The Sandia S-CO2 Recompression Closed Brayton Cycle (RCBC) utilizes a series of gas foil bearings in its turbine-alternator-compressors. At high shaft rotational speed these bearings allow the shaft to ride on a cushion of air. Conversely, during startup and shutdown, the shaft rides along the foil bearing surface. Low-friction coatings are used on bearing surfaces in order to facilitate rotation during these periods. An experimental program was initiated to elucidate the behavior of coated bearing foils in the harsh environments of this system. A test configuration was developed enabling long duration exposure tests, followed by a range of analyses relevant to their performance in a bearing. This report provides a detailed overview of this work. The results contained herein provide valuable information in selecting appropriate coatings for more advanced future bearing-rig tests at the newly established test facility in Sandia-NM.
This report outlines the thermodynamics of a supercritical carbon dioxide (sCO2) recompression closed Brayton cycle (RCBC) coupled to a Helium-cooled nuclear reactor. The baseline reactor design for the study is the AREVA High Temperature Gas-Cooled Reactor (HTGR). Using the AREVA HTGR nominal operating parameters, an initial thermodynamic study was performed using Sandia's deterministic RCBC analysis program. Utilizing the output of the RCBC thermodynamic analysis, preliminary values of reactor power and of Helium flow rate through the reactor were calculated in Sandia's HelCO2 code. Some research regarding materials requirements was then conducted to determine aspects of corrosion related to both Helium and to sCO2 , as well as some mechanical considerations for pressures and temperatures that will be seen by the piping and other components. This analysis resulted in a list of materials-related research items that need to be conducted in the future. A short assessment of dry heat rejection advantages of sCO2> Brayton cycles was also included. This assessment lists some items that should be investigated in the future to better understand how sCO2 Brayton cycles and nuclear can maximally contribute to optimizing the water efficiency of carbon free power generation
At Sandia National Laboratories (SNL), The Nuclear Energy Systems Laboratory / Brayton Lab has been established to research and develop subsystems and demonstrate the viability of the closed Brayton cycles (CBC), and in particular, the recompression CBC. The ultimate objective of this program is to have a commercial-ready system available for small modular reactors. For this objective, R&D efforts must demonstrate that, among other things, component and the system behavior is understood and control is manageable, and system performance is predictable. Research activities that address these needs include investigating system responses to various anticipated perturbations, and demonstrating that component and system performance is understood. To these ends, this paper presents system response to a perturbation, and turbomachinery performance results during steady state operation. A long duration test, with an extensive period at steady state, was completed in the simple CBC configuration. During this period, a cooling perturbation was initiated. Data from this test are presented and evaluated to explain the sequence of events following the perturbation. It was found that a cascading series of events ensued, starting with the fluid condensing effect of the cooling perturbation. The explanation of events emphasizes the highly interactive and nonlinear nature of CBC's. The comparisons of measured and predicted turbomachinery performance yielded excellent results and give confidence that the predictive methods originally envisioned for this system work well.
Small-scale supercritical CO2 demonstration loops are successful at identifying the important technical issues that one must face in order to scale up to larger power levels. The Sandia National Laboratories supercritical CO2 Brayton cycle test loops are identifying technical needs to scale the technology to commercial power levels such as 10 MWe. The small size of the Sandia 1 MWth loop has demonstration of the split flow loop efficiency and effectiveness of the Printed Circuit Heat Exchangers (PCHXs) leading to the design of a fully recuperated, split flow, supercritical CO2 Brayton cycle demonstration system. However, there were many problems that were encountered, such as high rotational speeds in the units. Additionally, the turbomachinery in the test loops need to identify issues concerning the bearings, seals, thermal boundaries, and motor controller problems in order to be proved a reliable power source in the 300 kWe range. Although these issues were anticipated in smaller demonstration units, commercially scaled hardware would eliminate these problems caused by high rotational speeds at small scale. The economic viability and development of the future scalable 10 MWe solely depends on the interest of DOE and private industry. The Intellectual Property collected by Sandia proves that the ~10 MWe supercritical CO2 power conversion loop to be very beneficial when coupled to a 20 MWth heat source (either solar, geothermal, fossil, or nuclear). This paper will identify a commercialization plan, as well as, a roadmap from the simple 1 MWth supercritical CO2 development loop to a power producing 10 MWe supercritical CO2 Brayton loop.