“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
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
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
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
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
8
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
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
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
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
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
8000
8100
8200
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
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
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
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)
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
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