Technology Development Of Modular, Low-Cost, High .
Technology Development ofModular, Low-Cost, High-TemperatureRecuperators for Supercritical CO2 Power CyclesDE-FE0026273 Kickoff MeetingNovember 12, 2015Lalit Chordia, Ph.D.Marc PortnoffThar Energy, LLCGrant MusgroveKlaus Brun, Ph.D.Southwest Research InstituteDE-FE0026273 Project Kickoff
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comOutline Project Participants Project and Technical Overview sCO2 Power Cycle sCO2 Heat Exchangers sCO2 Recuperators Proposed Scope Objectives Work Breakdown Project ManagementDE-FE0026273 Project Kickoff2
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comProject Participants Thar Energy, LLC Southwest Research Institute Oak Ridge National Labs Georgia Institute of TechnologyDE-FE0026273 Project Kickoff3
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comProject Participant RolesThar Energy Prime contractor Technical gap assessment Design for manufacturingFocus manufacturability & cost Multiple design analysis Design for operability, prototyping,& fabrication Down select Final Design for manufacturability Recuperator fabricationDE-FE0026273 Project KickoffSwRI Combined system engineering design Thermodynamic analysis FEA ModelingORNL Materials scienceLong-term corrosion resistance Creep resistance New alloy and/or coating formulation Georgia Institute of Technology CFD simulation & analysis of heatexchanger concepts4
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comDelivering clean energy solutions - rooted in natures' design Advanced Systems for Power GenerationAdvanced Heat Exchanger TechnologySustainable Heating & Cooling SolutionsCost Effective Water ProcessingCore competencies: 25 years commercializing “Green”supercritical fluid technologies (SCF) Designer and developer of supercriticalfluid processes, systems & majorcomponents Industrial scale 24/7/365 installations,world wide: Food Chemicals Nutraceutical Pharmaceutical Heat exchangers for high pressure, hightemperature applicationDE-FE0026273 Project KickoffShown here:Pharmaceutical production system Good Manufacturing Process Supercritical fluid extraction5
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comThar has a history of successfully designing &commercializing Green Products using recycledCarbon Dioxide.PressurizedVessel with SelfEnergizing SealLaunchSuprexSuprex sold toTeledyne IscoLaunchThar Brand19821985EarnPhDSpin outoperatingdivisions1990Launch Operating Div.Products and Processes2007 rds & Patents ReceivedDOE with sCO2 Thar ProcessBergerU.S. Patents #5,336,869, #5,461,648,Brayton Cycle Thar Pharmafrom#5,694,973, #5,850,934, #5,879,081,ConceptMetler#5,886,293, #6,908,557, #7,091,366,Toledo#6,698,214. U.S. Patents 4,814,089 & 4,871,453Chromatographic SeparationMethod and Associated ApparatusDE-FE0026273 Project KickoffntsemtrusIn2001, 2002 Governor’s Export Excellence Award Finalist2002 National Small Business Exporter of the Year2002 NIST ATP Awardee (Microrefrigeration)2002, 2003 Top 25 Biotech Companies2002, 2003 Top 100 Fastest Growing Companies2003 Fastest Growing Small Manufacturer Award2004 Manufacturer of the Year
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comSales, Design-Build, Install and ServiceThar InstrumentsThar SupercriticalChromatographySystemWorld’s LargestOver 5,000 greeninstallations world wideDE-FE0026273 Project KickoffOver 20 Industrial greeninstallations world wide
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comHigh PressuresCO2 PumpsThar Timeline (cont.)Thar Instruments, 125strong, Offices worldwide,Sold to Waters Corp.Air Side HXAdvanced HeatExchanger TechnologyDemonstrationNIST funds microrefrigerationproject1st R744Geothermal CoolingDemonstrationValidated potentialfor R744 DX heatpump cycle20022005MicroRefrigerationPatent US7,140,1972009Demonstrations at commercialscale - geothermal heating &cooling system (15-20 ton)LaunchLaboratory testing andcomponent development20102012Evaluation of CommercialDrill TechnologyPumpsRadiantFloorVertical and Horizontalwell fields installedDE-FE0026273 Project KickoffGeothermalEnergy SystemPatent US8,468,845Compressor2014
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comSouthwest Research Institute Independent, nonprofit applied researchand development organization founded in1947Eleven technical divisions––––––––––– Over 1,200 acres facility in San Antonio,Texas––––––––200 buildings, 2.2 million sq. ft oflaboratories & officesPressurized Closed Flow LoopsSubsea and High Altitude Test ChambersRace Oval and Crash Test TrackExplosives and Ballistics RangesRadar and Antenna RangesFire testing buildingsTurbomachinery labsTotal 2013 revenue of 592 million–– Aerospace Electronics, SystemsEngineering & TrainingApplied PhysicsApplied PowerAutomation & Data SystemsChemistry & Chemical EngineeringEngine, Emissions & Vehicle ResearchFuels & Lubricants ResearchGeosciences & EngineeringMechanical EngineeringSignal Exploitation & GeolocationSpace Science & Engineering 1.2 Miles 38% Industry, 36% Govt., 26% Govt. Sub 6.7 million was reinvested for internalresearch and developmentOver 2,800 staff–275 PhD’s / 499 Master's / 762 Bachelor's2.1 MilesBenefiting government, industry and the publicthrough innovative science and technologyDE-FE0026273 Project Kickoff9
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comMachinery Program Fluids & Machinery EngineeringDepartment– Mechanical Engineering Division (18) Specialties– Turbomachinery component designand testing– Root cause failure analysis– Rotordynamic design/audit– Pipeline/plant simulation– CFD and FEA analysis– Test stand design– Performance testingDE-FE0026273 Project Kickoff10
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comORNL is providing material support Bruce Pint, Group Leader of Corrosion group 30 years experience in high temp. oxidation Fellow of NACE International and ASM International Relevant prior experience Thin-walled heat exchangers for gas turbines (1995-2015)Materials for 760 C (1400 F) supercritical steam (2002-2015)Alloy selection for numerous high temperature applicationsExtensive commercial alloy corrosion performance database On-going supercritical CO2 compatibility work Fossil Energy (400-750 C) Concentrated Solar Power (700 -800 C)DE-FE0026273 Project Kickoff11
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comDevesh Ranjan, Associate Professor, Mechanical Engineering Expertise: Thermal-Hydraulics of Supercritical Fluids, Turbulent Mixing Current Active Projects: sCO2 oxy-combustion, ceramic heat exchangerdesign, & nucleation study in sCO2 flowsHeat ExchangerTest FacilityCoriolisflow meterGascooler5 KW DCpower supplyDE-FE0026273 Project Kickoff12
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comCurrent DOE sCO2 ProjectsPROJECTS2014 2nd3rdSunshot - 5.5 MW Recuperator1st Generation SwRI TharHigh T High Delta P - 100 kWRecuperator - 2nd GenerationModular - 47 MW Recuperator3rd GenerationSunshot - 2.5 MW Heater1st Generation SwRI TharOxy CombustionsCO2 Power CyclesAbsorption/DesorptionsCO2 Power Cycles4th20152nd3rd4th20162ndHeat Exchanger Rating (MW)DE-FE0026273 Project Kickoff4th20172nd3rdThar SwRIThar SwRI ORNL GTSwRI TharSwRI dularPhase 2Two years
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comProject andTechnology OverviewDE-FE0026273 Project Kickoff14
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comObjective: Advance high-temperature, high-differential-pressure recuperator technologies suitablefor use in sCO2 Recompression Brayton Cycle (RCBC) Evaluate, advance, and demonstrate recuperator concepts, materials, and fabricationmethods that facilitate the commercial availability of compact and low costrecuperators for RCBC conditions (e.g. temperatures exceeding 700 C and differentialpressures on the order of 200 bar) Emphasis placed on scalable solutions able to accommodate plant sizes from 10 1,000 MWe.Program will:(1) Address critical design, materials, and fabrication challenges(2) Significant impact on recuperator cost, performance, and scalabilityDE-FE0026273 Project Kickoff15
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comDevelop a scalable, high temperature recuperatorfor STEP facility conditions533 C24 MPa194 C24 MPa47 MWth581 C9.9 MPaDE-FE0026273 Project Kickoff204 C8.8 MPa16
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comWhy sCO2?70sCO2Thermal uperheatedSteamWHRIdealized sCO2Recompression3075% of Carnot2010300400500600700800900Temperature (C)100011001200sCO2, He, Supercritical Steam, and Superheated Steam are fromDriscol MIT-GFR-045, 2008DE-FE0026273 Project Kickoff17
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comThar Energy sCO2Recuperators, Heater HXs & Precooler HXsCounter-CurrentMicro-tube2.5 MW Inconel 740HHot Air–sCO2 HX5.5 MWLow TempRecuperatorPrimaryHeaterHeat InputHigh ompressorPrecoolerCoolingAirDE-FE0026273 Project eratedTypical2 raytonCycle18
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comSunshot Heater HX Design – 2.5 MWHot Gas to sCO2 HXInconel 740H ConstructionDesign Conditions:Gas Fired Burner/Blower Outlet Temperature: 870 CsCO2 Outlet Temperature: 715 CDE-FE0026273 Project Kickoff
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comsCO2 Gas Cooler HXs35-500 kWCO2-AirApproachTemperature asLow as 2 CTest FacilityAHU 2 TE1AHU 2 TE280Temp (deg F)757065605550115TonsDE-FE0026273 Project Kickoff10020030040020
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.com1st Generation Recuperator DesignsCO2 counter-current - microchannel heat exchanger Over 5 MW CapacityOperating Conditions: 567 C and 255 barDesign Conditions: 575 C @ 280 barFloating Head DesignServiceability and MaintenanceReplaceable Tube BundleEasier to manufacture and assembleDesigned per ASME Sec VIII, Div 1DE-FE0026273 Project Kickoff
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comSunshot Recuperator Tube BundleMicro-tubesHigh Pressure sCO2Cross-sectionaldiagram redacted - gAnnular SpaceLow Pressure sCO2 [tube count redacted]Tube Bundle4,500 m2/m3DE-FE0026273 Project KickoffCross-sectionaldiagram redacted - g
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comRecuperator Tube Bundle Cross Section9” diameter, over [count redacted – g] micro-tubesMicrochannel Printed Circuit HXOpacity: 38%0.8 mmEntropy 2015, 17, 3438-3457; doi:10.3390/e17053438Opacity: 74%DE-FE0026273 Project Kickoff23
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comImproving HTC 23% increase HTC & 7% increase Pressure DropDE-FE0026273 Project KickoffHTC (W/m-K)[Detail drawings redacted – g]Pressure Drop (bar)24
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comSoftware Tools to Enhance Design CFD models for enhanced design strategies for the inlet and outlet manifolds Heat transfer models FEA analysis of the floating end tube-sheetTube-sheet FEACFD Flow simulationRedacted - gDE-FE0026273 Project Kickoff
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.com2nd Generation – [redacted] Flange Design[redacted -g] Tube Sheet: ASME section VIII, Div 1, UHX-14 [redacted – g] tube-sheetcalculations by Thar verified SwRI’s simulation. Tube-sheet can handle unbalanced forces Hot side tube-sheet welded to vessel end capsHot LowPressure CO2[Redacted – g]Hot HighPressureCO2Cold HighPressureCO2Cold LowPressure CO2DE-FE0026273 Project Kickoff26
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.com2nd Generation – [redacted –g] Flange DesignBenefits New, [redacted – g] Flange DesignImprove Performance/Cost RatioOptimized materials’ use for hot and cold sidesImproved reliability with fewer metal seals & boltsEasier to assembleInconel 625[Redacted – g]Tube bundleDE-FE0026273 Project Kickoff316 Stainless
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.com5.5 MW Recuperator, Generation #1Cost EstimatesItemized tableredacted – b, f, g i]Major costs Machining Materials LaborDE-FE0026273 Project Kickoff28
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comProject Overview Engineering Assessment of Advanced Recuperator Concepts Critical enabling technologies or components Manufacturability of the proposed concepts Potential nth of a kind production cost Anticipated recuperator performance with respect tocurrent state of the art Prototype Fabrication, Testing and Evaluation Down Select and Fabrication of 47 MWt RecuperatorDE-FE0026273 Project Kickoff29
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comCriteria for Modular, Low-Cost, HighTemperature Recuperators Performance Temperatures 575 CDifferential pressures 200 barLifetime (corrosion, creep, etc.)Ease of maintenance Scalability 10 - 1,000 MWe FacilitiesTransport Cost 100/kWt DE-FE0026273 Project KickoffMaterials SelectionManufacturability
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comSOPO TasksA scaled prototype will verify the design processand technology before designing for 47 MWtTask 1.0Project Management and PlanningTask 2.0Engineering Assessment of Advanced Recuperator ConceptsOther Conceptsfrom brainstormTask 3.0Preliminary design (detail design of 100 kWt prototype)Task 4.0100 kWt prototype fabrication and testingGo/No-Go Milestone for Budget Period 2Task 5.0Detail design of 47 MWt recuperatorTask 6.0Fabrication of 47 MWt recuperatorDE-FE0026273 Project Kickoff31
TA S K 2 . 0150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comRecuperator concepts will be generated andranked based on performance and TRL2.1 Concept review and new concept development Review literature and hold a brainstorm session for additional concepts Evaluate concepts by: effectiveness, manufacturability, and production cost2.2 Concept technical gap assessment Assign TRL based on engineering analysis, literature, and industry knowledge2.3 Recuperator development plan Outline development plan for each concept to achieve the operatingrequirements of the high temperature recuperator while minimizing cost2.4 Component concept performance evaluation Techno-Economic Analysis and rank concepts on performance, TRL, cost, andmanufacturing challenges (Project specific deliverable) Select critical technologies and one or more concepts for preliminary design2.5 Critical components selection Design review and risk mitigation plan for critical technologies in the concept Conduct lab-scale efforts as needed to reduce risk for preliminary design stageDE-FE0026273 Project Kickoff32
TA S K 2 . 0150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comAt least three concepts are compared for performance, cost, risk, &TRLEach concept evaluated to identify: Critical enabling technology/components (assign TRL) Manufacturability (assign TRL) Expected performance compared to current state-of-the-art Assign overall TRLPerformance of each concept estimated with low fidelity modeling(i.e. one-dimensional)Other Concepts frombrainstormDE-FE0026273 Project Kickoff33
TA S K 2 . 0150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comPotential Design Concepts Corrosion-- Look at Coatings (e.g. Ag/Au - 90 Angstroms) Material: Sandvik, half the cost – comparable to Inconel 625 HTC enhancements with little effect on Delta P (e.g. air foilconcept) Integrate End Cap with Tube-sheet Reduce Short Circuiting Issues with Flange DesignDE-FE0026273 Project Kickoff34
TA S K 2 . 0150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comConcept performance is estimated with proven, low fidelity modelsH2OCO2400Temperature [K]380360340Wall temperature320300Water temperature2800510Distance Along Heat Exchanger [m]15Counter-flow tube-in-tube heat exchanger - Data from Pitla 2001DE-FE0026273 Project Kickoff35
TA S K 3 . 0150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comFor each concept selected3.1 Initial recuperator layout and sizing One-dimensional fluid-thermal network or FEA to estimate performance System level analysis to investigate modular configurations and scalability3.2 Feature analysis Detailed models of specific features using computational tools (CFD, CHT, FEA) Demonstrate the design meets STEP facility targets for effectiveness and DP3.3 Initial material selection Material selection in accordance with ASME code for STEP facility conditions Stress analysis of critical features and pressure containment3.4 Structural/Mechanical design Stress analysis considering the recuperator layout, flow path, and joints3.5 Design for manufacturing and operability Consider sealing and manufacturing methods for the materials selected in 3.3 Operability considerations: corrosion, maintenance, inspection, assembly3.6 System level design and optimization Evaluate modularity and scalability on recuperator design, consideringmaintenance and performance over a range of thermal dutyDE-FE0026273 Project Kickoff36
TA S K 3 . 0150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comComputational models are used to assess localvariations in fluid-thermal performance3.2 Feature analysis Detailed models of specific features using computational tools (CFD, CHT) Demonstrate the design meets STEP facility targets for effectiveness and DPCFD diagrams redacted - gDE-FE0026273 Project KickoffSource: DE-FE0024012 : “High Temperature Heat Exchanger Designand Fabrication for Systems with Large Pressure Differentials”37
TA S K 3 . 03.3 Initial material selection150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comAllowable Stress -2/3 Yield* (MPa)Allowable Stress vs. TemperatureTemperature ( C)Allowable Stress*DE-FE0026273 Project Kickoff(a) The allowable stress at design temperature for most materials is the lessor of 1/3.5 the minimum effective tensile strength or 2/3 the minimum yield stress of thematerial for temperatures below the creep and rupture values.(b) At temperatures in the range where creep and stress rupture strength govern the selection of stresses, the maximum allowable stress value for all materials isestablished by the Committee not to exceed the lowest of the following: (1) 100% of the average stress to produce a creep rate of 0.01%/1,000 h (2) 100Favg% ofthe average stress to cause rupture at the end of 100,000 h (3) 80% of the minimum stress to cause rupture at the end of 100 ,000 h38
TA S K 3 . 0150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.com3.3 Initial material selectionRupture Stress vs. TemperatureDE-FE0026273 Project Kickoff39
TA S K 3 . 0150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comFinite element analysis is used to estimatemechanical stresses and deflections3.4 Structural/Mechanical design Stress analysis considering the recuperator layout, flow path, and jointsStress [psi]Displacement [in]Source: DE-FE0024012 : “High Temperature Heat Exchanger Design and Fabrication for Systems with Large Pressure Differentials”DE-FE0026273 Project Kickoff40
150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comTA S K 3 . 03.5 Design for manufacturing and operability Consider sealing and manufacturing methods for the materials selected in 3.3 Operability considerations: corrosion, maintenance, inspection, assembly3.6 System level design and optimization Evaluate modularity and scalability on recuperator design, consideringmaintenance and performance over a range of thermal dutyCost Performance/Cost Ratio Optimize SizeEffectiveness Design for Manufacturabilitym2/m3DE-FE0026273 Project KickoffHTCApproachTemperaturePressureDrop
TA S K 4 . 0150 Gamma DrivePittsburgh, PA 15238www.tharenergyllc.comScaled testing is c
Recompression Brayton Cycle (RCBC) Evaluate, advance, and demonstrate recuperator concepts, materials, and fabrication methods that facilitate the commercial availability of compact and low cost recuperators for RCBC conditions (e.g. temperatures exceeding 700 C and differential pressures on the order of 200 bar)
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