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s1 3.00 per copy $1.50 to ASME Members THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS
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The Society shall not be responsible for statements or op nu,,, iced in papers or
rn discussion at meetings of the Society or of its Divrs e.-is :r Sr s. or printed in
its publications. Discussion is printed only if the pvw. -,,: p r ,blishod in. an ASME
^/F r Y'w MEG Journal or Proceedings Released for general publ.:,,t rim uprn ;. station Full
should be G ve, to ASME. thr fec lnnr, a U visinn and the auto ,r(sf
carbon dioxide.
1000 .2635 1.352 1841.1 .375 1.360 2221.8 1.240 1.667 5498.9
Y- 1.2
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13 500 .2505 1.377 1506.6 .364 1.375 1811.4 1.240 1.667 4458.7
GASES
He/CO2) will be less than their relative ratio of spe- walls is very much affected. At the same AP/P, helium
cific heats, due to the higher design stage enthalpy cooling will result in significantly lower metal tem-
drop of helium. peratures than air cooling. For the "in-bed" surface
of a fluidized bed combustor/heat exchanger, however,
Since the compressor is driven at the turbine
a change from helium-to-air cooling may make less than
shaft speed, the limiting tip speed criterion does
10% difference in the total surface required, but will
not exist because its blade tip diameter is substan-
not seriously affect metal temperatures.
tially smaller than those of the turbine. The limit-
ing factor in the compressor design, however, usually The relationship between the working fluid heat
lies in the blade annular flow area which is equal to transfer coefficient and the pressure drop can be de-
the blade height times the pitch circle circumference. rived as follows:
Because of large variations of gas density and volume
GD 0.8
flow, as the gas undergoes changes of its pressure and hD CU 1/3
temperature along the compressor stages, the required K e = 0.023 ( K
annular flow area or blade height will often exceed \ u e 1 (2)
the maximum limit at the compressor inlet stage or be- where
comes exceedingly small at the last stage, particular-
h = heat transfer ciefficient on the working
ly for working fluids operating at high pressure
fluid side
ratios.
D = equivalent diameter = 4 x flow Cross-
It is to be noted that the optimum operating pres- e
sectional area/wetted perimeter
sure ratios for air and He/CO 2 mixture are higher than
that for helium gas. Therefore, with a fixed design K = thermal conductivity of the working fluid
turbine inlet pressure, the air or He/CO 2 compressor
C = specific heat of the working fluid
inlet stage will operate at significantly lower pres- P
sure and will be more likely to encounter the blade p = viscosity of the working fluid
height limitation than the helium compressor inlet
G = mass flow velocity of the working fluid
stage. This may result in even lower rotative speed
than is allowed in the turbine design. The pressure drop across the tubes in the turbulent
regime is given by:
A design option such as splitting the turbine and
the compressor into high-pressure and low-pressure
0.25
units and operating them at different speeds is
4P = 0.3164 (3)
usually taken to circumvent this limitation. The com- (^D
'_ pe)G2
e^ (2pD
plexity associated with this option must be weighed
where
in a tradeoff against the reduced efficiency with
lower operating pressure ratio for lower molecular AP = frictional drop across the tubes
weight gases. However, it appears that adequate tur-
AL = length of the tubes
bomachinery can be designed for any of the common
candidate CCGT gases. p = mass density of the working fluid
Combining Eq. (2) and (3) by eliminating G leads to:
HEAT TRANSFER AND PRESSURE DROP
-0.667
0.086
e\
A number of heat exchangers, including fired gas 0
IC K }1 I
h = 0.0534
heaters, recuperators, coolers, unfired bottoming
cycle economizers and boilers, are employed in the
0.457
CCGT cycle. The cost and sizes of these heat exchan- D
e
gers are dependent upon the heat transfer coefficients (4)
PAP 0 4L Cp
of the CCGT working fluid and the allowable pressure
drops across these heat exchangers. Since the pres- Substituting the perfect gas equation p = (M/R)/(R/T)
sure drop is critical to the CCGT cycle thermal effi- in Eq. (4) gives:
ciency, it is desirable that working fluids with high
heat transfer and low flow friction characteristics -0.667
be selected.
C u )
h = 0.0543 1 p . u 0.086 , D 0.371
K e
In general, the required surface area for the un-
(
fired heat exchangers including the recuperator,
0.457
bottoming cycle heater or boiler, and the cooler is
almost directly proportional to the working fluid heat
p2 AP l
(C M
1 0.457 . C 0.543
(5)
RT P. AL / \ p / p
transfer coefficient (mainly because the controlling
thermal resistance is on the working fluid side). where
With fired heat exchangers, however, the combustion
M = molecular weight of the working fluid
gas side usually exerts the controlling influence on
the overall heat transfer coefficient. Hence, the R = universal gas constant per mole of work-
required surface area for the fired heat exchanger is ing fluid.
less strongly affected by the working fluid heat
transfer coefficient than for the unfired heat exchan- Pure Gases
ger. The effects of variation of CCGT gas side heat
For pure perfect gases containing equal numbers
transfer coefficient with the composition of the gas
of atoms, the molal specific heat (C 11 M) and the
are felt differently in various types and regions of
Prandtl number (Cjj p/K) are approximately constant.
the combustor/heat exchanger. In the radiant section
With constant values of tube diameter (D e ), operating
of a pulverized coal furnace, the heat transfer rate
pressure (P), temperature (T), and constant pres-
and wall surface required is only slightly affected
sure drop parameter per unit tube length, AP/PAL,
by variations in CCGT working fluid side heat trans-
the heat transfer coefficient of the working fluid
fer coefficient, but the temperature of the tube
4 a
fect gases using helium coefficient as the reference,
and based on constant pressure, temperature, tube
diameter and pressure drop parameter. The three lines
3X105
m E
m
2%10 5
having slopes equal to 0.543 represent families of Nm __
monatomic, diatomic, and triatomic gases. Obviously LL
0
.1
.09
.0B
.01
.00
.00 i
m
and helium are preferred. The heat transfer coeffi- z .07 .00 I Y
E
cient of helium is more than three times that of argon z .06 .00
.05 .00
and more than twice that of air, oxygen, or nitrogen at .5X10 Q
.04 o0
constant pressure drop parameter and constant tube
length. .03 .00
.02 00
I 111111 15
= 2 4 5 0 1 6 816 LU SI {U 50 60 08) 1(08
U 100% H. MOLECULAR WT, Mm, OF H./X. MIXTURES 100% X.
LL 2^
LL I ^L =ax
Mixture of Gases O I y,, ^D ` p,r GAS MI%TUBE
T
tube length of 30 feet, and an average pressure level
of 1000 psia. The gas mass flow velocity (G) through
the tube was varied so as to give a constant pressure
n min
za
loss factor, AP/P, of 3% over the 30-foot tube length. ^
U 6
5
06
.05
C p -0.667
0.127
a 4 ==== .0a h = 0.0589 1 K /
! -== INCONEL 617 (D ) (PAT q
C 3 RS188 .03 e
INCONEL 800 \
(CARBON CONTROLLED,
2 SOLUTION TREATED) \ ' 0 2
N. 0.291
.0 0.418 (8)
C M\0291
RT ) ( P ) I
fi X03 01
1400 1500 1600 1780 1800 In CCGT cycles using different working fluids, the
bulk working fluid temperature rise, AT, is usually
fixed, and the total heat input to the working fluid
Fig. 8. Rupture stresses and required tube wall
Q is also fixed by varying the mass flowrate m. In
thickness vs temperature
this case, the heat transfer coefficients for differ-
exchanger and to employ working fluids with better ent working fluids can be compared with equal heat
heat transfer characteristics such as helium and transfer surface areas AA h and hence equal average
helium/CO 2 gas mixtures. heat fluxes (q = Q/AA h ). Comparison can also be made
[from Eq. (7)] of the surface area required with each
The comparative heat transfer coefficients of
working fluid if the working fluid side heat transfer
these working fluids shown in Fig. 3 and 5 are based
coefficient h is fixed. In either case, the heat flux
on constant tube diameter and constant heat exchanger
obtained [through Eq. (7) and (8)] from the working
length (constant tube length) but with different num-
fluid side must correspond to the heat flux obtained
bers of tubes in parallel to give a constant pressure
from the combustion gas side. In addition, the as-
drop for a fixed total mass flowrate. In fired heat
signed AP/P value must also satisfy Eq. (2a).
exchanger designs, the combustion gas side heat trans-
fer coefficient is the controlling factor, and it Figure 9 shows plots of comparative heat transfer
would be more appropriate to evaluate the working values for various gas mixtures at 524 R (using
fluid side heat transfer coefficient on the basis of helium as the reference) based on constant heat input
constant average heat flux (constant total quantity and heat flux, and constant AP/P. The curves are
of heat transferred divided by constant total heat similar to those in Fig. 5, except that the straight
transfer surface area) with both tube length and num- lines joining the points for pure gases have a slope
ber of tubes varied to give a constant pressure drop. of 0.418 [from Eq. (7) and (8)] as compared to a
The derivation of the heat transfer equation based on slope of 0.543 [Eq. (5)]. The heat transfer coeffi-
this assumption is given in the following. cients for the three candidate working fluids, He,
He/CO 2 (M = 20) gas mixture and air (close to N 2 ) are
The heat exchanger is assumed to consist of a num-
ber of identical parallel circuits with equal equiva- I
lent diameter D e and equal flow path length AL. The
....................... Lin::
total free flow area, A ff , and the total wetted sur-
face area on the working fluid side (total heat trans- 0
fer surface area) AA h are related to the D e and AL as
follows:
^ C 4 ^ ^'
7t h
^'1'^ rOVi^
Substitution of Eq. (6) and the relationships p = (PM)/ .3 f
0
RT
PP = 0.1582_ r e^ .25 \4 A^ / =__= m1.75 (2a)
2.75 > > ^ 5 e ^ ^,o sn y, .n .n .n to ^e>to ,m ^a
f
MOLECULAR WEIGHT, (M.), L6/LB-MOLE
C \- 0.667 0.8
0.2 Fig. 9. Comparative heat transfer coefficients for
h = 0.023 1 K I /D 1 C (m 0.8/ (3a) various gas mixtures (based on equal pres-
/ p( / sure, temperature, equal average heat flux
e
Aff
and pressure loss ratio in the heat
exchanger)
wall temperature.
os
The operating pressure levels of the OCGT ._re
to a large extent, dictated by the capacity and design
of the turbocompressor. As discussed in the previous o.a o.w 6.1 04 oA 0.8 1 2 3 1 6 6 1 6 I
001 0.00
section on turbomachinery design, at a given shaft oofi o.i
can lead to some carburization attack but this is gen- Helium is one of the noble gases and one might
erally slow. Water vapor or hydrogen additions to the question the adequacy of its supply and price. An in-
atmosphere tend to reduce its carburizing potential vestigation of the helium supply situation with the
by reacting with carbon monoxide, and in some cases U.S. Bureau of Mines at Amarillo, Texas, was conducted.
could lead to decarburization. Helium is controlled by the U.S. government. The
present base price is $35 per 1000 scf. This price
Antill and Warbutron (Ref. 21) have characterized is only remotely related to the cost of production
the behavior of stainless steels in CO2-CO environ-
and storage, has not changed in many years, and is not
ments in the following way. For the 20/25/Nb-type
expected to escalate with inflation. Purchasers of
stainless steels in pure CO2, at temperatures up to helium now pay from about $45 to $65 per 1000 scf de-
1560 F, there is a small pickup of carbon during the pending upon the supplier. The difference from $35
initial stages of exposure, followed by a slow,
represents the cost of delivery and the cost of doing
steady decarburization up to at least 700 hours ex- business for the commercial suppliers. These differ-
posure at 1560 F. Increased initial carbon pickup
ential costs would be expected to escalate. If one
and long-term carburization are favored by large assumes that the total volumetric capacity of a 350-
additions of CO. Similarly, carburization can occur
MWe CCGT system is on the order of 60,000 actual cubic
in the long term if the protective oxide deteriorates, feet, the average pressure is 750 psia, and the aver-
and CO accumulation can occur in any porous, non- age temperature is 1000 F, then the volume of helium
protective scale that forms. This carburization is in the system is on the order of 1,000,000 scf. Re-
favored by a low Cr and/or Ni content, repeated cent information on the Oberhausen II CCGT installa-
thermal cycling, extremely long exposure times, or tion projects a yearly loss of one full helium charge.
temperatures sppreciably above 1560 F. High chromium At a cost of $50 per 1000 scf, the cost of one system
levels can apparently buy longer alloy lifetimes, as charge with helium would be $55,000. This compares
in air oxidation. with a yearly coal cost of $1 per million Btu and 65%
The detailed processing history can affect the load factor of approximately $17 million. One re-
susceptibility of stainless steels to carburization charge with helium per year would thus cost about
in CO2, and the rate and morphology of attack. Anneal- 3/10 of 1% of the cost of the coal. As the CCGT sys-
ing of AISI 316 in nitrogen instead of air, for in- tems provide about a 10% fuel savings over the stan-
stance, resulted in increased oxide scale thickness dard steam stations, this helium cost would be only
and greater depths of carbide penetration after expo- 3% of the coal savings relative to steam. If there
sure to CO2 at 1202 F for 3000 hours (Ref. 19). were 350,000 MW of helium-cooled CCGT capacity in the
United States, each requiring one yearly helium re-
Problems of variability in oxidation rates of zewal, the helium consumption would be about 1.33 x
2-1/4 Cr-1 Mo and 1 Cr-1/2 Mo steels in CO 2 at 1022 F 10-9 scf. This consumption rate is roughly equal to
have been correlated with the shape, form, and dis- the yearly consumption that existed in the United
tribution of MnS particles in the alloys (Ref. 17). States during the height of the missile and space
Minor constituents in the CO 2 , especially water vapor, program and would not constitute a serious drain upon
also exert an effect. Differences in terminal rates the supply. These facts concerning the costs and
of 0.0044 to 0.0857 mg/cm2/hr have been observed in availability of helium lead one to conclude that
exposures ranging up to 7000 hours although accelera- helium would be a viable CCGT system working fluid,
tion to the rapid corrosion rates can occur after a provided that the system's helium integrity were such
few, or 2 to 3000 hours exposure. as to avoid excessive helium losses.
It is apparent, then, that the alloy degradation
with He/CO 2 working fluid stems from essentially SAFETY
similar mechanisms as with the impure He gas. It is
related to localized accumulations of CO for the pro- The choice of working fluid influences the CCGT
tective scale-forming alloys, and to unpredictable system safety because of the possible hazardous effects
corrosion behavior for the low-alloy steels. Since of leakage, and possible explosions of pressure parts
He/CO 2 mixture would eventually become a mixture of due to metals embrittlement.
He/CO 2 /CO through reaction with the metallic com- The three leading working fluid contenders: 0.99
ponents, the ratio CO 2 /CO would have to be controlled He/0.01 02; 0.6 He/0.39 CO2/0.01 0 2 ; and air are
to maintain protective behavior. This could be accom- safe in that they are nontoxic, nonflammable, and non-
plished by maintaining a small percentage of oxygen embrittling. Hydrogen has very attractive heat trans-
(1 mole%) in the mixture to ensure a high CO 2 /CO ratio. few and fluid transport properties, but was not
seriously considered as a working fluid because it is
COST AND AVAILABILITY
so flammable, and embrittles many metals.
The cost and availability of a CCGT system working
CONCLUSIONS
fluid naturally influences its desirability for appli-
cation to real systems. Previous discussion has
1. Helium, air, and helium/carbon dioxide (0.6
brought out that helium, air, and mixtures of He/CO2
He/0.4 CO2 by mole) gas mixtures were selected as pos-
and He/Xe are strong contenders for application from
sible candidate working fluids for coal-fired, closed-
the viewpoint of heat transfer capability and mate-
cycle gas turbine power generation and cogeneration
rials compatibility.
systems. Both helium and He/CO2 gas mixture may re-
Xenon is a rare and expensive gas, with a cost/ quire the addition of small percentage (1 mole percent)
scf several thousand times that of helium and is not of oxygen to safeguard against carburization of the
a practical candidate on that account. alloy tube materials.
Air, nitrogen, and CO 2 are all available in un- 2. Air and He/CO2 working fluids having higher
limited supply and at very modest cost. It should be optimum operating pressure ratios, give slightly
understood that air will not be free in that it will higher thermal efficiencies than helium working fluid
need careful processing to remove moisture and par- at equal design pressure loss factors (AP/P).
ticulate matter.
11