Rocketdyne Development of the Supercritical CO 2 Power Conversion System

Rocketdyne Development of the Supercritical CO 2 Power Conversion System Michael McDowell Program Manager Reactor & Liquid Metal Systems Hamilton Sundstrand, Space Land & Sea-Rocketdyne Page 1

Rocketdyne Development of the Supercritical CO 2 Power Conversion System Rocketdyne Organization, Heritage & Capabilities Supercritical CO 2 System & Equipment System modeling / evaluation Turbomachinery design Heat exchanger evaluation Future Plans Page 2

United Technologies Corporation (UTC) $42.7B Sales (2005) $5.2B Operating profit >200,000 employees Operating in 180 countries Pratt & Whitney UTC Power Carrier Sikorsky Hamilton Sundstrand UTC Fire & Security Otis Page 3

Rocketdyne Alignment after UTC Purchase of Rocketdyne from Boeing (August 3, 2005) Hamilton Sundstrand Research Center Pratt & Whitney UTC Power Hamilton Sundstrand Space Land & Sea Rocketdyne Share Campus, Processes & Resources Pratt & Whitney Rocketdyne Advanced Power Systems Aligned with Hamilton Sundstrand Page 4

Rocketdyne Energy Heritage Fast Flux Nuclear Test Facility Nuclear SRE Clinch River Breeder Reactor Sodium Advanced Fast Reactor New Production Reactor Gen IV - Molten Salt / Liquid Metal Systems Solar Solar 1 10 MW Solar 2 10 MW Power Towers 15-100 MW Solar Dynamic 25 KW Dish Engine System 25 kw Fossil Coal Combustion Technologies Methane Combustion Coal Gas & Hydrogen Generation Technologies 1950 s 1960 s 1970 s 1980 s 1990 s 2000 s North American Gasification Pilot Plant Rockwell International Atomics International Energy Systems Rocketdyne Propulsion & Power Boeing UTC 2010 s PWR / HS SLS-R Page 5

PWR Rocket / Space Program Heritage 1958 1969 1971 1988 2002 2003 1950 s Navajo engine developed F-1 and J-2 engines launch Apollo to Moon Space Shuttle Main Engine contract Starts RS-27A launches first commercial Delta rocket 1960 s 1970 s 1980 s 1990 s XSS-10 Micro Satellite launched Radioisotope Thermoelectric Generator initiated Today 1958 1963 1965 1980 1985 1992 2002 Terminal High Altitude Area Defense development begins Redstone engine launches Explorer 1 RL10 First Flight Atlas Snap 10A - First nuclear reactor launched Peacekeeper Stage IV developed International Space Station contract start 1 st RD-180 Launch Atlas III 2000 Aerospike flight engine tests RS-68 launches Delta IV Page 6

Rocket Engine Competencies Applicable to Energy Markets High energy density combustion 6000º F 5000 psia Regenerative cooling Low metal temperatures High system efficiency High speed rotating equipment 36,000 rpm Hydrogen technology Low cost < $10 per kw thermal Unique design capabilities Advanced manufacturing processes Manufacturing and test Capacity > 200 GW thermal per year Rapid prototyping Extensive test capability Page 7

Key Rocketdyne Processes Advanced Analysis Test Materials Engineering Tools and processes linked electronically System Engineering Electronics Design Mechanical Design Manufacturing Page 8

Approach to Supercritical CO 2 System & Equipment Design Initiated technical evaluation in 2006 with internal funds System modeling / evaluation Turbomachinery conceptual design Heat exchanger evaluation Tools refinement CFD Small contract for Sandia Laboratory on turbomachinery & test concepts Using supercritical CO 2 system knowledge on advanced reactor concepts in 2007 Page 10

System Modeling / Evaluation Verified preceding wisdom on CO 2 cycle Literature review: MIT reports Select 300 Mwe LMR as baseline Power system modeling for efficiency Evaluated alternate configurations Defined parameters for turbomachinery & heat exchangers Extended power system modeling other power systems VHTGR Solar thermal power Flow=1-f RC Reactor 8 Flow=f MC 5 1 7b Cooler MT HT Recuper ator 7 7a LT Recuper 6 ator 2 3 4 Page 11

Modeling Results: VHTGR Power System Study * * Supercritical CO 2 Helium Brayton Supercritical Steam Single Reheat Supercritical Steam Double Reheat Subcritical Steam Plot from: Driscoll, M.J., Report No: MIT-GFR-019, Interim Topical Report Supercritical CO2 Plant Cost Assessment, September 2004, Center for Advanced Nuclear Energy Systems, MIT Nuclear Engineering Department ChemCad used to model supercritical CO 2 and helium Brayton cycles GateCycle used to model steam cycles Page 12

Not every power system benefits from supercritical CO 2 Rocketdyne solar power plant Molten salt thermal storage 550 to 300C across HX Normally Rankine cycle 1 2 Reactor MC MT 8 HT Recuperator 7 3 7b 7a LT Recuperator 6 Flow=f Cooler 4 5 CO 2 cycle performs poorly Cycle highly recuperated Wants reduced delta T Reduced delta T lowers storage & circulation effectiveness Added cost overcomes cycle efficiency Flow=1-f RC Solar Power Tower with Supercritical CO 2 Cycle Page 13

Turbomachinery Design: Summary of Results Baselined 300 Mwe LMR Established turbomachinery configuration and layout Common shaft for all machines driven by power turbine Shaft rotation speed (3600 rpm) compatible with industrial size electrical generators Separate shaft seals on each machine Balanced axial thrust 3-D equipment drawings completed Page 14

Turbomachinery Design: Summary of Results CO2 Compressor Efficiency Prediciton Identified preferred design approach for compressors Two stage centrifugal path selected for main compressor Four stage centrifugal path selected for recompressor Identified preferred design approach for turbine Three stage axial path Reaction blading Fir tree and shrouded blades with dampers Efficiency, % 100 90 80 CO2 Main Compressor 1 Stg D=20.5 in. @ 7000 RPM Overall Eff 85% 70 CO2 ReComp Compressor 2 Stg D=25.5 in. @ 7000 RPM Overall Eff 85% CO2 Main Compressor 2 Stg D=28.1 in. @ 3600 RPM Overall Eff 85% CO2 ReComp Compressor 4 Stg D=35.0 in. @ 3600 RPM Overall Eff 85% Best RMS Fit Roger's Impeller Only efficiency Test Predicted Impeller+Diffuser efficiency From Rogers Impeller Only Test 60 0 1000 2000 3000 4000 Impeller Specific Speed Turning GearTo Generator Turbine Coupling Main Compressor Re-Compressor Page 15

Turbomachinery Shaft Layout 45 Recompression Compressor Main Compressor Turning Gear Shaft Seal Radial Bearing Damper Seal Shaft Seal Radial Bearing Coupling Thrust Bearing Thrust Bearing Radial Bearing Shaft Seal Radial Bearing Coupling Page 16

Heat Exchanger Evaluation Basis: 300 Mwe LMR Evaluated heat exchanger for type (CHE or STHE) Sodium to supercritical CO2 IHX High temperature SCO2 recuperator Low temperature SCO2 recuperator Pre-cooler SCO2 to water heat exchanger Developed 3 designs/concepts for IHX Compact heat exchangers (CHE) Shell and tube heat exchanger (STHE) Straight tube Coiled tube Page 17

Heat Exchanger Evaluation Results CO 2 recuperators & pre-cooler Costs & configuration analyzed CHE preferred for CO 2 recuperators CHE pre-cooler very expensive Further evaluation needed IHX Comparison CHE Most compact Most expensive Thermal transient concern Sodium side plugging STHE Lower cost by factor of almost 5 Building cost higher Robust design Page 18

Supercritical CO 2 Turbomachinery Development Scenario/Schedule Task 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 Super subscale testing Single stage compressor Confirm modeling and state properties at most challenging supercritical point 1/10 th scale system test Integrated cycle Full scale demonstration Design Fabricate Test 1/10 th scale demonstrates high efficiency and confirms design of all components Prototype reactor online Design Fabricate Operations Demonstration on prototype reactor 300 to 600 Mwe SCO2 cycle Steam cycle maintained as backup Page 20

The Rocketdyne Path Forward Demonstrate the promise of supercritical CO 2 More detailed design & trade studies Bearings Disk / blade / crossover designs CFD analysis Re-look at multi-shaft configurations Dynamic system simulation analysis O&M and operability evaluations Implementation of development schedule Improve customer interest Funding for path forward Page 21