mechanical/thermal energy storage & recovery a case for ... larosiliere...
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The world turns to Elliott
Mechanical/Thermal Energy
Storage & Recovery – A Case for
High Performance Turbomachinery
Design
2020 Thermal, Mechanical, and Chemical
Energy Storage (TMCES) Workshop2/4/2020
Louis M. Larosiliere
Elliott Group
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• Turbomachines and turbomachinery systems are a key element in many energy storage schemes, and improvements in their performance and functionality have a direct link to techno-economic viability.
• A wide array of turbomachinery aero/mechanical arrangements can potentially enable practical realization of various energy storage thermodynamic cycles.
• Leveraging systems-level integrated thermodynamic cycle optimization coupled with turbomachinery topological design synthesis methods and practices from turbomachinery OEMs, may lead to significant advancements.
• Energy storage R&D programs should not only focus on “off-the-shelf” turbomachinery components, but also motivate the development of novel and improved turbomachinery architectures for maximum system benefit.
And the wheel keeps turning - innovative turbomachinery designs matter to a
reduced-carbon energy supply chain!
Message
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Backdrop:
Energy Storage &
Turbomachinery Performance
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CAES
LAES
MOSAS
Flywheels
Power-to-Fuels/Chemicals
Supercapacitors
BESS
PHS
Flow Batteries ETES
10 kW 100 kW 1 MW 10 MW 100 MW 1 GW
Seconds
Minutes
Hours
Days
Weeks/
Month
0
Du
rati
on
/Dis
ch
arg
e T
ime
Rated Power
Variety of Grid-Scale Storage Solutions:Off-the-shelf or “Clean Sheet” Turbomachinery?
Turbomachinery Centric
BESS – Battery Energy Storage System
ETES – Electro-Thermal Energy Storage
MOSAS – Molten Salt Energy Storage
Energy Storage Affordability: Balancing the techno-economics of power density,
efficiency, and reliability…
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Energy Carrier
Charging process
Dischargingprocess
Energy
Source
Demand
Energy
Turbomachinery Centric
Mechanical/Thermal Energy Storage
Stored
Energy
• For a chosen Energy Carrier, Turbomachinery
Technology and Thermodynamic Optimization of
Charging & Discharging processes are key elements.
• Figures of merit:
- High power density
- High storage efficiency
- Affordability Pneumatic Battery Analogue of Electric Battery
“Power cycles split into charging & discharging processes”
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Charging Period
Storage
Discharge
Period
Basic Principle of Adiabatic CAES:
Example of “Split” Brayton Cycle
Idealized Cavern Pressure Variation Profile Over an Operational Cycle
Cave
rn P
res
su
re (
Bara
)
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CAES Thermodynamic Optimization: Importance of Turbomachinery Performance
Idealized Analysis
Japikse & Di Bella, 2018
Energy Recovery
Efficiency:
Highest Temp, TR
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Why High Efficiency Turbomachinery?
• For turbomachinery polytropic
efficiency, ηp ≥ Rc, ERE is nearly
independent of storage pressure.
• For compressor exit energy
recovery effectiveness, Rc = 0.6,
ERE decreases with storage
pressure.
• High stored pressure can
adversely impact compressor off-
design matching and performance
Energy Recovery Efficiency (ERE):
• Ideal air
• No system pressure drop
• No external heating (TR / T3 = 1)
𝐸𝑅𝐸 = 1 + 𝑅𝑐𝐴η𝑐
𝐵
𝐴η𝑐η𝑡
If Rc = ηc , 𝐸𝑅𝐸 = η𝑐η𝑡 = 𝑅𝑐η𝑡
Mechanical
Storage EfficiencyThermal
Enhancement
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* Kartsounes and Kim, 1978, Argonne National Lab
Design Storage Pressure Impacts Cavern
Volume, Turbomachinery Arrangement, and
Capital Cost
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• System Performance (efficiency) & Operability (variability)- Efficient & flexible architectures, including blading shape
- Off-design performance matching & flow range
• Cyclic Operation - Startups & shutdowns
- Fatigue life
- Rotary inertia
• High Pressures and Temperatures- Materials
- Clearances, seals, and bearings
- Thrust management
- Rotor assembly
- Equipment protection in hostile environment
• Hostile Environment- Internal
- External
- Freezing concerns in expander
Some Turbomachinery Design &
Development Challenges for TMCES
These challenges are shared by OEMs across various turbomachinery applications sectors!
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*Copied from Wygant et al., Asia Turbomachinery & Pump Symposium 2016
Zones of Applicability for Typical
Industrial Compressor Types*
Typical Large-Scale
CAES/LAES
Possible Use for
Distributed Power Storage
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• Typical off-the-shelf turbine options for CAES or high-pressure applications:
- Two modules on single spool: HPT & LPT
• HPT modified from axial steam turbine design
• LPT from a conventional power generation gas turbine engine
• Incremental technology upgrade
- Integrally Geared Multi-stage Radial Inflow Expander
Highview Power StorageElliott Steam Turbine
Turbine/Expander Options
Multi-stage
Radial Inflow
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Turbomachinery Design
Practice in Support of Energy
Storage System Development
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Design Synthesis:
Configuration & Architecture
Design Intent & Performance Potential
Development Risks
Life Cycle Costs
Design Development:
Optimization – “Commercial Optimum”
Functional Verification
Risk Mitigation Tactics
Prototype Manufacturing
Technology Portfolio Business Intelligence
Soft C
om
puting:
Dis
covery
Specifications
Hard
Com
puting:
Maste
ry
Turbomachinery Design Phases(from discovery to mastery of a particular solution)
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Specified Design Operating Conditions
• Pressure rise or polytropic head, 𝒉𝒑• Suction volume flow rate, 𝑸𝟎
• Gas suction speed of sound & kinematic viscosity, 𝒂𝟎, ν𝟎• Impeller mean diameter, 𝑫𝟐𝒎
• Impeller structural material specific strength, 𝝈/𝝆𝒔• Rotor shaft speed, 𝛀
A Few Dimensionless Turbomachinery Operating Conditions:
Basic Specific Speed, 𝑛𝑠 =𝜴 𝑸𝟎
𝟎.𝟓
𝒉𝒑𝟎.𝟕𝟓 Specific Diameter, 𝑑𝑠 =
𝑫𝟐𝒎 𝒉𝒑𝟎.𝟐𝟓
𝑸𝟎𝟎.𝟓
Compressibility Specific Speed, 𝑛𝑎 =𝜴 𝑸𝟎
𝟎.𝟓
𝒂𝟎𝟏.𝟓Viscocity Specific Speed, 𝑛ν =
𝜴 𝑸𝟎𝟎.𝟓
(𝛀ν𝟎 )𝟎.𝟕𝟓
Stress Specific Speed, 𝑛σ =𝜴 𝑸𝟎
𝟎.𝟓
(𝝈/𝝆𝒔)𝟎.𝟕𝟓
Similarity Considerations for Compressor
Design, Selection & Performance
Correlation
𝐆𝐞𝐧𝐞𝐫𝐚𝐥𝐢𝐳𝐞𝐝 𝐃𝐢𝐦𝐞𝐧𝐬𝐢𝐨𝐧𝐥𝐞𝐬𝐬 𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐒𝐩𝐞𝐞𝐝, 𝐧𝑖 =𝜴 𝑸𝟎
𝟎.𝟓
(𝒗𝒊 )𝟏.𝟓
𝒗𝒊 is a set of effective velocities, expressed in terms of specified operating conditions, linked to certain
forces which determine the action (kinematic & dynamic) of the machine. For example:
𝒗σ = (𝝈/𝝆𝒔)𝟎.𝟓 ; 𝒗𝒔 = (𝒉𝒑)
𝟎.𝟓
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ni = Fi (p1, p2,pj,…pm )
pj is a set of dimensionless geometric, kinematic, and dynamic design parameters
Since m > I, certain “design choices” need to be made in order to close this underdetermined system.
Stage design process can be mathematically characterized as:
Fi is a set of functional relationships between a desired set of design parameters, as
dictated by physical balancing principles:
RF (WF, G(X : pj)) = 0 - Model Representation of Fluid Dynamics Constraint
RS (WS, G(X : pj)) = 0 - Model Representation of Structural Dynamics Constraint
G(X : pj) is the domain boundary geometric shape with geometric coordinates X and
flow/structural states WF & WS
Broad Statement of the Design Problem
G(X : pj) can be parameterized in terms of the geometric subset of pj
WF & Ws are linked to kinematic and dynamic subset of pj
Dimensionless
Operating Conditions
Physical Functional
Relation
i = 1, 2, …,I ; m > I
Dimensionless Design
Parameters
Determine the set of design parameters and associated geometric shape such
that the desired set of design operating conditions is achieved…
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Geometric Shaping is the Beginning &
End of Turbomachinery Design:Digital Geometry & Morphing Between Different Body ShapesInteger Representation of Geometry as Opposed to Traditional NURBS/BREP Construct
Geometric Morphing Process
G(X,t:pj)
Sphere to Cube
Shapes
Dra
g c
oeff
icie
nt
Morphing is based on parametric part
representation and can be used as the main
process in a solution to the design problem
Three main step:
Blade Shape Genomic Mapping
Blade Shape Re-parenting
Adaptation of Technological Features
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Radial
Mixed-Flow
The Compressor Selection Chart:Cordier Diagram as Solution to a Particular Phase of the
Design Problem
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Overall Compressor Basic Specific Speed
𝑵𝒔 =𝟏
𝜼𝒑
1/2 𝒗𝒔
𝑯𝒑𝟓/𝟐
1/2
𝜴 𝑷𝒔𝒉
Expected Overall
Performance
Specified Gas &
Thermodynamic
Cycle Conditions
Driver Requirements
for Given Application
𝒗𝒔 – Suction Specific Volume; 𝑷𝒔𝒉 – Overall Required Shaft Power; 𝑯𝒑 – Overall Polytropic Head
𝑵𝒔
𝒏𝒔
= 𝑸𝑺
𝑸𝟎
1/2𝒉𝒑𝑯𝒑
3/4
Connecting Overall Specific Speed to Individual Stage Specific Speed:
𝑸𝟎 – Individual Stage Suction Volume Flow; h𝒑 – Individual Stage Polytropic Head
Connecting Thermodynamic Cycle with
Turbomachinery Design Selection
𝑺𝒕𝒂𝒈𝒆 𝒄𝒐𝒖𝒏𝒕, 𝒏𝒔𝒕𝒂𝒈𝒆, 𝒊𝒏𝒄
=𝒏𝒔,𝒊𝒏𝒄
𝑵𝒔
4/3
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Analogy Between Hypothetical Incompressible &
Actual Compressible Multistage Machine
𝒏𝒔𝒕𝒂𝒈𝒆, 𝒊𝒏𝒄=
𝒏𝒔,𝒊𝒏𝒄
𝑵𝒔
4/3
𝒏𝒔𝒕𝒂𝒈𝒆 = 𝒏𝒔𝒕𝒂𝒈𝒆, 𝒊𝒏𝒄𝟎𝟏(𝑸𝒔
𝑸𝟎
)𝟐/𝟑(𝒏𝒔
𝒏𝒔,𝒊𝒏𝒄
)𝟒/𝟑𝒅𝒙
Stage count for equivalent pump
with constant specific speed
𝑫𝟐𝒎 = 𝒅𝒔𝒏𝒔𝑸𝟎
𝜴
1/3
Variation of Impeller Average Diameter
Compressor
Stage Count
Equivalent
Pump Stage
CountCompressibility
Correction
Δx = x Δn
ds from Cordier line given ns
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Well Anchored Design & Simulation Technologies Have Contributed
Towards High-Performing Centrifugal Compressors
URANS Simulation of Stage Performance
Calibration of Predictions with Test
Significant Stage Performance Evolution
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Efficient High Flow and High Pressure
Ratio Compression System: Hybrid
Architecture: Axial & Mixed-Flow
Transonic Axial Stage
Mixed-Flow Impeller
Radial Diffuser/Return
Channel
Potential use of
High Surface
Area for Cooling
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23
Blade design for efficient
transonic operation
Reducing stage count by almost 50% without sacrificing performance and operability!
Improved Design Practice Enables Higher Stage
Loadings without Penalizing Performance
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Storage
Tank
M/GC T
WR
TESWave Rotor* (WR): Pressure Exchanger
Integration of Wave Rotor in CAES –
Synergies with Industrial Steam Turbine
*Courtesy of D. Paxon, NASA Glenn
WR as “Effective” Reservoir
Pressure Topping
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• Turbomachinery performance and cost can play a major role in the practical
realization of various energy storage technologies.
• Compelling evidence and reason were given for seeking out novel turbomachinery
arrangements and achieving as high a turbomachinery efficiency as potentially
available, taking full advantage of current computational simulation tools (involving AI)
and advanced manufacturing techniques.
• Plenty of challenges remain. Multidisciplinary system-level thinking, along with careful
appropriation of existing turbomachinery engineering know-how (coupled to emerging
design methods) should light the path forward…
Back to Message
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Thanks for listening!