direct fired oxy-fuel combustor for sco2 power …...direct fired oxy-fuel combustor for sco2 power...
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Direct Fired Oxy-Fuel Combustor for sCO2 Power Cycles
Jacob Delimont, Ph.D.Nathan Andrews, Craig Nolen, Carolyn Day
Southwest Research Institute
Marc PortnoffLalit Chordia, Ph.D.Thar Energy L.L.C.
Wenting Sun, Ph.D., Tim Lieuwen, Ph.D.Ben Emmerson, Ph.D.
Georgia Tech
Subith Vasu, Ph.D. University of Central Florida
Paul Hsu, Ph.D., Sukesh Roy, Ph.D.Spectral Energies
Keith McManus, Ph.D.GE Global Research
Work supported by US DOE under DE-FE002401
10/31/2018 2018 University Turbine Systems Research Workshop 1
HEAT SOURCE
PRECOOLER
LOW TEMP RECUPERATOR
HIGH TEMPRECUPERATOR
EXPANDER
COMPRESSOR
RE-COMPRESSOR
P6 P7a P8
P1
P2
P3
P5
P7b
P7
P4
P4b
COOLING OUT COOLING IN
P4a
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Outline
• Background• Project Objectives• Combustor Design• Test Loop Design• Future Work
10/31/2018 2018 University Turbine Systems Research Workshop 2
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Why sCO2 Power Cycles?
• Offer +3 to +5 percentage points over supercritical steam for indirect fossil applications
• High fluid densities lead to compact turbomachinery
• Efficient cycles require significant recuperation
10/31/2018 2018 University Turbine Systems Research Workshop 3
Third Generation 300 MWe S-CO2 Layout from Gibba, Hejzlar, and Driscoll, MIT-GFR-037, 2006
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ThermalInput
CoolerRecuperater
Turbine
Compressor
Pump
What is Direct Fired Oxy-Fuel Combustion?
• Oxygen + fuel + CO2• Designer can choose
the O2/CO2 ratio, unlike typical gas turbine combustors
• ASU to produce oxygen
2018 University Turbine Systems Research Workshop 4
Water Removal
Excess CO2 Removal
O2
Fuel
CO2 from Recuperator
CO2 + Water
Direct Fired Oxy-Combustor
10/31/2018
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Why Direct Fired Oxy-Fuel Combustion?
10/31/2018 2018 University Turbine Systems Research Workshop 5
HEAT SOURCE
PRECOOLER
LOW TEMP RECUPERATOR
HIGH TEMPRECUPERATOR
EXPANDER
COMPRESSOR
RE-COMPRESSOR
P6 P7a P8
P1
P2
P3
P5
P7b
P7
P4
P4b
COOLING OUT COOLING IN
P4a
• Capture 99% of carbon dioxide• Higher turbine inlet
temperatures possible• Limiting component is the
recuperator, not the heater
CO2
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Project Objectives
Design a 1 MW thermal oxy-fuel combustor capable of generating 1200°C outlet temperature
• Manufacture combustor, assemble test loop, and commission oxy-fuel combustor
• Evaluate and characterize combustor performance – Optical access for advanced diagnostics
10/31/2018 2018 University Turbine Systems Research Workshop 6
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ScheduleCombustor & Associated
EquipmentTest Loop & Associated
Hardware
Oct 2017
Jan 2018
Apr 2018
July 2018
Combustor Design
Quotes for Combustor
Continuation Report
Combustor Casing
Mechanical Design Test Loop
Design
Fuel System Design
Quotes for Test Loop Hardware
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Outline
• Background• Project Objectives• Combustor Design• Test Loop Design• Future Work
10/31/2018 2018 University Turbine Systems Research Workshop 8
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Combustor Design
• Mechanical casing• Fluid flow path• Fuel injector• Oxygen injection• Combustor liner thermal management• Optical access• Instrumentation• Design for additive manufacturing
10/31/2018 2018 University Turbine Systems Research Workshop 9
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Conceptual Combustor Design
Cooling CO2
FuelO2
CO2
Cooling CO2
700 °C
375 °C
1600 °C >1200 °C 400 °C
Cooling CO2
Cooling CO2
Design Pressure: 250 barTemperature: 375-700 °C
Cooling CO2
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Computational Modeling
Goals• Rapid solution times• Iterate on geometry• Inform liner thermal
model• Reduce risks in a variety
of areas prior to combustor manufacturing
Modeling• RANS simulations by
SwRI• Relatively course mesh• Variety of reduced
chemical mechanisms• LES simulations
performed by others• Well over 100 cases run
10/31/2018 2018 University Turbine Systems Research Workshop 11
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Knowledge Base
2018 University Turbine Systems Research Workshop 12
CO2 concentration
PressureCurrent Application
P up to 200 barxCO2 up to 0.96 (mostly as diluent)
Well-Developed MechanismsP up to 20 bar
xCO2 < 0.10 (mostly as product)Sparse data at low pressure, high CO2
Sparse data at high pressure, low CO2
Knowledge front
Limited data available – Current UCF and Georgia Tech projects
10/31/2018
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Injector Geometry• 16 straight swirler passages, 40°
radial swirl w/ 10°down angle• 8 fuel injectors inject fuel midway
through swirler passage
2018 University Turbine Systems Research Workshop 13
40° Radial
10° Radial
10/31/2018
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Combustor Geometry• Effusion cooling on combustor
head and liner between head and dilution holes
• 0.05” wide dilution cooling slots, 1” apart
2018 University Turbine Systems Research Workshop 14
200 barOperating Pressure
10/31/2018
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Effusion Type Boundary Condition
• Effusion boundary condition created by mass source in first near wall element
• Energy source also used to make fluid injection temperature
2018 University Turbine Systems Research Workshop 1510/31/2018
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Design and Off-design CFD Boundary Conditions
• Design point simulations• Off-Design: Unique problem of sCO2 oxy-
fuel combustion is the cold startup case– Roughly order magnitude change in density
2018 University Turbine Systems Research Workshop 16
Design Point Cold Start
Fast Start Ramp
CO2 Mass Flow (kg/s) 1.53 1.02 1.02Pressure (bar) 200.00 133.33 133.33CO2 Inlet Temp (°C) 700 50 150CO2 Density (kg/m^3) 104.2 649.4 203.5O2 Mass Flow (kg/s) 0.0806 0.0806 0.1360CH4 Mass Flow (kg/s) 0.0200 0.0200 0.0338
10/31/2018
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Temperature Predictions
2018 University Turbine Systems Research Workshop 17
30°
40° Coarse
40° Fine
50°
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CO Concentrations
2018 University Turbine Systems Research Workshop 18
Light Purple zones are for mole fraction CO=0.008
30°
40° Coarse
40° Fine
50°
10/31/2018
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Selected Results with Dilution• Fairly strong recirculation zone• High temperature near walls
– Adiabatic wall boundary conditions– Additional cooling
2018 University Turbine Systems Research Workshop 1910/31/2018
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Cold Start Case
2018 University Turbine Systems Research Workshop 20
Desig
n Po
int
Cold
Sta
rt C
ase
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Possible Flame Holding Concerns
2018 University Turbine Systems Research Workshop 21
• Fuel injected within swirlerpassage
• Startup case where velocity is much lower than design point
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Collaboration on Combustor Modeling with Others
• Work with several small companies interested in modeling direct fired sCO2 combustion
• Universities interested in geometry
10/31/2018 2018 University Turbine Systems Research Workshop 22
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Cascade Technologies
10/31/2018 2018 University Turbine Systems Research Workshop 23
Shunn, sCO2 Oxy-combustion Working Group, Aug 2018
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Convergent Science
10/31/2018 2018 University Turbine Systems Research Workshop 24
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Outline
• Background• Project Objectives• Combustor Design• Test Loop Design• Future Work
10/31/2018 2018 University Turbine Systems Research Workshop 25
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Sunshot Test Loop
10/31/2018 2018 University Turbine Systems Research Workshop 26
• The project will use the “Sunshot” loop currently being commissioned at SwRI
• Sunshot turbine will be replaced with letdown valve
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Combustion Loop P&ID
10/31/2018 2018 University Turbine Systems Research Workshop 27
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Closed Test Loop Built to Minimize New Piping
• Combustor to be closely coupled with existing “Sunshotheater”
• Connecting pipes made from Inconel 740H
• Addition of water separation in the heat rejection portion of the loop
• Quotes obtained for all major and minor hardware and fixtures needed for testing
10/31/2018 2018 University Turbine Systems Research Workshop 28
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Outline
• Background• Project Objectives• Combustor Design• Test Loop Design• Future Work
10/31/2018 2018 University Turbine Systems Research Workshop 29
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Next Steps
• Place major component orders• Assemble test loop• Assemble combustor• Instrumentation and DAQ• Commissioning – End 2019, Early 2020• Test Campaign – 2020
10/31/2018 2018 University Turbine Systems Research Workshop 30
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QUESTIONS?
10/31/2018 2018 University Turbine Systems Research Workshop 31
ThermalInput