Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “turbo-expander”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

14 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Measurement and control system for cryogenic helium gas bearing turbo-expander experimental platform based on Siemens PLC S7-300

An experimental platform for cryogenic Helium gas bearing turbo-expanders is established at the Technical Institute of Physics and Chemistry, Chinese Academy of Sciences. This turbo-expander experimental platform is designed for performance testing and experimental research on Helium turbo-expanders with different sizes from the liquid hydrogen temperature to the room temperature region. A measurement and control system based on Siemens PLC S7-300 for this turbo-expander experimental platform is developed. Proper sensors are selected to measure such parameters as temperature, pressure, rotation speed and air flow rate. All the collected data to be processed are transformed and transmitted to S7-300 CPU. Siemens S7-300 series PLC CPU315-2PN/DP is as master station and two sets of ET200M DP remote expand I/O is as slave station. Profibus-DP field communication is established between master station and slave stations. The upper computer Human Machine Interface (HMI) is compiled using Siemens configuration software WinCC V6.2. The upper computer communicates with PLC by means of industrial Ethernet. Centralized monitoring and distributed control is achieved. Experimental results show that this measurement and control system has fulfilled the test requirement for the turbo-expander experimental platform.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2019

Development of a High-Efficiency Hot Gas Turbo-expander and Low-Cost Heat Exchangers for Optimized CSP Supercritical CO 2 Operation

Southwest Research Institute® (SwRI®) has developed a novel, high-efficiency, supercritical carbon dioxide (sCO 2 ), hot gas turbo-expander optimized for the highly-transient, solar-powerplant, duty-cycle profile. This MW-scale sCO 2 turbo-expander design advances the state-of-theart of sCO 2 turbo-expanders from a current Technology Readiness Level (TRL) of three (initial, small-scale, laboratory, size testing) to a full TRL6 (MW-scale prototype demonstration). A secondary objective of this project was to optimize novel compact heat exchangers for sCO 2 applications to drastically reduce their manufacturing costs. Significant learning was achieved on how to design and fabricate a more cost effective, high performance recuperator, at the MWt capacity. The sCO 2 turbo-expander and novel sCO 2 heat exchanger have been tested in a 1- MWe sCO 2 test loop, fabricated to demonstrate component performance and the performance of the optimized sCO 2 Brayton cycle over a wide range of part load conditions and during transient operations representative of a typical Concentrating Solar Power (CSP) duty cycle. The scalable sCO 2 expander design and improved heat exchanger address and close two critical technology gaps required for an optimized CSP sCO 2 power plant and provide a major stepping stone on the pathway to achieving CSP power at $\$ $0.06/kW-hr Levelized Cost of Electricity (LCOE), increasing energy conversion efficiency to greater than 50% and reducing total power block cost to below $\$ $1,200/kW installed. Construction of the facility and testing has been completed. Test targets of 1,320°F, 27,000 rpm, and 3,500 psi were reached during separate tests. Overall, the turbine saw 37.5 hours of operation with many other hours of testing and troubleshooting all of the loop components. All the test data and troubleshooting is useful and applicable for future tests and operations with not only this loop but in any sCO2 application.

14 SOLAR ENERGY↗
DOE OSTI2023

Particle Separator for Improved Flameless Pressurized Oxy-Combustion

The team of Southwest Research Institute® (SwRI®), ITEA, Electric Power Research Institute, Inc. (EPRI), and General Electric Global Research (GE) is advancing Flameless Pressurized Oxy-combustion (FPO), a novel coal technology. This effort seeks to develop a particle separator for the hot-gas stream leaving the FPO loop. In order to maximize the energy extracted from the cycle, the hot gas is put through a turbo-expander before flue-gas treatment. The particle separator designed under this project sought to operate at high temperature and with low-pressure drop, protecting the turbo-expander from erosion damage. The team engaged potential vendors for the test, developed plans for the pilot test loop modification, and refined requirements for the commercial turbo-expander.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

Commissioning and Testing of a new 4.5K Cold Box for JLab Cryogenic Test Facility

A new 4.5K cold box at Jefferson Lab (JLab) Cryogenic Test Facility (CTF) was recently installed and commissioned to upgrade the existing 4.5 K refrigeration system and work in parallel with the existing 4.5 K cold box. This new 4.5 K cold box is equipped with two turbo-expanders and, at its maximum capacity condition, it is expected to support at least 6.6 g/s of helium liquefaction or 650 W of refrigeration at 4.5 K. It can also handle up to 10 g/s 30 K return flow for 2 K refrigeration recovery that supports cryo-module and superconducting cavity testing. Performances of the cold box at its maximum capacity conditions as well as several other operating modes were tested for acceptance. Finally, we will briefly review the new 4.5 K cold box design features and discuss the commissioning and performance testing results.

42 ENGINEERING↗
DOE OSTI2014

Dynamic simulation of 10 kW Brayton cryocooler for HTS cable

Dynamic simulation of a Brayton cryocooler is presented as a partial effort of a Korean governmental project to develop 1∼3 km HTS cable systems at transmission level in Jeju Island. Thermodynamic design of a 10 kW Brayton cryocooler was completed, and a prototype construction is underway with a basis of steady-state operation. This study is the next step to investigate the transient behavior of cryocooler for two purposes. The first is to simulate and design the cool-down process after scheduled or unscheduled stoppage. The second is to predict the transient behavior following the variation of external conditions such as cryogenic load or outdoor temperature. The detailed specifications of key components, including plate-fin heat exchangers and cryogenic turbo-expanders are incorporated into a commercial software (Aspen HYSYS) to estimate the temporal change of temperature and flow rate over the cryocooler. An initial cool-down scenario and some examples on daily variation of cryocooler are presented and discussed, aiming at stable control schemes of a long cable system.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

MODELING AND TESTING OF A NOVEL ULTRA-LOW TEMPERATURE SCO2 OPPOSING PISTON EXPANDER

The Flameless Pressurized Oxy-Combustion (FPO) cycle, a novel flexible fuel technology, is being developed into a large pilot. This effort seeks to complete the preliminary engineering and planning of a 25 MWth Pilot Plant that will demonstrate the technology for scale-up to a commercial unit. The technology, pioneered by ITEA at the 5 MWth scale, must be brought to a higher technology readiness level (TRL) to be viable at the commercial scale. The 25 MWth pilot cycle was optimized for cost and technology development and demonstration. Preliminary drawings, layouts, and plans were defined. Process flow diagrams were used to describe the pilot configuration in greater detail. A heat and mass balance with stream data was created. A master equipment list specified the operating conditions for major pieces of equipment within the pilot using this heat and mass balance. The 25 MWth FPO pilot is assessed for environmental performance. A test campaign is developed to assess the type of test and number of hours required for pilot demonstration. The environmental performance is compared against projected performance at the commercial scale. This project builds upon extensive evaluation of the techno-economic performance of the FPO technology already performed by ITEA. This includes system improvements, such as the addition of a turbo-expander to the flue gas stream. Some of the performance-enhancing components are not as well defined as others. The primary goal of this effort was to bring all of the core cycle components to the same level of design maturity. A techno-economic assessment (TEA) evaluated the FPO technology at the commercial scale in comparison to the NETL baseline cases. The reference plants were used in combination with proprietary equipment estimates to build a plant capital cost and cost of electricity evaluation. FPO performed better than the sub-bituminous post-combustion capture cases. Further preliminary estimates of improvements to the FPO cycle show even further gains when compared to conventional carbon capture methods.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2019

Pre-Project Planning for a Flameless Pressurized Oxy-Combustion Pilot Plant (Final Technical Report)

The team of Southwest Research Institute® (SwRI®), ITEA, Electric Power Research Institute, Inc. (EPRI), GE Global Research (GE), Jacobs Engineering (Jacobs), and Peter Reineck Associates (PRA) are advancing Flameless Pressurized Oxy-Combustion (FPO), a novel coal technology. This effort seeks to complete the preliminary engineering and planning of a 50-MWth Pilot Plant that produces electricity and steam for district heating. The technology, pioneered by ITEA at the 5-MWth scale, must be brought to a higher technology readiness level (TRL) to be viable at the commercial scale. This project builds upon extensive evaluation of the techno-economic performance of the FPO technology already performed by ITEA. This includes system improvements, such as the addition of a turbo-expander to the flue gas stream. Some of the performance-enhancing components are not as well defined as others. The primary goal of this project was to bring all of the core cycle components to the same level of design maturity. Extensive cycle modeling and evaluation explored various configurations of the process. Different coals, operating conditions, and heat recovery devices were considered and modeled using Aspen Plus. The results of the cycle modeling informed the pilot plant configuration and the planned configuration at the commercial scale. The system pressurization is maintained in the flue gas clean-up and water removal. This allows for efficient and cost-effective carbon dioxide compression and sequestration package. Once the cycle was optimized, preliminary drawings, layouts, and plans defined the pilot facility. Process flow diagrams (PFD) were used to describe the pilot configuration in greater detail. A heat and mass balance with stream data was created. A master equipment list specified the operating conditions for major pieces of equipment within the pilot using this heat and mass balance. A detailed cost estimate for the planned configuration was completed with an Association for the Advancement of Cost Engineering (AACE) Class IV level of cost analysis. A site selection effort evaluated a variety of potential candidate sites. The selection effort focused on three sites for an in-depth evaluation of the merits and viability of hosting a pilot demonstration. The ability of the host site to support the project with cost sharing was also assessed. The selection process chose the University of Wyoming (UW) as the host site, and cost estimates for the pilot capital estimate were made using local data. A preliminary test plan and operation plan, which creates figures of merit, control, and instrumentation was produced. An effort that outlines methods of pilot cost reduction was completed near the end of the project. A techno-economic assessment (TEA) evaluated the FPO technology at the commercial scale in comparison to the NETL baseline cases. The reference plants were used in combination with proprietary equipment estimates to build a plant capital cost and cost of electricity evaluation. FPO performed better than the sub-bituminous post-combustion capture cases. Further preliminary estimates of improvements to the FPO cycle show even further gains when compared to conventional carbon capture methods.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

DEVELOPMENT OF A 25 MWTH FLAMELESS PRESSURIZED OXY-COMBUSTION PILOT

The Flameless Pressurized Oxy-Combustion (FPO) cycle, a novel flexible fuel technology, is being developed into a large pilot. This effort seeks to complete the preliminary engineering and planning of a 25 MWth Pilot Plant that will demonstrate the technology for scale-up to a commercial unit. The technology, pioneered by ITEA at the 5 MWth scale, must be brought to a higher technology readiness level (TRL) to be viable at the commercial scale. The 25 MWth pilot cycle was optimized for cost and technology development and demonstration. Preliminary drawings, layouts, and plans were defined. Process flow diagrams were used to describe the pilot configuration in greater detail. A heat and mass balance with stream data was created. A master equipment list specified the operating conditions for major pieces of equipment within the pilot using this heat and mass balance. The 25 MWth FPO pilot is assessed for environmental performance. A test campaign is developed to assess the type of test and number of hours required for pilot demonstration. The environmental performance is compared against projected performance at the commercial scale. This project builds upon extensive evaluation of the techno-economic performance of the FPO technology already performed by ITEA. This includes system improvements, such as the addition of a turbo-expander to the flue gas stream. Some of the performance-enhancing components are not as well defined as others. The primary goal of this effort was to bring all of the core cycle components to the same level of design maturity. A techno-economic assessment (TEA) evaluated the FPO technology at the commercial scale in comparison to the NETL baseline cases. The reference plants were used in combination with proprietary equipment estimates to build a plant capital cost and cost of electricity evaluation. FPO performed better than the sub-bituminous post-combustion capture cases. Further preliminary estimates of improvements to the FPO cycle show even further gains when compared to conventional carbon capture methods.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Enabling Coal Technology with Carbon Capture for Future Markets with Flameless Pressurized Oxy-Combustion (FPO)

Future markets for power are expected to require more load following power plants, which reduces output during the night and early morning. This is when the demand for electricity is the lowest, so plants must respond rapidly at any time to peak loads resulting from the variable output of wind and solar power. A coal power plant based on Flameless Pressurized Oxy-combustion (FPO) can go from 5% to 100% of capacity rate in less than 30 minutes in response to fluctuating demand, operating at capacity when power prices are highest. FPO is a proven oxy-combustion technology that was developed to recover energy from low ranking coal, other brown fuels and wastes. ITEA began developing FPO in 2003 on a 5-MWth pilot in Gioia del Colle, Italy, to destroy hazardous industrial waste and as such, design objectives were very high combustion efficiencies and capture of metals in the fuel in the vitreous slag. The technology was subsequently deployed in 2009 at the 15-MWth scale at the Jurong Island petrochemical cluster in Singapore for waste incineration. FPO is an oxy-combustion process whereby oxygen is separated from the air, and it is used in combustion with recirculated flue gas to maintain combustion temperatures at acceptable levels. The resultant flue gas is primarily CO 2 and water, which allows for a relatively simple and cheap CO 2 capture process. This is in contrast to air-combustion systems which require a complex and costly post-combustion capture (PCC) process. Coal is fed to the combustor slurried in water, and the combustor operates at elevated pressure (approximately 12 bar) which improves the overall efficiency and reduces the size and cost of the combustor. Notably, the FPO cycle maintains high efficiency by recovering most of the heat of vaporisation of the contained water. The combustor is designed to coalesce the molten ash particles so that they settle to the chamber walls and drain to the outlet, significantly reducing the particulate content in the exhaust gas and allowing the use of coals with up to 40% alkaline ash content. FPO is a low-emission technology: zero thermal NOx minimises overall NOx; any organic nitrogen is converted to elemental nitrogen (N2). Total organic content (TOC) at combustor exit is hundreds of times lower than for traditional combustion processes, with dioxin and furans close to zero. Work commenced on a DOE funded pilot demonstration project in October 2016 to provide the design for a 50-MWth FPO pilot plant that can fire a wide range of high-to-low rank coals. The project will investigate updating and improving the cycle for power generation with CO 2 capture by incorporating a turbo-expander with a principal steam power island that utilizes a heat recovery steam generator, increasing the overall efficiency of the cycle. A cost study is also performed on the updated FPO design as part of the project. The FPO pilot plant built based on the design will then be demonstrated over a 3-year test program to generate data for the design of a commercial-scale 500 MWth firing module commercial power plant with integral carbon capture and sequestration (CCS), which could start construction in 2025. A discussion of the levelized cost of electricity (LCOE) of various cases are presented, including a comparison of established supercritical with PCC (SCPC) technologies with FPO fitted with CO 2 compression and liquefaction, and FPO ready for carbon capture and sequestration (CCS-ready). This would enable CO 2 capture for use in enhanced oil recovery (EOR) or sequestration when market conditions make it attractive to do so. In addition, a comparison of LCOE of FPO and conventional processes for firing low-ranking coals with high water and ash content will be provided.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2013

Beowawe Bottoming Binary Unit

This binary plant is the first high-output refrigeration based waste heat recovery cycle in the industry. Its working fluid is environmentally friendly and as such, the permits that would be required with a butane based cycle are not necessary. The unit is modularized, meaning that the unit’s individual skids were assembled in another location and were shipped via truck to the plant site. This project proves the technical feasibility of using low temperature brine. The development of the unit led to the realization of low temperature, high output, and environmentally friendly heat recovery systems through domestic research and engineering. The project generates additional renewable energy for Nevada, resulting in cleaner air and reduced carbon dioxide emissions. Royalty and tax payments to governmental agencies will increase, resulting in reduced financial pressure on local entities. The major components of the unit were sourced from American companies, resulting in increased economic activity throughout the country.

15 GEOTHERMAL ENERGY↗