“Development of a Nelium Turbo-Brayton cryogenic ......“Development of a Nelium Turbo-Brayton...
Transcript of “Development of a Nelium Turbo-Brayton cryogenic ......“Development of a Nelium Turbo-Brayton...
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“Development of a Nelium Turbo-Brayton cryogenic refrigerator for the
FCC-hh”EASITrain project status overview
EASITrain – European Advanced Superconductivity Innovation and Training. This Marie Sklodowska-Curie Action (MSCA) Innovative Training Networks (ITN) has received funding from the
European Union’s H2020 Framework Programme under Grant Agreement no. 764879
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 2
Outline
Motivation
Work performed:
- Former cycle baseline
- Limiting factors
- Improved design
Secondments & Trainings & Dissemination events
Next steps
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 3
Motivation
Cryogenic system for the FCC-hh
Total power consumption:
~σ 200 MW : 20 MW // 10 Plants // 100 km
Cooling capacity per plant:
- from 60 to 40 K
thermal shields – 78 kW
beam screens – 504 kW
- from 300 to 40 K
pre-cooling of the helium cycle – 270 kW
C
T
T
C
Quenchbuffer
BCE F D
CM
Qcm
Shaft
C
Qts
Tunnel
Qcl
Cavern
T
T
T
C CC
C
Qbs Qts
Cryoplant layout
(L. Tavian)
Ring layout (L. Tavian)
Nelium cycle
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 4
Baseline cryogenic cycle
Key components:
- multi-stage centrifugal compressor (~10 MW range)
- turbo-expander ~700 kW → power recovery in compressor
Previously considered Nelium composition: 33 vol. % of neon
Nelium Turbo-Brayton cycle: former
baseline cycle layout
Image courtesy: MAN Diesel and Turbo
Image courtesy: SKF
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 5
Limiting factors
1. Turbo-compressor design
Currently developed 1-tandem design:
- up to 40 vol. % He;
- total compressor isentropic efficiency: ~73 %
0
2
4
6
8
0 0.2 0.4 0.6 0.8 1Nu
mb
er o
f co
mp
ress
or
casi
ng
s
Helium content (vol.)
Number of required compressor casings depending
on the helium content
(M. Podeur, University of Stuttgart; MAN)
0
2
4
6
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10
0 0.2 0.4 0.6 0.8 1
Re
lati
ve g
as
ma
ss
Helium content (vol.)
Theoretical relative gas mass compared to a pure helium cycle
(excluding the buffer)
Total
Neon
Helium
1
1.5
2
2.5
3
0 0.2 0.4 0.6 0.8 1
Re
lati
ve v
olu
me
Helium content (vol.)
Relative heat exchanger sizes
2. System size and gas mass
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 6
Compared cycle arrangements
Cycle A (baseline) Cycle B Cycle C
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 7
2 inner heat exchangers reduced pressure ratio reduced pressure ratio
easier pressure control higher volumetric flow to the second
compressor casing
reduced pressure ratio of pre-cooling turbine
compared to cycle B
higher pressure ratio additional heat exchanger additional heat exchanger
high speed of the pre-cooling turbine (high
pressure ratio)
Compared cycle arrangements
Chosen arrangement
Cycle A (baseline) Cycle B Cycle C
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 8
5.3
5.4
5.5
5.6
5.7
5.8
5.9
6
6.1
6.2
0.3 0.4 0.5 0.6 0.7
Pre
ssu
rera
tio
Helium content (vol.)
Required pressure ratio depending on the gas mixture
composition
Cycle C Cycle A
Compared cycle arrangements
Cycle C - > new baseline
Advantages:
- Reduced pressure ratio
- Higher volumetric flow on the inlet of the second casing
Thus, for 40 % helium:
Cicle A: 𝑉1 𝑐𝑎𝑠𝑖𝑛𝑔
𝑉2 𝑐𝑎𝑠𝑖𝑛𝑔~2,4
Cycle C: 𝑉1 𝑐𝑎𝑠𝑖𝑛𝑔
𝑉2 𝑐𝑎𝑠𝑖𝑛𝑔~1,9 (var)
Increase helium content up to 60 vol. % He - 1 compressor impeller → +4..5 % to the total
compresor ηs↑
or
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 9
Improved cycle concept
Case study (under progress): matching the turbo-compressor middle pressure with the
cycle parameters
Estimated total power for the chosen case: ~9.7 MW
New baseline cycle flow diagram
7500
7600
7700
7800
7900
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8100
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11 13 15 17 19
Isen
tro
pic
wo
rk o
f co
mp
ress
ion
, kW
Inlet pressure to the 2nd compressor casing, bar
Total isentropic power of the compressor depending on the middle
pressure (for NTU1=18)
26.06.2019: “Improved concept of the Nelium Turbo-Brayton cycle
for the FCC-hh beam screen cooling”,
S. Savelyeva, S. Klöppel, Ch. Haberstroh, H. Quack
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 10
Upper heat exchanger design
Reduction of the heat exchanger cross-
section area and the cold box diameter
IHX1
IHX2
New baseline cycle flow diagram
Cold box cross section
Length: 5.6…6 m;
Diameter: 3.6..3.8 m
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 11
Natural Nelium concept
- Corresponds to the neon-helium ratio in the air:
Natural Nelium: (Ne:He) ~(3:1) + (3…8 %) H2
- Economically advantageous
- Current target composition: 60 % neon, 40 % helium → cheaper helium can be added
Crude nelium mixture production flow
diagram
- Hydrogen presence in the mixture: good
thermophysical properties
- Problem: instability of composition
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 12
Secondments & Trainings & Dissemination events
- Secondment – Linde Kryotechnik, Pfungen, Switzerland (29.04.-14.06.2019)
- Scientific cooperation with ESR 15 – University of Stuttgart, Germany (18.03.-05.04.19)
- Cryogenics conference 2019, Prague, Czech Republic (07.04.-11.04.19)
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 13
Next steps
- Case study for the cycle design matching with the turbo-compressor design
- Part-load operation and buffer optimisation for the new cycle baseline
- Compander designReview of the cycle performance calculation
- Cool-down operation of the new cycle baseline
- Further study of the Natural Nelium concept
- Participation in experiments on the neon-helium turbo-compressor test rig (University
of Stuttgart)
- Secondment 2
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EASITrain project status overview
Technical University Dresden
Bitzer Chair of Refrigeration, Cryogenics and Compressor Technology // Sofiya Savelyeva
FCC Week 2019, Brussels // 27.06.2019
Slide 14
Thank you for your attention!
EASITrain – European Advanced Superconductivity Innovation and Training. This Marie Sklodowska-Curie Action (MSCA) Innovative Training Networks (ITN) has received funding from the European Union’s H2020 Framework
Programme under Grant Agreement no. 764879
“Development of a Nelium Turbo-Brayton cryogenic refrigerator for the FCC-hh”
EASITrain project status overviewS. Savelyeva, Ch. Haberstroh