Of the mechanisms to improve efficiency for solar-thermal power plants, one of the most effective ways to improve overall efficiency is through power cycle improvements. As increases in operating temperature continue to be pursued, supercritical CO 2 Brayton cycles begin to look more attractive despite the development costs of this technology. Further, supercritical CO 2 Brayton has application in many areas of power generation beyond that for solar energy alone. One challenge particular to solar-thermal power generation is the transient nature of the solar resource. This work illustrates the behavior of developmental Brayton turbomachinery in response to a fluctuating thermal input, much like the short-term transients experienced in solar environments. Thermal input to the cycle was cut by 50% and 100% for short durations while the system power and conditions were monitored. It has been shown that despite these fluctuations, the thermal mass in the system effectively enables the Brayton cycle to continue to run for short periods until the thermal input can recover. For systems where significant thermal energy storage is included in the plant design, these transients can be mitigated by storage; a comparison of short-and long-term storage approaches on system efficiency is provided. Also, included in this work is a data set for stable supercritical CO 2 Brayton cycle operation that is used to benchmark computer modeling. With a benchmarked model, specific improvements to the cycle are interrogated to identify the resulting impact on cycle efficiency and loss mechanisms. Status of key issues remaining to be addressed for adoption of supercritical CO 2 Brayton cycles in solar-thermal systems is provided in an effort to expose areas of necessary research.

In this study, an elastohydrodynamic model was created for predicting the pressure field in a compliant thrust bearing assembly lubricated by high pressure CO2. This application is of significance due to ongoing research into the closed-cycle supercritical CO2 turbine as a high-efficiency alternative to steam turbines. Hardware development for this concept has been led by Sandia National Laboratories, where turbomachinery running on gas foil thrust and journal bearings is being tested. The model accounts for the fluid velocity field, hydrodynamic pressure, and frictional losses within the lubrication layer by evaluating the turbulent Reynolds equation coupled with an equation for structural deformation in the bearings, and the fluid properties database RefProp v9.0. The results of numerical simulations have been compared with empirical correlations, with reasonable agreement attained. Of particular interest is the contrast drawn between the performance of high pressure CO2 as a lubricant, and ambient pressure air. Parametric studies covering a range of fluid conditions, operating speeds, and thrust loads were carried out to illustrate the value of this model as a tool for improved understanding and further development of this nascent technology.

Performance Characteristics of an Operating Supercritical CO2 Brayton CycieSupercritical CO2 (S-CO2) power cycles offer the potential for better overall plant economics due to their high power conversion efficiency over a moderate range of heat source temperatures, compact size, and potential use of standard materials in construction. Sandia Nationai Labs (Albuquerque, NM) and the U.S. Department of Energy (DOE-NE) are in the process of constructing and operating a megawatt-scale supercritical CO2 split-flow recompression Brayton cycle with contractor Barber-Nichols Inc. (Arvada, CO). This facility can be counted among the first and only S-CO2 power producing Brayton cycles anywhere in the world. The Sandia-DOE test-loop has recently concluded a phase of construction that has substantially upgraded the facility by installing additional heaters, a second recuperating printed circuit heat exchanger (PCHE), more waste heat removal capability, higher capacity load banks, higher temperature piping, and more capable scavenging pumps to reduce windage within the turbomachinery. With these additions, the loop has greatly increased its potential for electrical power generation, and its ability to reach higher temperatures. To date, the loop has been primarily operated as a simple recuperated Brayton cycle, meaning a single turbine, single compressor, and undivided flow paths. In this configuration, the test facility has begun to realize its upgraded capacity by achieving new records in turbine inlet temperature (650°FI615K), shaft speed (52,000rpm), pressure ratio (1.65), flow rate (2.7kgls), and electrical power generated (20 kWe). Operation at higher speeds, flow rates, pressures, and temperatures has allowed a more revealing look at the performance of essential power cycle components in a supeicritical CO2 working fluid, including recuperation and waste heat rejection heat exchangers (PCHEs), turbines and compressors, bearings and seals, as well as auxiliary equipment. In this report, performance of these components to date will be detailed, including a discussion of expected operational limits as higher speeds and temperatures are approached.

Through multi-year funding from DOE-NE, Sandia National Labs supercritical carbon dioxide (SCO2) closed Brayton cycle (CBC) research and development team have recently overseen the completion of the SCO2 CBC recompression test assembly (TA), and delivery from the development contractor's facility to Sandia, Albuquerque. The primary components of the completed TA include two turboalternator-compressors and associated motor/controllers, three printed circuit heat exchangers, and six shell-and-tube heaters and associated controllers. Principal supporting components include a cooling tower, electricity-dissipating load bank, and leakage flow management equipment. With this milestone completed, significant increase in CBC R&D is anticipated with the objective of advancing the technology readiness level of components seen by industry as immature. This report presents detailed descriptions of all components and operating software necessary to operate the recompression CBC.

Supercritical CO2 (S-CO2) power cycles offer the potential for better overall plant economics due to their high power conversion efficiency over a moderate range of heat source temperatures, compact size, and potential use of standard materials in construction [1,2,3,4]. Sandia National Labs (Albuquerque, NM, US) and the US Department of Energy (DOE-NE) are in the process of constructing and operating a megawatt-scale supercritical CO2 split-flow recompression Brayton cycle with contractor Barber-Nichols Inc. [5] (Arvada, CO, US). This facility can be counted among the first and only S-CO2 power producing Brayton cycles anywhere in the world. The Sandia-DOE test-loop has recently concluded a phase of construction that has substantially upgraded the facility by installing additional heaters, a second recuperating printed circuit heat exchanger (PCHE), more waste heat removal capability, higher capacity load banks, higher temperature piping, and more capable scavenging pumps to reduce windage within the turbomachinery. With these additions, the loop has greatly increased its potential for electrical power generation — according to models, as much as 80 kWe per generator depending on loop configuration — and its ability to reach higher temperatures. To date, the loop has been primarily operated as a simple recuperated Brayton cycle, meaning a single turbine, single compressor, and undivided flow paths. In this configuration, the test facility has begun to realize its upgraded capacity by achieving new records in turbine inlet temperature (650°F/615K), shaft speed (52,000 rpm), pressure ratio (1.65), flow rate (2.7 kg/s), and electrical power generated (20kWe). Operation at higher speeds, flow rates, pressures and temperatures has allowed a more revealing look at the performance of essential power cycle components in a supercritical CO2 working fluid, including recuperation and waste heat rejection heat exchangers (PCHEs), turbines and compressors, bearings and seals, as well as auxiliary equipment. In this report, performance of these components to date will be detailed, including a discussion of expected operational limits as higher speeds and temperatures are approached.

A liquid sodium cooled fast reactor coupled to a supercritical carbon dioxide Brayton power cycle is a promising combination for the next generation nuclear power production process. For optimum efficiency, a microchannel heat exchanger, constructed by diffusion bonding, can be used for heat transfer from the liquid sodium reactor coolant to the supercritical carbon dioxide. In this work, we have reviewed the literature on corrosion of metals in liquid sodium and carbon dioxide. The main conclusions are 1) pure, dry CO 2 is virtually inert but can be highly corrosive in the presence of even ppm concentrations of water, 2) carburization and decarburization are very significant mechanism for corrosion in liquid sodium especially at high temperature and the mechanism is not well understood, and 3) very little information could be located on corrosion of diffusion bonded metals. Significantly more research is needed in all of these areas.

The U.S. Department of Energy is currently focused on the development of nextgeneration nuclear power reactors, with an eye towards improved efficiency and reduced capital cost. To this end, reactors using a closed-Brayton power conversion cycle have been proposed as an attractive alternative to steam turbines. The supercritical-C02 recompression cycle has been identified as a leading candidate for this application since it can achieve high efficiency at relatively low operating temperatures with extremely compact turbomachinery. Sandia National Laboratories has been a leader in hardware and component development for the supercritical-C02 cycle. With contractor BarberNichols Inc., Sandia has constructed a megawatt-class S-CO2 cycle test-loop to investigate the key areas of technological uncertainty for this power cycle and to confirm model estimates of advantageous thermodynamic performance. Until recently, much of the work has centered on the simple S-CO2 cycle-a recuperated Brayton loop with a single turbine and compressor. However, work has recently progressed to a recompression cycle with split-shaft turbo-alternator-compressors, unlocking the potential for much greater efficiency power conversion, but introducing greater complexity in control operations. The following sections use testing experience to frame control actions made by test loop operators in bringing the recompression cycle from cold startup conditions through transition to power generation on both turbines, to the desired test conditions, and finally to a safe shutdown. During this process, considerations regarding the turbocompressor thrust state, CO2 thermodynamic state at the compressor inlet, compressor surge and stall, turbine ulc ratio, and numerous other factors must be taken into account. The development of these procedures on the Sandia test facility has greatly reduced the risk to industry in commercial development of the S-CO2 power cycle.

Currently, waste heat rejection from electrical power systems accounts for the largest fraction of water withdrawals from the US fresh water table. Siting of nuclear power plants is limited to areas with access to a large natural supply of fresh or sea water. Due to a rise in energy needs and increased concern over environmental impact, dry air cooling systems are poised to play a large role in the future energy economy. In practice, the implementation of dry air-cooled condensing systems at steam plants has proven to be capital-intensive and requires the power cycle to take a significant efficiency penalty. These shortcomings are fundamental to dry-air steam condensation, which must occur at a fixed temperature. Closed-cycle gas turbines are an alternative to the conventional steam Rankine plant that allow for much improved dry heat rejection compatibility. Recent research into advanced nuclear energy systems has identified the supercritical CO2 (s-CO2) Brayton cycle in particular as a viable candidate for many proposed reactor types. The s-CO2 Brayton cycle can maintain superior thermal efficiency over a wide range of ambient temperatures, making these power systems ideally suited for dry air cooling, even in warm climates. For an SFR operating at 550°C, thermal efficiency is calculated to be 43% with a 50°C compressor inlet temperature. This is achieved by raising CO2 compressor inlet pressure in response to rising ambient temperatures. Preliminary design studies have shown that s-CO2 power cycle hardware will be compact and therefore well-matched to near-term and advanced integral SMR designs. These advantages also extend to the cooling plant, where it is estimated that dry cooling towers for an SFR-coupled s-CO2 power cycle will be similar in cost and scale to the evaporative cooling tower for an LWR. The projected benefits of the s-CO2 power cycle coupled to dry air heat rejection may enable the long-awaited rise of next-generation nuclear energy systems, while re-drawing the map for siting of small and large nuclear energy systems.