Low-Cost Recuperative Heat Exchanger For ScCO2 Power Systems Pr Proje ject Kic Kick-of off Meet Meeting ng Co Contract No No. DE DE-SC000 00010 1095 95 By By Dr. J . John ohn T. K . Kel elly Altex ex Tec Technol hnologies es C Cor orpor poration 244 244 Sobr obran ante Way ay Sunny unnyvale, C CA 94086 94086 For U. S . S. . Depar epartm tment of E of Ener nergy National onal E Energy gy T Technol nology ogy Labor orat ator ory Seth A eth A. . Law Lawson on, P Ph.D h.D Dec ecem ember er 3, 3, 2014 2014 ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 1
Low-Cost Recuperative Heat Exchanger for ScCO2 Power Systems Thi his s mat ateri erial is s prot protected under t under the D he DOE Progra rogram grant grant regul regulations. ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 2
High gh Effectiv ivene eness Low Cost (HELC) LC) Heat at E Exchang hanger er Manufactured and tested 30 kWt preliminary unit with early design inserts Stai ainless steel eel pl plat ates and and ins nserts • Nicke ckel-bas based ed braz aze e alloy • Tes ested to o 3, 3,50 500 ps psi at at low ow tem empe perature • Cor ore int nteg egrity pr proven • Man anifold upda update def define ned • ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 3
HELC LC Advant antage age for ScCO2 2 Cycle le Applic licat atio ions ns HELC Advantages for ScCO2 Cycle Applications High pressure capability Bonded core assembly tested up to 5,000 psi High temperature Stainless steel core ; test coupons fabricated with Inconel 625 for higher temperature and corrosion capability resistance, Nickel coating enhances base stainless steel corrosion resistance Thermal stress capability Flexible insert structure to mitigate thermal shock transients Enhanced heat transfer Insert structures that enhance heat transfer with limited pressure drop impact Single core and manifold bonding step; LAB bonding process, where surface finish, furnace loading, Significantly lower cost process time are substantially reduced versus diffusion bonding; lower part count for same heat transfer; less material Configurational and Modules of various widths and heights capacity flexibility ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 4
HELC LC Applic licat atio ions ns of Interest Internal heat exchangers for ScCO2 power cycles Fos ossil fuel uel • Nuclear ear • Conc ncent ntrat ating ng solar ar • Geot eothermal • Waste heat heat • ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 5
Applic plication ion of Interes est Waste heat from simple cycle GTs (e.g. LM2500) D-R and Echogen 7.5 Mwe Waste Heat ScCO2 Power System ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 6
Projec oject O Objec ectiv ives es Dev evelop, des design and and bui build a a 500 500 kWt High gh Effec ectivenss and and Low Low • Cos ost (HELC) RHEX capa apable of of ope operating at at 3500 3500 ps psi and and 1100 1100 F Show how anal analytically that hat it pr provides nee needed ther hermal and and structural • per performance tar arge geted for or the he Echo hogen and and Dresser-Rand and waste e heat at ScCO2 2 power er system em applicat ation on Bond ond the he uni unit us using pr proven ISO900 9001:2008 and and AS910 9100:2009 Rev ev C, • ASM ASME E Se Sect VI VIII, Div 1 certified manufacturer, Va Vacuum Pr Process Enginee neering ng (VPE) Tes est uni unit int nteg egrity, heat heat tran ansfer and and pr pressure dr drop per performance in n • Echogen’s 250 250 kWe (500 500 kw ther hermal) was aste heat heat pow power system dem demonstrator to o pr prove per performance and and int nteg egrity at at oper operating cond nditions ons of interes est ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 7
Projec oject T Team Alt Altex – Proj ojec ect l lead ead • Echoge hogen n – Per erformance t e tes est l lead ead • Babc abcoc ock and and Wilcox ox – Pow ower er s system heat heat ex exchang hanger • guidanc gui dance Dres esser R Rand and – Com ommer ercial al appl application on gui guidanc dance • Vac acuu uum Proc oces ess E Engi ngineer neering g – Manuf anufac acturing and g and • bondi bonding s ng suppor upport ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 8
HELC LC Projec ject Schedul edule ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 9
Task 1 – Project Management and Planning • Manag nage an and dir irect pr project in in ac accor ordanc dance wit ith the he Pro roject Manag anagem ement ent Pla Plan (PM PMP) P) and nd pr prepar epare ne neede eded doc docum ument nts and and brief br efing ngs ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 10
Task 1 – Project Management and Planning Project Management Plan Exec ecut utive e summar ary • Risk manag agem ement nt • Proj ojec ect timeline ne and miles eston ones es • Fun unding and and cos ost pr prof ofiles • Organi ganizat ational onal struc uctur ure e and managem nagement ent • Suc uccess criteria and and dec decision poi point nts • SO SOPO PO • ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 11
Task 1 – Project Management and Planning Risk management issues and mitigation Type of Risk Impact Probability Strategies Does not meet High Low Use established models, supported by data, performance to predict heat transfer and pressure drop specifications performance Does not meet integrity High Low Use FEA models, supported by data, to specification predict stresses under conditions of interest and use large safety factor Test systems do not High Low Use proven and well supported available operate as planned Echogen laboratory and demonstrator test systems Team management High Low Define interfaces, responsibilities and use experienced staff that has multi-group project experience Cost share problems Moderate Low Limit cost share relative to financial strength of team ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 12
Task 1 – Project Management and Planning Organization Structure ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 13
Task 1 – Project Management and Planning HELC success criteria Budget Criteria Milestone Success Criteria Period 1 Coupon bonds 4/30/15 Bonds have pull tests at base material yield strength 1 30kWt integrity 4/30/15 Passes helium leak check to nuclear standards and 5,000 psi hydrostatic test 1 30kWt performance 4/30/15 Under 10 psi pressure drop and meets 30kWt heat transfer 2 500kWt integrity 11/15/15 Passes helium leak check to nuclear standards and 5,000 psi hydrostatic test 2 500kWt performance 2/21/16 Under 10 psi pressure drop and meets 500kWt heat transfer at test system operating conditions 2 Cost reduction versus 5/31/16 Sixty percent cost reduction conventional ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 14
Task 1 – Project Management and Planning Task 1 Milestone Log Milestone Task Planned Start Planned Actual Verification Milestone Number Number Date Completion Date Completion Date Measure Held 1 1 Kickoff Meeting 12/3/2014 12/3/2014 12/3/2014 Meeting Produced 2 1 Project Plan Production 10/1/2014 11/1/2014 11/1/2014 Plan Meeting 6 1 Annual Presentation to DOE 10/31/2015 10/31/2015 Held Meeting 12 1 Final Presentation to DOE 5/1/2016 5/31/2016 Held Doc 13 1 Submit Final Report to DOE 5/1/2016 5/31/2016 Produced ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 15
Task 2 – Define Applications, Goals and Specifications • Def efine goal goals and and speci specifications f for t or the he application appl on of of int nter erest ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 16
Tas ask 2 k 2 – Def efine ne Appl pplicat ation ons, s, G Goal oals and and Spec pecificat ation ons Requi equired 30K d 30KWt H HELC LC spec pecifications ns UA=1.5 kW/°C ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON
Tas ask k 2 2 – Def efine ne Appl pplicat ation ons, s, G Goal oals and and Spec pecificat ation ons Requi equired 500K d 500KWt H HELC LC spec pecification ons UA=35 kW/°C ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON
Task 2 – Define Applications Goals and Specifications Task 2 Milestone Log Planned Milestone Task Planned Actual Verification Milestone Completion Number Number Start Date Completion Date Measure Date DOE Review and Comment of 3 2 10/1/2014 11/1/2014 Approval App, Goals and Specs ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 19
Task 3 – Refine Design and Assess Performance and Manufacturability • Desi esign a a prot prototype e HELC LC for pow or power er syst stem em demonst strat rator t or testing a ng at Echoge chogen t that hat w will si simul ulate a a ful ull-scal scale e heat heat excha exchanger r operat operation ALTEX T TECHNOL OLOGI OGIES C COR ORPOR ORATION ON 20
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