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At least 163 records · Page 9

Analysis and design of an ultrahigh temperature hydrogen-fueled MHD generator

A coupled gas dynamics/radiative heat transfer analysis of partially ionized hydrogen, in local thermodynamic equilibrium, flowing through an ultrahigh temperature (10,000-20,000 K) magnetohydrodynamic (MHD) generator is performed. Gas dynamics are modeled by a set of quasi-one-dimensional, nonlinear differential equations which account for friction, convective and radiative heat transfer, and the interaction between the ionized gas and applied magnetic field. Radiative heat transfer is modeled using nongray, absorbing-emitting 2D and 3D P-1 approximations which permit an arbitrary variation of the spectral absorption coefficient with frequency. Gas dynamics and radiative heat transfer are coupled through the energy equation and through the temperature- and density-dependent absorption coefficient. The resulting nonlinear elliptic problem is solved by iterative methods. Design of such MHD generators as onboard, open-cycle, electric power supplies for a particular advanced airbreathing propulsion concept produced an efficient and compact 128-MWe generator characterized by an extraction ratio of 35.5 percent, a power density of 10,500 MWe/cu m, and a specific (extracted) energy of 324 MJe/kg of hydrogen. The maximum wall heat flux and total wall heat load were 453 MW/sq m and 62 MW, respectively.

Moder, Jeffrey P.↗

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↗

An Analysis of the Strayton Engine, a Brayton and Stirling Cycle Recuperating Engine

This paper explores the novel Strayton engine concept. This engine combines the cycles of a Brayton engine with that of a Stirling engine to create a highly efficient recuperating gas turbine engine. In the explored case, both Brayton cycle and Stirling cycle engines are used to generate electrical power. Additionally, the Stirling engine is used to draw heat out of the Brayton turbine (acting to cool the turbine blades), while also pumping heat into Brayton cycle just before combustion occurs (acting as the mechanism for recuperation). The purpose of this paper is to detail the system level modeling techniques used to generate the simulation, perform a cycle analysis of the combined cycle engine, identify key technologies and challenges associated with the concept, and compare potential performance gains with existing gas turbine engines and internal combustion engines. Topics such as controls, blade cooling effects, engine weight, and heat transfer using heat pipe are also explored. Results from this work show potential architectures that could provide the required heat transfer rates, potential control strategies, and performance benefits, including efficiency gains between 10% and 3% on engines ranging from 200HP to 670HP with the combined cycle engine.

Chapman, Jeffryes W.↗

An Analysis of the Strayton Engine, a Brayton and Stirling Cycle Recuperating Engine

This paper explores the novel Strayton engine concept. This engine combines the cycles of a Brayton engine with that of a Stirling engine to create a highly efficient recuperating gas turbine engine. In the explored case, both Brayton cycle and Stirling cycle engines are used to generate electrical power. Additionally, the Stirling engine is used to draw heat out of the Brayton turbine (acting to cool the turbine blades), while also pumping heat into Brayton cycle just before combustion occurs (acting as the mechanism for recuperation). The purpose of this paper is to detail the system level modeling techniques used to generate the simulation, perform a cycle analysis of the combined cycle engine, identify key technologies and challenges associated with the concept, and compare potential performance gains with existing gas turbine engines and internal combustion engines. Topics such as controls, blade cooling effects, engine weight, and heat transfer using heat pipe are also explored. Results from this work show potential architectures that could provide the required heat transfer rates, potential control strategies, and performance benefits, including efficiency gains between 10% and 3% on engines ranging from 200HP to 670HP with the combined cycle engine.

Gas turbine engine↗

Analytical investigation of thermal barrier coatings for advanced power generation combustion turbines

An analytical evaluation was conducted to determine quantitatively the improvement potential in cycle efficiency and cost of electricity made possible by the introduction of thermal barrier coatings to power generation combustion turbine systems. The thermal barrier system, a metallic bond coat and yttria stabilized zirconia outer layer applied by plasma spray techniques, acts as a heat insulator to provide substantial metal temperature reductions below that of the exposed thermal barrier surface. The study results show the thermal barrier to be a potentially attractive means for improving performance and reducing cost of electricity for the simple, recuperated, and combined cycles evaluated.

Amos, D. J.↗

EM-Enhanced HyPOR Loop for Fast Fusion Cycles

Vacuum pumps are the heart of a fusion energy facility – fusion power cannot be generated without them. Nevertheless, the vacuum technology needed to operate a viable fuel cycle for a compact fusion power plant does not exist. Commercial vacuum technology offers the best solution to this challenge, but a pump oil recycling and detritiation system is necessary. Conventional oil detritiation processes have only been developed to deal with legacy waste and are too slow and destructive to the oil. Further, post hoc detritiation strategies are intrinsically inefficient. Our approach is to rethink the challenge holistically by designing the pumping fluid and tritium extraction system in an integrated manner to achieve an innovative solution. By selecting an oil for the specific task of pumping tritium and then designing our catalytic system to selectively target the tritium-bearing functional groups, an effective detritiation system (hydrocarbon pump oil recycling, HyPOR, loop) for fusion power plants can be obtained. The project demonstrated a HyPOR loop process that can selectively remove heavier hydrogen isotopes from pump oil, reaching the target of 99.5 % removal, with an uptake of less than 0.01% of tritium throughput, while also purifying the oil of radiation-induced damage. The recycled oil retained its pumping characteristics over 7 recycles and gamma irradiation over 30 MGy. By meeting these targets, the project enable a reduction in pump operational costs from $\$$14.5M/year to $\$$103k/year (>140× reduction), reducing pump electric power consumption from 2.8 MW to 0.25 MW (>10× reduction), and reducing in-process tritium inventory from 2.03 kg to 0.48 kg (>4× reduction).

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Forecasting Solar-Thermal Systems Performance under Transient Operation Using a Data-Driven Machine Learning Approach Based on the Deep Operator Network Architecture

Modeling and prediction of the dynamic behavior of thermal systems operating under intermittent energy input and variable load requirements represent one of the greatest challenges in the development of efficient and reliable renewable-based power generation technologies. In this work, a data-driven machine learning modeling framework was developed based on a modified version of the Deep Operator Network architecture where the time coordinate in the trunk net is replaced with historical data of the predicting quantity. The modeling framework can be used to accurately predict the performance of renewable-based energy conversion technologies including wind- and solar-based power plants. This novel framework was applied on a solar-thermal system that consists of a solar collection loop using a flat plate collector, a power generation loop comprising an Organic Rankine Cycle, and a thermal energy storage tank connecting both loops. Variable solar irradiance, air temperature, and power load profiles were used by the Deep Operator Network to predict the State-of-Charge and the efficiency of the thermal system for several days. The results were compared with the State-of-Charge and efficiency functions calculated using a physics-based model. For a simple operation scenario, characterized by a clear sky solar irradiance profile and constant load, the standard deviation in the State-of-Charge prediction by Deep Operator Network is below 0.9% during a seven-day prediction time horizon. For the most realistic operation scenario that considers real solar irradiance and a rough load profile, the maximum standard deviation in the predictions for the State-of-Charge and efficiency are below 6.8% and 2.5%, respectively. A comparison between Deep Operator Network and Long Short Term Memory network was also performed. In general, both networks predict very well the State-of-Charge for different data density conditions; however, a higher accuracy, with a standard deviation below 2.0%, is obtained by the Deep Operator Network during three and half days using sparser training data of 20-minute points. The same accuracy for the State-of-Charge prediction with the Long Short Term Memory network is achieved only for 14 h. Average standard deviations for the State-of-Charge prediction of 1.1% with the Deep Operator Network and 1.5% with the Long Short Term Memory network are obtained for a four-day prediction time using a denser training data of 5-minute points.

DeepONet↗

Development of a differentially balanced magnetic bearing and control system for use with a flywheel energy storage system

The purpose of a magnetically suspended flywheel energy storage system for electric utility load leveling is to provide a means to store energy during times when energy is inexpensive to produce and then return it to the customer during times of peak power demand when generated energy is most expensive. The design of a 20 kWh flywheel energy storage system for electric utility load leveling applications involves the successful integration of a number of advanced technologies so as to minimize the size and cost of the system without affecting its efficiency and reliability. The flywheel energy storage system uses a carbon epoxy flywheel, two specially designed low loss magnetic bearings, a high efficiency motor generator, and a 60 cycle AC power converter all integrated through a microprocessor controller. The basic design is discussed of each of the components that is used in the energy storage design.

Higgins, Mark A.↗

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↗

Modeling of Supercritical CO2 Shell-and-Tube Heat Exchangers Under Extreme Conditions. Part I: Correlation Development

Abstract High-temperature supercritical CO2 Brayton cycles are promising possibilities for future stationary power generation and hybrid electric propulsion applications. Heat exchangers are critical components in supercritical CO2 thermal cycles and require accurate correlations and comprehensive performance modeling under extreme temperatures and pressures. In this paper (Part I), new Colburn and friction factor correlations are developed to quantify shell-side heat transfer and friction characteristics of flow within heat exchangers in the shell-and-tube configuration. Using experimental and computational fluid dynamics (CFD) data sets from existing literature, multivariate regression analysis is conducted to achieve correlations that capture the effect of multiple critical geometric parameters. These correlations offer superior accuracy and versatility as compared to previous studies and predict the thermohydraulic performance of about 90% of the existing experimental and CFD data within ±15%. Supplementary thermohydraulic performance data are acquired from CFD simulations with supercritical CO2 as working fluid to validate the developed correlations and demonstrate its capability to be applied to supercrtical CO2 heat exchangers.

Engineering↗

A simple performance calculation method for LH2/LOX engines with different power cycles

A simple method for the calculation of the specific impulse of an engine with a gas generator cycle is presented. The solution is obtained by a power balance between turbine and pump. Approximate equations for the performance of the combustion products of LH2/LOX are derived. Performance results are compared with solutions of different engine types.

Schmucker, R. H.↗

Systems Analysis of Biomass and Coal Co-firing Power Plants with Deep Carbon Capture Toward Net-zero Emissions

Achieving a net-zero emission economy in the United States requires integrating diverse low-carbon and negative-emission technologies into the existing fossil fuel-dominant power fleet. Potential technologies from the low-carbon portfolio include renewable power, fossil power with carbon capture and storage (CCS), bioenergy with CCS (BECCS), and direct air capture (DAC). Renewable power is a clean energy source but has to pair with costly battery storage to provide dispatchable electricity. Fossil power with CCS offers dispatchable electricity yet still relies on DAC to offset residual emissions, even when deploying deep CCS with more than 90% CO2 capture. Coal-biomass co-firing with CCS, a subset of BECCS, is a reliable energy production technology that can be retrofitted from existing electricity generation units (EGUs). Power plant retrofit maximizes the use of the current U.S. coal power fleet without the need for large-scale deployment of new renewable power, battery storage, or DAC. Retrofitting coal-biomass co-firing with deep CCS in EGUs is a promising option, but not a universal solution. Biomass co-firing at a power plant introduces economic challenges and indirectly poses pressure on land and water resources. Meanwhile, retrofitting deep CCS affects plant efficiency and raises electricity generation costs. Overall, the technical feasibility and economic viability of plant retrofits vary across EGUs, as they are contingent upon the regional availability of biomass, unit-specific characteristics, site-specific fuel supply costs, and adjacent CO2 storage potential. Government incentives like 45Q can improve the retrofit viability, though the impact requires further quantification. A comprehensive analysis at the unit level is essential to address the question regarding the fate of the U.S. coal-fired electricity generation fleet toward the net-zero emission goal. This study conducts a systematic techno-economic-environmental assessment of EGUs to identify the viability of biomass co-firing and deep CCS retrofits in the U.S. coal-fired power fleet. Specifically, it characterizes the techno-economic performance of deep carbon capture, estimates life cycle greenhouse gas (GHG) emissions, and conducts a fleet-level assessment on retrofit viability. The key objectives are (1) to estimate the unit-specific performance and retrofitted cost under various biomass co-firing levels and CO2 capture rates; (2) to determine the possibility of reaching net-zero emission at the fleet level; (3) to quantify the cumulative capacities that are suitable for plant retrofits under current and future biomass supply scenarios; and (4) to improve the understanding of policy impacts on such retrofits to help the power sector’s transition to a net-zero economy. Techno-economic Model of Deep Carbon Capture. This study develops the performance and economic models for Monoethanolamine-based post-combustion CO2 capture at 95–99% capture rates. The process is simulated in Aspen Plus, analyzing the performance of carbon capture technology by varying the plant sizes, solvent lean loading, CO2 concentrations, and flue gas inlet temperature. Based on the key inputs and output parameters of CO2 capture, a reduced-order performance model of deep carbon capture is formulated. In addition, an engineering-economic model integrating the performance metrics is developed to estimate the capital as well as operation and maintenance (O&M) costs. Capital cost estimations follow the framework of the Integrated Environmental Control Model (IECM) and incorporate data regressions from three technical reports by IECM, the National Energy Technology Laboratory (NETL), and the National Renewable Energy Laboratory. The O&M cost estimation utilizes the actual inventory consumption rate and labor requirements. Both performance and cost models are embedded into IECM v13.0-beta, a fossil-fuel power plant modeling tool. Life Cycle Assessment of Power Plants. This study estimates the GHG emissions of power plants through life cycle assessment (LCA). The LCA scope includes fuel supply, combustion-based power generation, and CO2 transport and storage. The fuel-based life cycle module is designed following the framework of the NETL Unit Process Library and CO2U LCA Guidance Toolkit. The module is then incorporated into IECM v13.0-beta. The process-based LCA is applied to estimate the GHG emissions of coal and biomass supply, coal- and coal-biomass co-firing power plant operation, as well as CO2 pipeline transport and geographical sequestration. An uncertainty analysis is conducted to quantify the variability and uncertainty associated with the LCA using the Latin Hypercube Sampling (LHS) method. Fleet-level Assessment. This study evaluates the technical and economic feasibility of selected coal-fired EGUs, examines the role of tax credits in retrofit viability, and assesses the competitiveness of retrofitted units against other low-carbon options. Unit screening identifies EGUs for the study, focusing on new, efficient baseload units with air pollution controls. The power plant databases are then established to organize unit-specific information on performance and operating conditions from the relevant public databases. Biomass for co-firing retrofits is selected based on home and neighboring county availability, ensuring sustained operation with at least a 5% co-firing level. The CO2 storage site is determined by state-level storage potential, with ArcGIS Pro and NETL CO2 Saline Storage Cost Model used to identify the optimal balance between the nearest transport distances and affordable storage costs. The latest IECM v13.0-beta is then employed to configure and evaluate the eligible EGUs with or without the deployment of deep CCS and biomass co-firing. A supply curve is established to illustrate the cumulative installed capacity suitable for retrofits at different cost levels. A sensitivity analysis on tax credits for carbon sequestration is performed. Finally, a unit-level cost comparison is conducted among retrofitted plants, renewable power with battery storage, and abated fossil fuels with DAC. Expected Results. This study evaluates the technical, economic, and environmental metrics of each EGU across an array of CO2 capture rates and biomass co-firing level scenarios. Unit-level comparisons will identify critical factors influencing technical performance. The supply curves with and without tax incentives will provide insights into the impact of tax credits on biomass co-firing and CCS deployment. The cost comparisons with renewables and DAC-retrofit will assess the competitiveness of the retrofitted units. Life cycle emissions from each unit will be assessed to identify the scenarios under which net-zero emissions can be achieved. These analyses are expected to determine the total coal-fired capacity suitable for serving as a low-carbon energy source with or without tax incentives. The study results are novel in identifying optimal unit-specific strategies for producing carbon-neutral power, whether through retrofitting EGUs with deep CCS, biomass co-firing, DAC, or installing renewable power with battery. The findings will provide insight into nationwide efforts to ensure reliable, affordable, and low-carbon electricity. It also will inform investment decisions and policies in the deployment of deep carbon capture and negative emission technologies for a net-zero energy future.

Biomass Co-firing↗

Steam Generators: Thermal Hydraulic Measurements and Instrumentation

Steam generators are integral components of both conventional and advanced reactors utilizing steam power cycles, as they influence the power conversion performance. Steam generator designs are highly influenced by the type of reactor coolant used, which mainly governs the different control, monitoring, and safety system actuation requirements. Therefore, the present work reviews the thermal hydraulics instrumentation within steam generators designed for pressurized water reactors (PWRs), high-temperature gas-cooled reactors (HTGRs), sodium fast reactors (SFRs), and molten salt cooled reactors (MSRs). Emphasis is given to measurement techniques that are either unique or particularly important to specific reactor types. Lastly, a discussion is provided on the instrumentation and measured parameters. The work identifies standard parameters of interest and is expected to aid the development of test beds and novel measurements techniques.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

Evaluating Microchannel Heat Exchanger Lifetime for Concentrating Solar Power Applications FY24Q4 (RPPR-1)

Microchannel heat exchanger technology is being pursued for next generation CSP concepts for primary power cycle heat addition and power cycle heat recuperation due to the high heat transfer coefficients and pressure containment advantages of small sCO 2 channels. The economics of future CSP plants as dictated by the SETO 2020 or 2030 targets depend on a heat exchanger with a 30-year lifetime (resisting creep, fatigue, corrosion, erosion) and operational characteristics such as fast ramping and the ability to withstand thermal shock. However, the lifetime and operational limits of microchannel heat exchangers operating at high-temperatures, particularly those constructed from high-nickel alloys, are not well known. This uncertainty has resulted in heat exchanger vendors not being able to accurately forecast heat exchanger lifetime as required by customers, specify operational limits as required by process engineers to prevent premature heat exchanger failure, or overdesign heat exchanger which leads to higher cost than necessary. Our goal is to evaluate heat exchanger lifetime and operational limits for the manufacturing and prototype design for next-generation CSP heat exchanger technology through a combination of collecting experimental data and modeling studies.

14 SOLAR ENERGY↗

Gen 3 Particle Pilot Plant (G3P3) -- High-Temperature Particle System for Concentrating Solar Power (Phases 1 and 2)

The U.S. Department of Energy Solar Energy Technologies Office initiated the Generation 3 Concentrating Solar Power (CSP) program to achieve higher operating temperatures (>700 °C) to enable next-generation CSP high-temperature power cycles such as the supercritical CO 2 (sCO2) Brayton Cycle. Three teams were selected to pursue high-temperature gas, liquid, and solid pathways for the heat-transfer media. Phases 1 and 2, which lasted from 2018 – 2020, consisted of design, modeling, and testing activities to further de-risk each of the technologies and develop a design for construction, commissioning, and operation of a pilot-scale facility in Phase 3 (2021 – 2024). This report summarizes the activities in Phases 1 and 2 for the solid-particle pathway led by Sandia National Laboratories. In Phases 1 and 2, Sandia successfully de-risked key elements of the proposed Gen 3 Particle Pilot Plant (G3P3) by improving the design, operation, and performance of key particle component technologies including the receiver, storage bins, particle-to-sCO2 heat exchanger, particle lift, and data acquisition and controls. Modeling and testing of critical components have led to optimized designs that meet desired performance metrics. Detailed drawings, piping and instrumentation diagrams, and process flow diagrams were generated for the integrated system, and structural analyses of the assembled tower structure were performed to demonstrate compliance with relevant codes and standards. Instrumentation and control systems of key subsystems were also demonstrated. Together with Bridgers & Paxton, Bohannan Huston, and Sandia Facilities, we have completed a 100% G3P3 tower design package with stamped engineering drawings suitable for construction bid in Phase 3.

14 SOLAR ENERGY↗

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↗

NETL Natural Gas Lifecycle Model

This is the excel-based life cycle model that contains all the parameters and Monte Carlo simulation capabilities to model the techno-regions contained in the report: Life Cycle Analysis of Natural Gas Extraction and Power Generation: U.S. 2020 Emissions Profile.

conventional gas↗