off-site power (LOOP). Availability results are presented for a 12-module RAIR plant with and without turbine bypass enabled during a LOOP and for different possible connections to the off-site power distribution grid and dedicated service loads. Results indicate that a very high level of availability can be achieved at relatively high power output levels, regardless of turbine bypass and dedicated load connection, compared to the operating fleet.
Iron Chromium Aluminum alloys (FeCrAl) have been developed at Oak Ridge National Laboratory as an advanced fuel cladding for light water reactors (LWR). In contrast to zirconium-based alloys employed today, FeCrAl has slower oxidation kinetics and higher strength. A test (QUENCH-19) at Karlsruhe Institute of Technology’s QUENCH facility is planned to test and demonstrate the performance of FeCrAl cladding under postulated accident conditions. This test will replicate the previous QUENCH-15 test but will use FeCrAl instead of zirconium-based materials. During these tests, a small bundle of fuel rod simulators is electrically heated in a steam and argon environment. The temperature history, oxidation thickness, and in-situ hydrogen generation are the primary measurements of interest.The CORA/BWR code was previously developed and utilized in the 1980’s and 1990’s to simulate BWR bundle degradation during the CORA test series. A modified version of the CORA/BWR code, named CORA/BWR-QUENCH, has been developed to model the QUENCH test facility. The CORA/BWR-QUENCH code was used to model the QUENCH-15 test which used zirconium-based materials. The code predictions and test data were found to be in good agreement. The code was then used to model the planned QUENCH-19 test utilizing FeCrAl cladding, shroud, and spacer grids. The simulation predicts the peak cladding temperature to be 1620 K (~1347°C) for QUENCH-19 which is significantly lower than that during QUENCH-15 with the zirconium-based alloy. The predicted hydrogen generation is also significantly lower for the FeCrAl clad QUENCH-19 as compared to QUENCH-15: ~1.7 g versus ~48.8 g. These results align with expectations given the much slower oxidation kinetics of FeCrAl alloys.
The FARM (Feasible Actuator Range Modifier) software module is a component of the RAVEN-based FORCE framework for analysis of Integrated Energy Systems (IES). FARM aids the HERON software module in the evaluation of the optimal dispatch for the different IES components. Set-point trajectories are required to meet limits on both production variables (i.e., the variables to be optimized such as the electrical power, the hydrogen production rate, etc.) and process variables tied to the service life of equipment (e.g., steam flowrate, vessel pressure, turbine firing temperature, etc.). To evaluate the feasibility of HERON generated set-points and to do so in an acceptable time, FARM employs reduced order models to represent the dynamic behavior of the systems to be dispatched. These surrogate models take the form of a linear dynamic system with sets of Linear Parameter Varying (LPV) matrices that are mapped to the system operating space. These matrices are derived from the trajectories of system state variables and system output variables during transients. The accuracy of LPV matrices depends on the selection of state variables. In previous reports, state variables were selected by adopting a complicated workflow requiring multiple software licenses and an advanced level of user expertise. In this report, a new workflow that automates the state variable selection process is presented. It significantly reduces the frequency of user interventions and does not require multiple software licenses. Each module in the new workflow is described in detail, and the input / output examples in each step of the workflow are provided. It was demonstrated that this workflow can greatly reduce the complexity of the state variable selection process, and that the updated FARM-Gamma and FARM-Delta validators can benefit from this workflow when solving the power dispatch problem of a representative IES test case. Finally, some code improvements that can further enhance the efficiency are suggested.
New nuclear power plants may be one of the technologies for future zero carbon electricity production. These future systems will however also need significant flexibility to cope with fluctuating demand and large share of intermittent renewable supply, rather than running in conventional baseload generation. The present work explores the use of thermal energy storage (TES) as a buffer between the reactor heat and its conversion to electricity, enabling flexible operation of nuclear plants. The focus is on maximizing flexibility, ideally as full decoupling of the nuclear and power cycle islands, as well as on system efficiency in various modes. A system design presented for a high temperature gas cooled reactor (HTGR) presents a slightly complex solution, as separate high- and low-temperature TES systems are required in order to cover the extended temperature range. Although this configuration imposes certain limitations on the discharge system configuration, it also presents the opportunity to design a more efficient system. For this case in particular, a steam reheat cycle is advantageous. Dynamic models were developed for the decoupled system in order to generate insights into aspects of off design operation and system control. A technoeconomic analysis, furthermore, provides sizing and costing of the component, followed by size and dispatch economic optimization considering energy arbitrage. This optimization shows that in all explored markets, the addition of TES system with the proposed configuration results in positive impact on project net present value. Further sensitivity analyses show impact of multiple inputs and possible technical limitations.