Milton E. Vernon

Operation and analysis of a supercritical CO2 Brayton cycle.

Sandia National Laboratories is investigating advanced Brayton cycles using supercritical working fluids for use with solar, nuclear or fossil heat sources. The focus of this work has been on the supercritical CO{sub 2} cycle (S-CO2) which has the potential for high efficiency in the temperature range of interest for these heat sources, and is also very compact, with the potential for lower capital costs. The first step in the development of these advanced cycles was the construction of a small scale Brayton cycle loop, funded by the Laboratory Directed Research & Development program, to study the key issue of compression near the critical point of CO{sub 2}. This document outlines the design of the small scale loop, describes the major components, presents models of system performance, including losses, leakage, windage, compressor performance, and flow map predictions, and finally describes the experimental results that have been generated.

Supercritical CO2 direct cycle Gas Fast Reactor (SC-GFR) concept.

This report describes the supercritical carbon dioxide (S-CO{sub 2}) direct cycle gas fast reactor (SC-GFR) concept. The SC-GFR reactor concept was developed to determine the feasibility of a right size reactor (RSR) type concept using S-CO{sub 2} as the working fluid in a direct cycle fast reactor. Scoping analyses were performed for a 200 to 400 MWth reactor and an S-CO{sub 2} Brayton cycle. Although a significant amount of work is still required, this type of reactor concept maintains some potentially significant advantages over ideal gas-cooled systems and liquid metal-cooled systems. The analyses presented in this report show that a relatively small long-life reactor core could be developed that maintains decay heat removal by natural circulation. The concept is based largely on the Advanced Gas Reactor (AGR) commercial power plants operated in the United Kingdom and other GFR concepts.

Design Considerations for Concentrating Solar Power Tower Systems Employing Molten Salt

The Solar Two Project was a United States Department of Energy sponsored project operated from 1996 to 1999 to demonstrate the coupling of a solar power tower with a molten nitrate salt as a heat transfer media and for thermal storage. Over all, the Solar Two Project was very successful; however many operational challenges were encountered. In this work, the major problems encountered in operation of the Solar Two facility were evaluated and alternative technologies identified for use in a future solar power tower operating with a steam Rankine power cycle. Many of the major problems encountered can be addressed with new technologies that were not available a decade ago. These new technologies include better thermal insulation, analytical equipment, pumps and values specifically designed for molten nitrate salts, and gaskets resistant to thermal cycling and advanced equipment designs.

Supercritical CO2 Brayton Cycle Power Generation Development Program and Initial Test Results

The DOE Office of Nuclear Energy and Sandia National Labs are investigating supercritical CO2 Brayton cycles as a potentially more efficient and compact power conversion system for advanced nuclear reactors, and other heat sources including solar, geothermal, and fossil or bio fuel systems. The focus of this work is on the supercritical CO2 Brayton cycle which has the potential for both high efficiency, in temperature range (400–750 C), and for reduced capital costs due to very compact turbomachinery. The cycle achieves high efficiency due to the non-ideal behavior of supercritical CO2 , and it achieves extremely high power density because the fluid in the turbomachinery is very dense, 10%–60% the density of water. Sandia and its contractor Barber Nichols Inc. have fabricated and are operating a supercritical CO2 (S-CO2 ) compression test-loop to investigate the key technology issues associated with this cycle. The compression loop is part of a multi-year phased development program to develop a megawatt (MW) heater-class closed S-CO2 Brayton cycle to demonstrate the applicability of this cycle to heat sources above 400 C. Other portions of the program include modifications to the compression loop to operate it as a simple heated Brayton loop by adding a small turbine and a heater, but with no recuperator. The early testing of this simple Brayton cycle is under way. A more ambitious effort is currently constructing a recompression cycle Brayton loop (1) which is some times called a split-flow Brayton cycle. This cycle is used to increase the efficiency of the system by providing large amounts of recuperation using printed circuit heat exchangers. The re-compression (or split-flow) Brayton cycle is designed to operate at 1000 F (538 C) and produce up to 250 kWe with a 1.47″ OD radial compressor and a 2.68″ OD radial turbine. The current compression loop uses a main compressor that is identical to the main compressors in all the Brayton cycles that are being developed at Sandia. The key issues for the supercritical Brayton cycle include the fundamental issues of compressor fluid performance and system control near the critical point. Near the critical point very non ideal fluid behavior is observed which means that standard tools for analyzing compressor performance cannot be used. Thus one of the goals of the program is to develop data that can be used to validate the tools and models that are used to design the turbomachinery. Other supporting technology issues that are essential to achieving efficiency and cost objectives include bearing type, thrust load and thrust load balancing, bearing cooling, sealing technologies, and rotor windage losses. The current tests are providing the first measurements and information on these important supercritical CO2 power conversion system questions. Some of this data is presented in this report. In the testing to date, the turbomachinery has reached maximum speeds of 65,000 rpm, peak flow rates of over 9 lb/s and pressure ratios of just over 1.65. Compressor inlet fluid densities have been varied from 14% to 70% the density of water. Although the data from these tests are only the first results to be analyzed, they indicate that the basic design and performance predictions are sound. The loops have operated the turbo-compressor on the liquid and vapor side of the saturation curve, very near the critical point, above the critical point and even on the saturation dome. We have also operated the compressor near the choked flow regime and even in surge. At the current operating speeds and pressures, the observed performance map data agrees extremely well with the model predictions. These results have positive implications for the ultimate success of the S-CO2 cycle. In general the main compressor shows no adverse behavior while operating over a wide range of normal operating conditions. It operates reliably and with performance values that are very near the predicted results. Future efforts will focus on operating the Brayton cycle loop at sufficiently high temperatures that electrical power can be produced near the end of 2009. The compression-loop hardware is now the test bed for confirming the remaining parameters to support the next stage of development — which is the 1 MW heater-class split-flow or re-compressor Brayton cycle.Copyright

Description and Test Results from a Supercritical CO2 Brayton Cycle Development Program

The Supercritical CO2 Brayton cycle (S-CO2) can potentially offer more efficient and compact power conversion systems for advanced nuclear reactors, solar, or fossil fuel systems. The DOE Office of Nuclear Energy, Knolls Atomic Power Laboratory, and Sandia National Labs are investigating this cycle in a phased development program because it has the potential for high efficiency (in the temperature range from 400 °C to 750 °C), is very compact making it transportable, and may reduce capital costs due to the very compact turbomachinery. This paper describes resent test results from a supercritical CO2 closed Brayton cycle test loop. Sandia manufactured the loop through its contractor Barber Nichols Inc. The paper describes experimental test measurements of the main compressor performance map, the operational behavior of the supercritical loop at the critical point and below the critical point, and it illustrates the approach to break-even power production at very low turbine inlet temperatures (60 °C / 140 °F) using 78 kW of heater power.

SULFURIC ACID DECOMPOSITION FOR THE SULFUR BASED THERMOCHEMICAL CYCLES.

Abstract In this work, we describe a novel design for a H2SO4 decomposer. The decomposition of H2SO4 to produce SO2 is a common processing operation in the sulfur-based thermochemical cycles for hydrogen production where acid decomposition takes place at 850°C in the presence of a catalyst. The combination of a high temperature and sulfuric acid creates a very corrosive environment that presents significant design challenges. The new decomposer design is based on a bayonet-type heat exchanger tube with the annular space packed with a catalyst. The unit is constructed of silicon carbide and other highly corrosion-resistant materials. The new design integrates acid boiling, superheating, decomposition, and heat recuperation into a single process and eliminates problems of corrosion and failure of high-temperature seals encountered in previous testing using metallic construction materials. The unit was tested by varying the acid feed rate and decomposition temperature and pressure.

CFD Modeling of Bayonet Type High Temperature Heat Exchanger and Chemical Decomposer With Different Packed Bed Designs

The present work is concerned with use of bayonet type high temperature heat exchanger as silicon carbide integrated decomposer (SID) which produces sulfuric acid decomposition product - sulfur dioxide. The product can be used within the sulfur iodine thermo-chemical cycle portion of the hydrogen production process. The chemical decomposition occurs in packed bed area of the decomposer. The engineering design of the packed bed is very much influenced by the structure of the packing matrix, which is governed by the shape, dimensions and the loading of the constituent particles. Optimum design of catalyst pellet in terms of shape configuration, packing method and available surface area can promote catalytic activity and the prevailing transport properties of the system. Knowledge of the underlying factors should enable designers to engineer the optimum design for a given system with prescribed conditions. The investigations of fluid flow and the arrangement of cylindrical and spherical pellets in packed bed are presented in the paper.Copyright

Sandia’s Supercritical CO2 Direct Cycle Gas Fast Reactor (SC-GFR) Concept

The advanced nuclear concept group at Sandia National Laboratories has been investigating two advance right size reactors (RSR); this paper will discuss one of these two systems. The supercritical carbon dioxide (S-CO2), direct cycle gas fast reactor (SC-GFR) concept was developed to determine the feasibility of a RSR type concept using S-CO2 as the working fluid in a direct cycle fast reactor. Although a significant amount of work is still required, this type of reactor concept maintains some potentially significant advantages over ideal gas-cooled systems and liquid metal-cooled systems. The analyses presented in this paper show that a relatively small long-life reactor core could be developed that maintains decay heat removal by natural circulation. The SC-GFR concept is a relatively small (200 MWth) fast reactor that is cooled with CO2 at a pressure of 20 MPa. The CO2 flows out of the reactor vessel at ∼650°C directly into a turbine-generator unit to produce electrical power. The thermodynamic cycle that is used for the power conversion is a supercritical gas Brayton cycle with CO2 as the working fluid. With the CO2 gas near the critical point after the heat rejection portion of the cycle, it can be compressed with less power as compared to a standard gas Brayton cycle, thereby allowing for a higher thermal efficiency at the same turbine inlet temperature. A cycle efficiency of 45–50% is theoretically achievable for an optimized configuration. The major advantages of the concept include the following: • High thermal efficiency at relatively low reactor outlet temperatures; • Compact, cost-effective, power conversion system; • Non-flammable, stable, inert, non-toxic, inexpensive, and well-characterized coolant; • Potential long-life core and closed fuel cycle; • Small void reactivity worth from loss of coolant; • Natural convection decay heat removal; • Feasible design using today’s technologies. The goal of this work was to develop a SC-GFR concept and perform scoping analyses, including a review of other concepts that are similar in nature, to determine concept feasibility, advantages, disadvantages, and issues requiring further investigation. Overall, the SC-GFR concept as described in this paper appears feasible and warrants further study.Copyright

A fission fragment reactor concept for nuclear thermal propulsion

The Space Exploration Initiative requires the development of nuclear thermal and nuclear electric technologies for space propulsion for future Luna and Mars missions. Sandia National Laboratories has proposed a new nuclear thermal propulsion concept that uses fission fragments to directly heat the propellant up to 1000 K or higher above the material temperatures. The concept offers significant advantages over traditional solid‐core nuclear rocket concepts because of higher propellent exit temperatures, while at the same time providing for more reliable operation due to lower structure temperatures and lower power densities. The reactor can be operated in either a steady‐state or pulsed mode. The steady‐state mode provides a high thrust and relatively high specific impulse, as compared to other nuclear thermal concepts. The pulsed mode requires an auxillary radiator for cooling, but has the possibility of achieving very high specific impulses and thrust scaleable to the radiator size. The propellant temper...