Design of a single-shaft compressor, generator, turbine of ...

Design of a single-shaft compressor, generator, turbine

of a small scale supercritical CO2 system

for waste heat to power conversion applications

M. De Miol, G. Bianchi, G. Henry, N. Holaind, S. A. Tassou, A. Leroux

2nd European Seminar on

Supercritical CO2 (sCO2) Power Systems

Essen, 30/08/2018

Outline• The I-ThERM project

• Overview of the sCO2 high-grade heat to power activities

• The HT2C facility at Brunel University London

• Design of the compressor, generator, turbine unit (CGT)

– Aerodynamic

– Structural

– Ancillaries

• Conclusions and future challenges

2nd European Seminar

on Supercritical CO2 (sCO2) Power Systems

Design of a sCO2 system for industrial waste heat recovery applicationsG. Bianchi 2 /21




https://doi.org/10.1016/j.egypro.2017.07.263

http://dx.doi.org/10.1016/j.rser.2015.12.192

https://doi.org/10.1016/j.applthermaleng.2018.04.043


http://dx.doi.org/10.1016/j.rser.2015.12.192

https://doi.org/10.1016/j.applthermaleng.2018.04.043

Design of a sCO2 system for industrial waste heat recovery applications

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 680599

I-ThERM Project aim is to…

Investigate, design, build and demonstrate innovative plug and play waste heat recovery solutions to facilitate optimum utilisation of energy in selected applications

with high replicability and energy recovery potential in the temperature range 70℃ – 1000℃

4 /21



G. Bianchi

Scope of the I-ThERM’s sCO2 project

• Power output 50 kWe

• 1st law efficiency ≈ 20 %

• High TRL

• Low CAPEX (short PBP)


Design of sCO2 system and

Test rig

Design and manufacturingof turbomachinery and

Heat exchangers

Experimentalcampaign

5 /21



G. Bianchi


High Temperature Heat To power Conversion (HT2C) at Brunel University London

6 /21

Heat source:~ 1MW gas fired heat source

Heat sinks:• Water/glycol dry cooler• CO2 gas cooler

C G T

Heater:Micro-tube heat exchanger

Recuperator:Printed circuit heat exchanger

Cooler:Plate heat exchanger



G. Bianchi

min/max pressure [bar]

min/max Temperature [°C]

CO2 mass flow rate [kg/s]

75/127.5 35/400 2.25


Process and Instrumentation Diagram (P&ID)

7 /21



G. Bianchi

G

G

Inverter

Solenoid valve

Needle valve

Pressure relief valve

Non return valve

CO2

Oil

Oil+CO2

Flue gas

Water

Electrical power

filter

Oil separator

pump

Refrigerationcompressor

G sight glass

Vibration

Temperature

Pressure

Flow

Flanged connection

Heat source

Heat sink

vent

heater

recuperator

cooler

Filling tank

Recovery tank

receiver

C T

G

G

Inverter

Solenoid valve

Needle valve


Non return valve

CO2

Oil

Oil+CO2

Flue gas

Water

Electrical power

filter

Oil separator

pump


G sight glass

Vibration

Temperature

Pressure

Flow

Flanged connection

Heat source

Heat sink

vent

heater

recuperator

cooler

Filling tank

Recovery tank

receiver

C T G

G

Inverter

Solenoid valve

Needle valve


Non return valve

CO2

Oil

Oil+CO2

Flue gas

Water

Electrical power

filter

Oil separator

pump


G sight glass

Vibration

Temperature

Pressure

Flow

Flanged connection

Heat source

Heat sink

vent

heater

recuperator

cooler

Filling tank

Recovery tank

receiver

C T

G

G

Inverter

Solenoid valve

Needle valve


Non return valve

CO2

Oil

Oil+CO2

Flue gas

Water

Electrical power

filter

Oil separator

pump


G sight glass

Vibration

Temperature

Pressure

Flow

Flanged connection

Heat source

Heat sink

vent

heater

recuperator

cooler

Filling tank

Recovery tank

receiver

C T G

G

Inverter

Solenoid valve

Needle valve


Non return valve

CO2

Oil

Oil+CO2

Flue gas

Water

Electrical power

filter

Oil separator

pump


G sight glass

Vibration

Temperature

Pressure

Flow

Flanged connection

Heat source

Heat sink

vent

heater

recuperator

cooler

Filling tank

Recovery tank

receiver

C T

G

G

Inverter

Solenoid valve

Needle valve


Non return valve

CO2

Oil

Oil+CO2

Flue gas

Water

Electrical power

filter

Oil separator

pump


G sight glass

Vibration

Temperature

Pressure

Flow

Flanged connection

Heat source

Heat sink

vent

heater

recuperator

cooler

Filling tank

Recovery tank

receiver

C T

G

G

Inv

ert

er

Sole

no

id v

alv

e

Ne

ed

le v

alv

e

Pre

ssu

re r

eli

ef

va

lve

No

n r

etu

rn v

alve

CO

2

Oil

Oil+

CO

2

Flu

e g

as

Wa

ter

Ele

ctri

cal p

ow

er

filt

er

Oil

sep

ara

tor

pu

mp

Re

frig

era

tio

nco

mp

ress

or

Gsi

ght

gla

ss

Vib

rati

on

Te

mp

era

ture

Pre

ssu

re

Flo

w

Fla

ng

ed

co

nn

ect

ion

He

at

sou

rce

He

at

sin

k

ven

t

he

ate

r

recu

pe

rato

r

coo

ler

Filli

ng

ta

nk

Re

cove

ry t

an

k

rece

iver

CT

Main features:

• Gas booster

• Needle valves

• CGT ancillaries➢ Cooling➢ Drainage➢ Lubrication

• Heat from dry cooler at thestart-up

Design of a sCO2 system for industrial waste heat recovery applications 8 /21



G. Bianchi

Brunel’s HT2C – CAD concept

Heat source

sCO2 heater

CGT

recuperator

cooler8ft

18ft




G. Bianchi

Electric cabinet

CGTRTJ flanges

G

G

Inverter

Solenoid valve

Needle valve


Non return valve

CO2

Oil

Oil+CO2

Flue gas

Water

Electrical power

filter

Oil separator

pump


G sight glass

Vibration

Temperature

Pressure

Flow

Flanged connection

Heat source

Heat sink

vent

heater

recuperator

cooler

Filling tank

Recovery tank

receiver

C T

Enogia’s CGT – CAD concept

WaterCO2

Oil

CO2+Oilelectric

5

43

2

1

5

4

3

2

1


P&IDheat source

10 /21



G. Bianchi

Degrees of freedom• Mass flow rate• temperature




G. Bianchi

Turbomachinery for sCO2 systems

Sienicki et al. (2011)

High revolution speeds + small impeller diameters




G. Bianchi

Turbomachinery design procedure

Baljecharts

Meanlinedesign

CAD CFD FEA

https://bura.brunel.ac.uk/handle/2438/14568

Presented at the 1st

EU sCO2 symposium

Max

Min Absolute pressure


https://bura.brunel.ac.uk/handle/2438/14568


Compressor Turbine

Rotor Diameter 55 mm 72 mm

Number of blades 7 14

Nozzle Number of blades 11 17

Isentropic efficiency (total-static) 76% 70%




G. Bianchi

Aerodynamic design - Results

compressor turbine




G. Bianchi

CGT overall architecture

Rotor

Stator

Stator

Drain

Passive seals Rotational guidance

Casing maintained via tie rod

High pressure High pressureLow pressure

TurbineCompressor

Longer shaft




G. Bianchi

Rotodynamic calculations and tests




G. Bianchi

Generator Assembly

Magnet implementation Generator and cooler

Conclusions• sCO2 systems could be successfully applied on fossil, nuclear

and industrial waste heat to power generation

• Within I-ThERM, BUL and Enogia developed one of the first

full experimental sCO2 facility in Europe with high TRL

– Tens of kW as power output (small-scale)

– Novel heat transfer equipment

– Packaged design of the turbomachinery unit

1st European Seminar



Future work• sCO2 rig fabrication

• Certification according to PED

• Experimental campaign

1st European Seminar



Ongoing activities

• Theoretical energy and exergy analysis on sCO2 cycle layouts https://doi.org/10.1016/j.energy.2018.02.005

• Transient modelling and control of sCO2 equipment and systems

• 3D CFD modelling of sCO2 equipment

https://doi.org/10.1016/j.energy.2018.02.005




G. Bianchi

Acknowledgments

BUL’s team

• Prof. Savvas A. Tassou

• Dr. Giuseppe Bianchi

• Dr. Samira Sayad Saravi

• Dr. Konstantinos M. Tsamos

• Dr. Lei Chai

• Mr. Matteo Marchionni

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant

agreement No. 680599

Enogia’s team

• Mr. Arthur Leroux

• Mr. Romain Loeb

• Mr. Norman Holaind

• Mr. Nicolas Goubet

• Mr. Gabriel Henry

• Dr. Gael Leveque

• Mr. William Derue

www.foodenergy.org.uk www.enogia.com

http://www.foodenergy.org.uk/

http://www.enogia.com/




G. Bianchi

www.foodenergy.org.uk/ERCoM_2018_Workshop.html

http://www.foodenergy.org.uk/ERCoM_2018_Workshop.html

Design of a single-shaft compressor, generator, turbine

of a small scale supercritical CO2 system

for waste heat to power conversion applications

M. De Miol, G. Bianchi, G. Henry, N. Holaind, S. A. Tassou, A. Leroux

2nd European Seminar on

Supercritical CO2 (sCO2) Power Systems

Essen, 30/08/2018

Design of a single-shaft compressor, generator, turbine of ...

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