A comparison of flow path designs for axial turbines operating with pure CO2 and CO2 mixtures

Supercritical CO2 (sCO2) mixtures have been found to be promising for enhancing the performance of power cycles for concentrated solar power (CSP) applications, with up to a 6% enhancement in cycle efficiency compared to a simple recuperated CO2 cycle depending upon the mixture and cycle configuration chosen. Given that turbine efficiency significantly affects the overall plant performance, it is important to confirm whether turbines operating with CO2 mixtures can achieve the same efficiencies compared to pure CO2, whilst exploring whether the use of mixtures introduces any differences in the turbine design. This study aims to investigate the differences in turbine flow path designs produced for pure CO2 compared to CO2 mixtures, whilst taking into account aerodynamic, rotordynamic and mechanical design aspects, as assessed during the mean-line design process. The aim of this study extends to evaluating the effect of key turbine design variables, such as the loading coefficient, flow coefficient and degree of reaction, on the flow path design and overall aerodynamic performance. Multiple flow path designs have been produced for axial turbines operating with pure CO2 and mixtures of CO2 with titanium tetrachloride (TiCL4), hexafluorobenzene (C6F6) and sulphur dioxide (SO2) for installation in a 100 MWe CSP plant. It is found that turbines operating with either pure CO2 or CO2 mixtures result in overall total-to-total efficiencies in excess of 92.5%; where the highest turbine efficiency is achieved for the turbine operating with pure CO2, whilst this reduces by a maximum of 1.1 percentage points for the CO2/TiCL4 mixture. This reduction in efficiency is because the CO2/TiCL4 turbine is limited to a maximum of six design stages in order to meet the imposed mechanical design criteria, whilst the pure CO2 turbine can accommodate thirteen stages leading to higher aerodynamic efficiency. The difference between the two cases is the result of a higher mass-flow rate for the CO2/TiCL4 mixture (66% greater than for pure CO2), which results in high rotor bending stresses and limits the number of stages to comply with the design criteria. It is also found that designing the turbine at loading and flow coefficients of 0.8 and 0.6 respectively, whilst fixing the degree of reaction and pitch-to-chord ratio to values of 0.5 and 0.85 respectively, resulted in an efficiency enhancement of 0.2% with respect to a baseline design produced at loading and flow coefficients of 1.0 and 0.5. This increase is due to being able to increase the number of stages from eleven to fifteen. This indicates that there is not much benefit in modifying key design parameters to improve the turbine efficiency as the 0.2% efficiency enhancement is considered within the margin of accuracy of mean-line flow path design

A modified loss breakdown approach for axial turbines operating with blended supercritical carbon dioxide

In this paper, a modified loss breakdown approach is introduced for axial turbines operating with supercritical carbon dioxide (sCO2) mixtures using computational fluid dynamics (CFD) results. Loss breakdown analysis has been previously developed using two approaches, however each approach has its own uncertainties. The first approach neglects the effects of the cross-interaction between the different loss sources, while the second approach ignores the potential changes to the boundary layer thicknesses and the loss source domains. Although the second methodology accounts for the interactions between the different loss sources, it may produce less accurate predictions for compact machines like sCO2 turbines where the boundary layer may dominate the flow passage. The proposed methodology aims to obtain the turbine loss breakdown using a single CFD model where all sources of aerodynamic loss coexist, while considering variable loss regions defined based on the velocity and entropy distribution results. A steady state, single-stage, single-passage, 3D numerical model is set up to simulate the turbine and verify the loss audit methodology. The results are verified against the published loss audit methodologies for a 130 MW axial turbine operating with CO2/C6F6 blend, designed using an in-house mean line design code. The results show a good agreement between the proposed approach and the multiple-model approaches from the literature. However, the existing approaches appear to overestimate endwall losses by 13-16% and underestimate the profile losses by 11-31% compared to the proposed approach. Compared to mean line loss models, large differences in loss sources are observed from the CFD results, especially for the stator and rotor endwall losses which are found to be 3.2 and 1.6 times the CFD values, respectively. This helps to indicate limitations in existing mean line loss models

Off-design performance assessment of an axial turbine for a 100 MWe concentrated solar power plant operating with CO2 mixtures

This paper presents an investigation of the aerodynamic performance of a 130 MW axial turbine operating with a CO2/SO2 mixture using a mean-line off-design performance model; where the validity of this model has been confirmed through verification against results from the literature and computational fluid dynamic (CFD) simulations. This analysis also includes assessing the impact of varying the number of stages on the part-load operation. Additionally, the application of similitude theory to non-dimensionalise performance characteristics is validated by assessing the performance of the same turbine with different working fluids, mixture compositions, and rotational speeds. The mean-line performance model applied throughout this study is based on the Aungier loss model, whilst a multi-stage, Reynolds averaged CFD model is employed to assess the 3D flow behaviour using the�−���� turbulence model. Significant deviations in total-to-total efficiency were observed between the mean-line and CFD results during part-load operation, especially at lower mass flow rates. These deviations can reach up to 18% when the blade Mach number exceeds the design point by 12%. This is attributed to flow separation, which is evident from the CFD simulations, and the mean-line loss model fails to predict. From a purely aerodynamic standpoint, the turbine can operate at part-load conditions up to 88.5% of the design flow coefficient based on the CFD results and achieve an efficiency of 80.2%. It was also found that increasing the number of stages from 4 to 14 can improve the off-design total-to-total efficiency by approximately 7.7% at 93% of the design flow coefficient. This demonstrates that increasing the number of stages enhances turbine performance at both design and part-load operations. Finally, the similitude scaling laws formulated using real-gas equation of state were found to remain valid for all the mixtures, molar compositions, and operating conditions considered.</p

Design of a 130 MW axial turbine operating with a supercritical carbon dioxide mixture for the SCARABEUS project

Supercritical carbon dioxide (sCO2) can be mixed with dopants such as titanium tetrachloride (TiCl4), hexafluoro-benzene (C6F6), and sulphur dioxide (SO2) to raise the critical temperature of the working fluid, allowing it to condense at ambient temperatures in dry solar field locations. The resulting transcritical power cycles have lower compression work and higher thermal efficiency. This paper presents the aerodynamic flow path design of a utility-scale axial turbine operating with an 80–20% molar mix of CO2 and SO2. The preliminary design is obtained using a mean line turbine design method based on the Aungier loss model, which considers both mechanical and rotor dynamic criteria. Furthermore, steady-state 3D computational fluid dynamic (CFD) simulations are set up using the k-ω SST turbulence model, and blade shape optimisation is carried out to improve the preliminary design while maintaining acceptable stress levels. It was found that increasing the number of stages from 4 to 14 increased the total-to-total efficiency by 6.3% due to the higher blade aspect ratio, which reduced the influence of secondary flow losses, as well as the smaller tip diameter, which minimised the tip clearance losses. The final turbine design had a total-to-total efficiency of 92.9%, as predicted by the CFD results, with a maximum stress of less than 260 MPa and a mass flow rate within 1% of the intended cycle’s mass flow rate. Optimum aerodynamic performance was achieved with a 14-stage design where the hub radius and the flow path length are 310 mm and 1800 mm, respectively. Off-design analysis showed that the turbine could operate down to 88% of the design reduced mass flow rate with a total-to-total efficiency of 80%.</p

Axial turbine flow path design for concentrated solar power plants operating with CO2 blends

The utilisation of certain blends based on supercritical CO2 (sCO2), namely CO2/TiCl4, CO2/C6F6 and CO2/SO2, have been found to be promising for enhancing the performance of power cycles for Concentrated Solar Power (CSP) applications; allowing for up to a 6% enhancement in cycle efficiency with respect to a simple recuperated CO2 cycle, depending upon the nature of the used blend and the cycle configuration of choice. This paper presents an investigation of the impact of adopting these sCO2-based blends on the flow path design for a multi-stage axial turbine whilst accounting for aerodynamic, mechanical and rotordynamic considerations. This includes assessing the sensitivity of the turbine design to selected working fluid and imposed optimal cycle conditions. Ultimately, this study aims to provide the first indication that a high-efficiency turbine can be achieved for a large-scale axial turbine operating with these non-conventional working fluids and producing power in excess of 120 MW. To achieve this aim, mean-line aerodynamic design is integrated with mechanical and rotordynamic constraints, specified based on industrial experience, to ensure technically feasible solutions with maximum aerodynamic efficiency. Different turbine flow path designs have been produced for three sCO2 blends under different cycle boundary conditions. Specifically, flow paths have been obtained for optimal cycle configurations at five different molar fractions and two different turbine inlet pressure and temperature levels of 250 & 350 bar and 550 & 700?C respectively. A total-to-total turbine efficiency in excess of 92% was achieved, which is considered promising for the future of CO2 plants. The highest efficiencies are achieved for designs with a large number of stages, corresponding to reduced hub diameters due to the need for a fixed synchronous rotational speed. The large number of stages is contrary to existing sCO2 turbine designs, but it is found that an increase from 4 to 14 stages can increase the efficiency by around 5%. Ultimately, based on the preliminary cost analysis results, the designs with a large number of stages showed to be financially feasible compared to the designs with a small number of stages