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Ramgen Supersonic Shock Wave Ramgen Supersonic Shock Wave Compression Technology 2012 NETL CO 2 Capture Technology Meeting Sheraton Station Square, Pittsburgh, PA July 9, 2013 Aaron Koopman Ramen Power Systems 1 0900-01420

Transcript of Ramgen Supersonic Shock WaveRamgen Supersonic Shock …€¦ · Ramgen Supersonic Shock WaveRamgen...

Page 1: Ramgen Supersonic Shock WaveRamgen Supersonic Shock …€¦ · Ramgen Supersonic Shock WaveRamgen Supersonic Shock Wave Compression Technology 2012 NETL CO 2 Capture Technology Meeting

Ramgen Supersonic Shock WaveRamgen Supersonic Shock Wave Compression Technology

2012 NETL CO2 Capture Technology MeetingSheraton Station Square, Pittsburgh, PA

July 9, 2013

Aaron KoopmanRamen Power Systems

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Company Background

• Privately-held R&D company founded in 1992

• Focused on unique applications• Focused on unique applicationsof proven supersonic aircrafttechnology

• Primary technology innovations– Supersonic air & gas compressors– High velocity vortex combustor– Supersonic expander

–Product embodiments– High Pressure ratio, high efficiency CO2

Compressor

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Compressor– High Efficiency ISC Engine

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Project Overview

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Objectives and Funding• Overall CCS Project Objectives:

– Compressor Project: Development and demonstration of analysis tools to design high-efficiency, low-cost CO2 compression using supersonic shock wave technology to significantly reduce capital and operating costs associated with gy g y p p gcarbon capture and storage

• Overall Project Performance DatesSt t A t 1 2009– Start: August 1, 2009

– End: June 30, 2014

• FundingFunding– $ 50M Total Compressor and Engine DOE Funding– $ 29.7M Private funding including Dresser-Rand contribution

• Project Participants– Dresser-Rand: Engineering support and host to Olean CO2 test facility

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Dresser-Rand Investment in Ramgen

• Dresser-Rand invests in Ramgen’s “game-changing technology”– Support on-going CO2 compressor development– Satisfy DOE matching funds requirementSatisfy DOE matching funds requirement– Consistent with strategy to be technology leader– Extend served market into Electric Utility industry– Investment to:

▪ Fund development & demonstration▪ Obtain an option to purchase assets

• Dresser-Rand is consistently ranked among top three manufacturers in its d kserved markets

– Turbomachinery– Reciprocating compressors– Steam turbines– Steam turbines

• Leading supplier of CO2 compressors• Global sales & service presence

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Ramgen Technology FundamentalsRamgen Technology Fundamentals

Compressorp

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Shock Waves to Supersonic Inlets

M0 = 1.7 Inflow

Oblique shock causesinstantaneous compression

Schlieren Photo of Projectile with Shocks Schlieren Photo of Inlet Center-body and Cowl with Shocks

and heat from compression

Mrel = ~2M = ~0.3 - 0.5 M = ~0.5

Supersonic Rampressor

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F-15 Inletp

Rotor

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Typical Rotating Supersonic Flow PathSubsonicDiffuser

Compression Ramp • Rotor Flow Path:– Three Supersonic Compression Inlet Flow Paths

“Pre-Inlet” Flow Surface

Strake Wall

Three Supersonic Compression Inlet Flow Paths On Disk Rim

– High Efficiency, Compact Compression– Flow Path Geometry Similar For Different

Pressure RatiosStrake Wall essu e at os

• Combination of Supersonic Flight Inlet & Conventional Axial Flow Compressor Aerodynamics:Aerodynamics:

– Rotor Rim Radius Change Produces Compression

– 3 “Blades” (Strakes) Do Minimal Flow WorkA i l I fl /O fl f h h– Axial Inflow/Outflow for the rotor shown

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Capture Technology Drives Operating Conditions

Advanced Amine

Amine Wet-Scrubber$118/ton Carbon

Current Stateof the

Capture Technology

CO2 Capture Technologies

Can be retrofit to existing plants

Plant Type

Combustion Plants(New Construction)

Commercial/Near Commercial

Aqua Ammoniaw/ Byproduct Sales

$72/ton Carbon

Chilled Ammonia$140/ton Carbon

Advanced Amine$99/ton Carbon

Advanced

Advanced OxyfuelCombustion$56/ton Carbon

Oxyfuel Combustion$70/ton Carbon

Advanced Amine$153/ton Carbon

Gasification-BasedPlants

(New Construction)

Commercial/Near Commercial

Advanced Rectisol$161/ton Carbon

Hydrogen Membranes$39/ton Carbon

Advanced Selexol w/Hydrogen Co-production

$49/ton Carbon

Advanced

FutureGen w/ CarbonCapture and Storage

$0/ton Carbon (net) Potential

Clathrate Process$32/ton Carbon

Source: Internal NETL Review

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Ramgen technology works with all capture technologies and can provide heat to regenerate solvents/delivery media

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Program Targets and BenefitsRamgen CO2 Compressor TargetsMAN Turbo CO2 Compressor

• 10-stage 6000 hp– $8 0 million $1350/hp

MAN Turbo

• Pr 10+:1 per stage; intercooled$8.0 million $1350/hp

– Pr 200:1 1.70 per stage• 8-stage 20,000 hp

– $15.0 million $750/hp$23 0 illi i ll d$1150/h

• Smaller physical size• 40-50% of the installed capital cost• ~Same shaft input power requirements• Recover of ~80% of the input Btu at 500F

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– $23.0 million installed$1150/hp– Pr 143:1 1.86 per stage

• Recover of ~80% of the input Btu at 500 F– Improve CCS efficiency– Reduce power plant de-rate

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LCOE with Advanced Capture and Compression

14

16

60

70

13.58

64

Uses of Heat• Solvent generation• Boiler feed water

heating

10

12

s ($

/kW

h)

50

e

11.55 51

(¢/k

Wh)

g• Coal drying• Combustion air pre-

heat• Organic Rankine cycle

8

10

Ener

gy C

osts

30

40

$/to

nne

LCO

E

ost p

er to

nne

nne

6 07

8.56

28

g y

4

6

Life

Cyc

le E

20

OE

Co

LCO

E

Cos

t per

ton

LCO

E

er to

nne

6.07

0

2

0

10LCO C

Cos

t pe

Baseline Capture w/ Advanced Amines Advanced Capture

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CaseBaseline

(No Capture)Capture w/

ConventionalCompression

Advanced Aminesw/ Ramgen

CompressionTargets

Advanced Capturew/ Ramgen

CompressionTargetsRef: ASME GT2010-22974

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Technical and Economic Challenges• Technical challenges – Demonstrating targets

– Test Rig – new 10MW closed loop CO2 systems, components, controls, motor, gearbox, VFD

– Pressure Ratio/Efficiency – not proven until demonstrated in test

– Maintainability – mean time between replacement

– Turndown – key operational consideration efficient operation over changing inlet and outlet plant conditions

• Economic challenges – Realizing reduced LCOE– Capital Cost – lowest costs will involve the integrated design of

capture and compressioncapture and compression

– Capture heat of compression – Each plant has unique opportunities for uses of heat. The system must be integrated into h l l

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the plant cycle.

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Project Status

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Project Schedule – CO2 Compressor

• 10 MW Test Facility Complete - Fall 2011

F ll S d T t R t R C l t Wi t /S i 2012• Full Speed Test Rotor Runs Complete - Winter/Spring 2012–10 MW VFD, Motor, Gearbox, Couplings and Bearing Systems validated

• Build 1 compressor testing September 2012 and continuing• Build 1 compressor testing - September 2012 and continuing–Demonstrated 7.7:1 pressure ratio and supercritical CO2 in a single stage

• Build 1 compressor test completion - July 2013Build 1 compressor test completion July 2013

• Build 2 compressor design underway – September 2013–Oakridge National Laboratory Supercomputer utilized for CFD optimizationOakridge National Laboratory Supercomputer utilized for CFD optimization

studies–Flowpath configuration identified–Static hardware in design development

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• Build 2 test – Q1 2014

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CFD Development at Oak Ridge National Labs

Shockwave rotor development greatly accelerated by the ORNL Supercomputers

Ramgen executed 200 000 core run to analyze 800 configurations in 18 hours

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Ramgen executed 200,000 core run to analyze 800 configurations in 18 hours

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High Pressure CO2 Compressor Facility

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10MW HP CO2 Compressor Test Stand

Suction

Discharge

Compressor

Oil trench

Dresser-Rand Facility, Olean, NY 10MW Electric Variable Speed Drive0 ec c a ab e Speed e Closed loop CO2 P1 = 210 psia P2 = 2100 psia

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HP CO2 Build 1 Comparison of CFD and Test

CFD Prediction 210 psia suction

Test Data 6/27/13135 psia suction

Suction Corrected Mass Flowrate (lb/sec) 84.8 82.5

Bleed Flow-rate (factor from target) 1.0 1.8

Pressure Ratio 8.37 7.74

Discharge Temperature (factor from target) 1.0 .997g p ( g )

Test data thus far is showing very good agreement with pre-test predictions.

Additional testing and mechanical configuration changes are expected to improve matching even further.

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CFD/Test Comparison of Efficiency

Probable unstart at original design point 

2.6 pt drop in efficiency at 105% Speed

rpm

400 rpm

Un‐start Line

ncy

32,340 rpm

30,870 

29,4

34,500 rpm

MC

OS

Test Data

wpa

th Efficien

M

Flow

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79 80 81 82 83 84 85Corrected Flow (lb/sec)

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CFD/Test Comparison of Pressure Ratio

8 00

8.50

un‐start Line

7.50

8.00

e Ratio Probable 

unstart at original design point

0.75 drop in stage PR at  105% Speed

m

Test Data(PR 7.74:1)

7.00

Stage Pressure

32,340 rp

m

30,870 rp

m

point 

rpm

34,500 rp

mM

CO

S

6.50

29,400 r

6.0079 80 81 82 83 84 85

Corrected Flow (lb/sec)

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• Measured pressure ratio is 7.74 versus prediction of 8.37

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Future Testing and Commercialization

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Technology Development Roadmap

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contacts:

Aaron [email protected]

(425) 828-4919 ext 235

Pete [email protected]

(425)-736-7272 (c)( ) ( )www.ramgen.com

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