2nd European Seminar on

Supercritical CO2 (sCO2) Power Systems

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

Essen, 30/08/2018
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

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

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 2 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

https://doi.org/10.1016/j.egypro.2017.07.263
https://doi.org/10.1016/j.applthermaleng.2018.04.043
http://dx.doi.org/10.1016/j.rser.2015.12.192

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 3 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

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℃

This project has received funding from the European Union’s Horizon 2020 research
and innovation programme under grant agreement No. 680599
G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 4 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

Scope of the I-ThERM’s sCO2 project

• Power output 50 kWe
• 1st law efficiency ≈ 20 %
• High TRL
• Low CAPEX (short PBP)

Design of Design and manufacturing Experimental

sCO2 system and of turbomachinery and campaign
Test rig Heat exchangers

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 5 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

High Temperature Heat To power Conversion (HT2C)

at Brunel University London
Heat source:
~ 1MW gas fired heat source
Heater:
Micro-tube heat exchanger

Recuperator:
Printed circuit heat exchanger
C G T

Cooler:
Plate heat exchanger

min/max min/max CO2 mass flow Heat sinks:

pressure [bar] Temperature [°C] rate [kg/s] • Water/glycol dry cooler
75/127.5 35/400 2.25 • CO2 gas cooler
G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 6 /21
 Refrigeration
Oil separator

compressor
2nd European Seminar

sight glass

pump
filter
on Supercritical CO2 (sCO2) Power Systems
Heat source

G
G
Process and Instrumentation Diagram (P&ID) heater
Heat source Heat source
Inverter
Heat source Heat source

Temperature
Main features:

Vibration
Pressure
Heat source heater heater

Flow
cooler

• Gas booster heater heater

recuperator

recuperator

Heat sink Inverter

heater

• Needle valves
C G T
recuperator recuperator
receiver

recuperator recuperator C

• CGT ancillaries G

Pressure relief valve

Flanged connection
vent

receiver

Non return valve

Filling tank recuperator C

➢ Cooling Solenoid valve

Recovery tank

Needle valve
G G
receiver receiver C G T
Filling tank Filling tank

➢ Drainage cooler
receiver receiver
G G
Filling tank

Filling tank Filling tank

Heat sink

➢ Lubrication vent
Filling tank
receiver
G
cooler cooler

Heat sink Heat sink

• Heat from Recovery tank

vent Heat sink
vent
cooler

Heat sink
cooler

dry cooler at the

cooler

Heat sink Recovery tank vent Recovery tank vent

start-up Flow sight glass CO2

G
Solenoid valve
Oil
vent Pressure filter
Recovery tank Recovery tank
Needle valve Oil+CO2
Oil separator
Solenoid valve Solenoid valve Flow
Flue gas Flow G sight glass G sight gla
Temperature
Pressure relief valve Recovery tank Water
pump Pressure Pressure filter filter
Vibration Needle valve Needle valve Electrical power
Non return valve Solenoid valve Solenoid valve Flow Flow G sight glass G sight gla
Temperature Temperature Oil separator Oil sepa
Refrigeration
Flanged connection Pressure relief valve
Pressure relief valve
compressor Pressure Pressure filter filter
Needle pump pump
Solenoid valve Flow valve Needle valve G Vibration
sight glass Vibration CO2
Non return valve Non return valve Oil separator Oil sepa
Temperature Temperature
Oil
Refrigeration Refriger
Pressure
Pressure relief valve
Pressure relief valve filter Oil+COpump
G. Bianchi Design of Needle
a sCOvalve
2 system for industrial waste heat
Flanged recovery
connection Flangedapplications
connection Vibration Vibration compressor
2 7pump
/21
compre
Non return valve Non return valve Oil separator
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

Brunel’s HT2C – CAD concept 18ft

recuperator

CGT

Heat source

8ft
sCO2 heater cooler

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 8 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

Enogia’s CGT – CAD concept

Inverter
RTJ flanges
CGT
3
3
4 4 2
2
C G T 1
1
5
5

Water CO2+Oil
CO2 electric Electric cabinet
Oil
G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 9 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

P&ID
heat source

Degrees of freedom
• Mass flow rate
• temperature

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 10 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

Turbomachinery for sCO2 systems

Sienicki et al. (2011)

High revolution speeds + small impeller diameters

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 11 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

Turbomachinery design procedure

Balje Meanline
CAD CFD FEA
charts design

Presented at the 1st https://doi.org/10.1016/j.egypro.2017.07.256

EU sCO2 symposium

Max

Min Absolute pressure

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

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 12 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

Aerodynamic design - Results

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%

compressor turbine
G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 13 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

CGT overall architecture

Passive seals Longer shaft Rotational guidance

Stator
Compressor Rotor Turbine

Stator
High pressure Low pressure High pressure

Drain Casing maintained via tie rod

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 14 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

Rotodynamic calculations and tests

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 15 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

Generator Assembly

Magnet implementation Generator and cooler

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 16 /21
 1st European Seminar
on Supercritical CO2 (sCO2) Power Systems

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

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 17 /21
 1st European Seminar
on Supercritical CO2 (sCO2) Power Systems

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

Future work
• sCO2 rig fabrication
• Certification according to PED
• Experimental campaign
G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 18 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

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

BUL’s team Enogia’s team

• Prof. Savvas A. Tassou • Mr. Arthur Leroux
• Dr. Giuseppe Bianchi • Mr. Romain Loeb
• Dr. Samira Sayad Saravi • Mr. Norman Holaind
• Dr. Konstantinos M. Tsamos • Mr. Nicolas Goubet
• Dr. Lei Chai • Mr. Gabriel Henry
• Mr. Matteo Marchionni • Dr. Gael Leveque
• Mr. William Derue
www.foodenergy.org.uk www.enogia.com

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 19 /21
 2nd European Seminar
on Supercritical CO2 (sCO2) Power Systems

www.foodenergy.org.uk/ERCoM_2018_Workshop.html

G. Bianchi Design of a sCO2 system for industrial waste heat recovery applications 20 /21
 2nd European Seminar on
Supercritical CO2 (sCO2) Power Systems

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

Essen, 30/08/2018