rocketdyne development of the supercritical co2 power...

Rocketdyne Development of the Supercritical CO2Power Conversion System

Rocketdyne Development of the Supercritical CO2Power Conversion System

Michael McDowellProgram Manager Reactor & Liquid Metal SystemsHamilton Sundstrand, Space Land & Sea-Rocketdyne

Rocketdyne Development of the Supercritical CO2 Power Conversion SystemRocketdyne Development of the Supercritical CO2 Power Conversion System

• Rocketdyne – Organization, Heritage & Capabilities

• Supercritical CO2 System & Equipment

• System modeling / evaluation

• Turbomachinery design

• Heat exchanger evaluation

• Future Plans

United Technologies Corporation (UTC)

Carrier

UTC Fire & Security

Sikorsky

Pratt &Whitney

Otis

HamiltonSundstrand

UTC Power

• >200,000 employees• Operating in 180 countries• $42.7B Sales (2005)

• $5.2B Operating profit

Rocketdyne Alignment after UTC Purchase of Rocketdyne from Boeing (August 3, 2005)

Hamilton Sundstrand Space Land & Sea

Rocketdyne

Pratt & Whitney Rocketdyne

UTC Power

Research CenterHamilton Sundstrand

Pratt & Whitney

Advanced Power Systems Aligned with Hamilton SundstrandAdvanced Power Systems Aligned with Hamilton Sundstrand

Share Campus, Processes & Resources

Rocketdyne Energy HeritageRocketdyne Energy HeritageN

ucle

arSo

lar

Foss

il

Coal Combustion Technologies

Solar 110 MW

Solar 210 MW

Fast Flux Nuclear Test Facility

Clinch River Breeder Reactor

Sodium Advanced Fast Reactor

New Production Reactor

MethaneCombustion

Dish Engine System 25 kW

SolarDynamic

25 KW

SRE

Coal Gas & Hydrogen Generation Technologies

Gen IV - Molten Salt / Liquid Metal Systems

1950’s 1970’s 1990’s 2000’s1960’s 1980’s

Atomics International Energy Systems Rocketdyne Propulsion & PowerRockwell International Boeing

2010’sNorth American UTC

PWR / HS SLS-R

GasificationPilot Plant

Power Towers15 -100 MW

PWR Rocket / Space Program HeritagePWR Rocket / Space Program Heritage

RS-27A launchesfirst commercial

Delta rocket

19701970’’s s 19901990’’s s 19601960’’ss 19801980’’ss TodayToday19501950’’ss

Navajo engine developed

Redstone engine launches Explorer 1

1958

1958

Space Shuttle Main Engine

contract Starts

1971

Terminal High Altitude Area Defense

development begins

1992

International SpaceStation contract

start

1980

RS-68 launchesDelta IV

1969 1988

F-1 and J-2 engines launch Apollo to Moon

Radioisotope Thermoelectric

Generator initiated

2002

2003

Snap 10A - First nuclear reactor

launched

19651965

PeacekeeperStage IV

developed

1985

2000

Aerospike flight engine tests

XSS-10Micro Satellite

launched

2002

19631963

RL10 First

Flight Atlas

1st RD-180 Launch Atlas III

• High energy density combustion• 6000º F• 5000 psia

• Regenerative cooling• Low metal temperatures• High system efficiency

• High speed rotating equipment• 36,000 rpm

Rocket Engine CompetenciesApplicable to Energy Markets

• Hydrogen technology• Low cost < $10 per kW thermal

• Unique design capabilities• Advanced manufacturing

processes• Manufacturing and test

• Capacity > 200 GW thermal per year

• Rapid prototyping• Extensive test capability

Electronics Design

Test

Key Rocketdyne Processes

Tools and processes linked

electronically

Tools and processes linked

electronicallyMaterials Engineering

Advanced Analysis

Mechanical Design

System Engineering

Manufacturing







• Future Plans

Approach to Supercritical CO2 System & Equipment DesignApproach to Supercritical CO2 System & Equipment Design

• Initiated technical evaluation in 2006 with internal funds


• Turbomachinery conceptual design


• Tools refinement – CFD

• Small contract for Sandia Laboratory on turbomachinery & test concepts

• Using supercritical CO2 system knowledge on advanced reactor concepts in 2007

System Modeling / EvaluationSystem Modeling / Evaluation

• Verified preceding wisdom on CO2 cycle• Literature review: MIT reports• Select 300 Mwe LMR as baseline• Power system modeling for efficiency• Evaluated alternate configurations• Defined parameters for turbomachinery

& heat exchangers

• Extended power system modeling other power systems• VHTGR• Solar thermal power

Reactor

MC

RC

MT

HT Recuper

ator

Cooler

LT Recuper

ator

12

3

4

5

6

7

8

7b

7a

Flow=f

Flow=1-f

Modeling Results: VHTGR Power System StudyModeling Results: VHTGR Power System Study

Plot from: Driscoll, M.J., Report No: MIT-GFR-019, “Interim Topical ReportSupercritical CO2 Plant Cost Assessment”, September 2004, Center for Advanced Nuclear Energy Systems, MIT Nuclear Engineering Department

*

*

Supercritical CO2

Helium BraytonSupercritical Steam Single ReheatSupercritical Steam Double ReheatSubcritical Steam

ChemCad used to model supercritical CO2 and helium Brayton cycles

GateCycle used to model steam cycles

Not every power system benefits from supercritical CO2

Not every power system benefits from supercritical CO2

Reac

tor

MC

RC

MT HT

Re

cupe

rato

r

Cool

er

LT

Recu

pera

tor

1

2 3 4

5

6

7

8

7b

7a

Flow

=f

Flow

=1-

f

Solar Power Tower with Supercritical CO2 Cycle

• Rocketdyne solar power plant• Molten salt thermal storage• 550 to 300C across HX• Normally Rankine cycle

• CO2 cycle performs poorly• Cycle highly recuperated

• Wants reduced delta T• Reduced delta T lowers

storage & circulation effectiveness

• Added cost overcomes cycle efficiency

Turbomachinery Design: Summary of ResultsTurbomachinery Design: Summary of Results

• Baselined 300 Mwe LMR

• Established turbomachinery configuration and layout • Common shaft for all machines

driven by power turbine• Shaft rotation speed (3600 rpm)

compatible with industrial size electrical generators

• Separate shaft seals on each machine

• Balanced axial thrust• 3-D equipment drawings

completed

Turbomachinery Design: Summary of ResultsTurbomachinery Design: Summary of Results

• Identified preferred design approach for compressors• Two stage centrifugal path

selected for main compressor • Four stage centrifugal path

selected for recompressor

• Identified preferred design approach for turbine• Three stage axial path• Reaction blading• Fir tree and shrouded blades

with dampers

TurbineTurning Gear

Re-CompressorMain Compressor

To Generator

Coupling

CO2 Compressor Efficiency Prediciton

60

70

80

90

100

0 1000 2000 3000 4000

Impeller Specific Speed

Effic

ienc

y, %

CO2 Main Compressor 1 Stg D=20.5 in. @ 7000 RPM Overall Eff 85%

CO2 ReComp Compressor 2 Stg D=25.5 in. @ 7000 RPM Overall Eff 85%

CO2 Main Compressor 2 Stg D=28.1 in. @ 3600 RPM Overall Eff 85%

CO2 ReComp Compressor 4 Stg D=35.0 in. @ 3600 RPM Overall Eff 85%

Best RMS Fit Roger's Impeller Only efficiency Test

Predicted Impeller+Diffuser efficiency From Rogers Impeller Only Test

Turbomachinery Shaft LayoutTurbomachinery Shaft Layout

45”45”

Shaft Seal

Recompression Compressor

Main Compressor

CouplingDamper

Seal

RadialBearingRadial

Bearing

ThrustBearing

TurningGear

Shaft Seal

RadialBearing

ThrustBearing

Shaft Seal

RadialBearing

Coupling

Heat Exchanger EvaluationHeat Exchanger Evaluation

• Basis: 300 Mwe LMR

• Evaluated heat exchanger for type (CHE or STHE)• Sodium to supercritical CO2 IHX• High temperature SCO2 recuperator • Low temperature SCO2 recuperator• Pre-cooler SCO2 to water heat exchanger

• Developed 3 designs/concepts for IHX• Compact heat exchangers (CHE)• Shell and tube heat exchanger (STHE)

• Straight tube• Coiled tube

Heat Exchanger Evaluation ResultsHeat Exchanger Evaluation Results

• CO2 recuperators & pre-cooler• Costs & configuration analyzed • CHE preferred for CO2 recuperators• CHE pre-cooler very expensive

• Further evaluation needed• IHX Comparison

• CHE• Most compact• Most expensive• Thermal transient concern• Sodium side plugging

• STHE • Lower cost by factor of almost 5• Building cost higher• Robust design







• Future Plans

Supercritical CO2 Turbomachinery Development Scenario/ScheduleSupercritical CO2 Turbomachinery Development Scenario/Schedule

Super subscaletesting

Single stage compressor

Task 20172016201520142013201220112010200920082007

Design Fabricate Test

Design Fabricate Operations

Confirm modeling and state properties at most challenging supercritical point

1/10th scale demonstrates high efficiency and confirms design of all components

Demonstration on prototype reactor • 300 to 600 Mwe SCO2 cycle• Steam cycle maintained as backup

Prototype reactor on-line

1/10th scale system testIntegrated cycle

Full scale demonstration

The Rocketdyne Path ForwardDemonstrate the promise of supercritical CO2

The Rocketdyne Path ForwardDemonstrate the promise of supercritical CO2

• More detailed design & trade studies• Bearings• Disk / blade / crossover designs• CFD analysis• Re-look at multi-shaft configurations

• Dynamic system simulation analysis

• O&M and operability evaluations

• Implementation of development schedule

• Improve customer interest – Funding for path forward

rocketdyne development of the supercritical co2 power...

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