Energy & Durability

Into a sustainable future

Group 13
Jasper, Koen, Peter, Remon, Sander,
Stefan, Willem, Wouter
1
Outline
1
Introduction
2
Thermodynamics
3
Life Cycle Analysis
4
Mechanics of rotating parts
5
Conclusion
2
"Our dependence on fossil fuels amounts to global pyromania, and the
only fire extinguisher we have at our disposal is renewable energy."
Hermann Scheer
3
The Problem
Water
Electricity
Environment
4
Approach
Thorough analysis of the exact
problem
Analysis of possible solutions to
solve the problem
Development of three Concepts
Optimizing the final concept
5
Sevilla
Losses
Inlet pressure/temperature
Condenser
6
Thermodynamics
As s umpt i ons
Adiabatic process (except for HEX and CS)

Heat transfer possible with T > 40 degrees

Isentropic efficiency 85%

Salt efficiency 95%
7
Concepts
Conc ept one Ranki ne
Up scaled and improved PS10
+ High efficiency - High Temperatures
+ Proven concept - Corrosion
Concept t wo - Or gani c
+ No MS needed - ideal for waste
heat
+ two phase turbine
not needed
+ fluid easily superheated
Conc ept t hr ee - St i r l i ng
+ Very high thermal - Complex
efficiency - 3000 needed
- Difficult to scale
- High temperatures
MED vs SWRO
When using SWRO (compared to MED)
+ Efficiency + 0,7% - Utilization factor -37,5%
8
Chosen Concept
The Rankine Cycle
Optimization
Thermal Efficiency 29.2%
Utilization Factor 73.7%
Power Output 98.5 MW
Labor Input 1.2 MW
Heat Input Receiver 338 MW
9
10
11
T-s Diagram
Loss 2 3
12
h-s Diagram
13
Goal Definition
Continuous production
Producing electricity and fresh
water
14
Goal Definition
Boundaries
Windmills are excluded
Transport limited to two phases
15
Goal Definition
Geographical Validity
Sun intensity
Space
Reachability
Civilization
Sea water
16
Goal Definition
Temporal Validity
Building materials
Usage
Priorities
Innovations
Legislation
Population
17
Midpoint Effects
Human Toxicity
Chemicals

Terrestrial Ecotoxicity
Chemicals

Metal Depletion
Components

Marine Ecotoxicty
Brine

Natural Land Transformation
Extraction of raw materials



Fossil Fuel Depletion
Fuel usage

Terrestrial Edification
fuel

Photochemical Oxidant
Formation
Particles react with sun
Particulate Matter Formation
incineration

Climate Change
incineration


18
Functional Unit
Producing 98,5 MW of electricity and 41 tons fresh
water each day throughout one year
Producing 3.5 petajoules of electricity and 15000 tons of water
each year
25000 households supplied with electricity and fresh water each
year
ALTERNATIVES
19
Inventory Analysis
Current
20
Life Cycle
HFO modeled as electricity
2% extra material to
compensate maintenance
21
From To Distance (km)
Ship VS Aruba 3500
Lorry Harbor Building site 5
HFO Transport by pipeline
System Subassembly Sub-
Subassembly
Material Mass total
(ton)
Mass per FU
(ton)
Disposal
Steam cycles Boiler 7x - Carbon Steel 1670 47.7 100% Waste Scenario ( VS )
Pumps 7x Pump blades Stainless steel 14 0.4 90% Reuse
10 % Waste Scenario (VS)
- Casing Cast Iron 56 1.6 90 % Reuse
10% Waste Scenario (VS)
Turbines 5x Blades CrMoV 67.5 1.93 90% Reuse
10 % Waste Scenario (VS)
- Turbine CrMoNi Steel 350 10 90 % Reuse
10 % Waste Scenario (VS)
- Housing Cast Iron 90 2.57 90 % Reuse
10% Waste Scenario (VS)
- Foundation Concrete 207.5 5.93 50 % Landfill
50 % Waste Scenario (VS)
Condensor - Stainless Steel 30 0.86 100 % Waste Scenario (VS)
Cooling Tower - Stainless Steel 5 0.14 100 % Waste Scenario (VS)
Piston Engines - Engine block Cast Iron 405 11.57 90 % Reuse
10 % Waste Scenario (VS)
- Coil Copper 148 4.23 90 % Reuse
10 % Waste Scenario (VS)
- Others Stainless Steel 184 5.26 90 % Reuse
10 % Waste Scenario (VS)
Generator in
total
- Stator Steel 204.7 5.85 90 % Reuse
10 % Waste Scenario (VS)
- Rotor Copper 46.3 1.32 90 % Reuse
10 % Waste Scenario (VS)
WHRB - - Stainless Steel 30 0.86 100 % Waste Scenario (VS)
Water
Production
MSF Housing Stainless Steel 70 2 100 % Waste Scenario (VS)
- Tubes Titanium 30 0.86 100 % Waste Scenario (VS)
- Tubes Aluminum-brass 120 3.43 100 % Waste Scenario (VS)
SWRO Casing Stainless Steel 10 0.29 100 % Waste Scenario (VS)
- Membrane Polyamide 79.6 2.27 100 % Waste Scenario (VS)
Pipes in total - - Stainless Steel 200 5.71 100 % Waste Scenario (VS)
Gearbox total - - Stainless Steel 3.5 0.1 90 % Reuse
10 % Waste Scenario (VS)
Foundation
Total
- - Concrete 20000 571.4 50 % Landfill
50 % Waste Scenario (VS)
Inventory Analysis
New
22
Life Cycle
From To Distance (km)
Ship VS Aruba 3500
Lorry Harbor Building site 5
2% extra material to
compensate maintenance
23
Cycle Sub-
Assembly
Sub-Sub
assembly
Material Mass (ton) Mass/Fu Disposal
Salt Cycle HSS Housing Fire Brick 300 8,57 100% Waste Scenario (VS)
Isolation Glass wool 20 0,57 100 % Waste Scenario (VS)
CSS Housing Fire Brick 300 8,57 100 % Waste Scenario (VS)
Isolation Glass wool 20 0,57 100 % Waste Scenario (VS)
Heliostat
2800x
(combined)
Mirrors Glass (Silver) 3360 96 100 % Waste Scenario (VS)
Frame Steel 15000 424 100% Waste Scenario (VS)
Foundation Concrete 16000 456 50 % Landfill
50 % Waste Scenario (VS)
Receiver Tower Reinforced
concrete
64000 1828 50 % Landfill
50 % Waste Scenario (VS)
HEX 2x Stainless steel 60 1,71 100 % Waste Scenario (VS)
Salt KNO3/NANO3 280.000 8.000 90 % Reuse
10 % Waste Scenario ( VS )
Steam cycle Pumps 5x
(combined)
Pump blades Stainless steel 10 0,29 90 % Reuse
10 % Waste Scenario (VS)
Casing Cast iron 40 1,14 90 % Reuse
10 % Waste Scenario (VS)
Turbines 2x
(combined
Blades CrMoV steel 27 0,77 90 % Reuse
10 % Waste Scenario (VS)
Turbine CrMoNi Steel 140 4 90 % Reuse
10 % Waste Scenario (VS)
Housing Cast Iron 36 1,03 90 % Reuse
10 % Waste Scenario (VS)
Foundation Concrete 83 2,37 50 % Landfill
50 % Waste Scenario (VS)
Condensor Stainless steel 30 0,86 100 % Waste Scenario (VS)
MED Housing Stainless steel 70 2 100 % Waste Scenario (VS)
First row Titanium 30 0,86 100 % Waste Scenario (VS)
Tubes Aluminium-
brass
120 3,43 100 % Waste Scenario (VS)
Generator
(combined)
Stator Steel 204,7 5,85 90 % Reuse
10 % Waste Scenario (VS)
Rotor Copper 46,3 1,32 90 % Reuse
10 % Waste Scenario (VS)
Pipes Stainless steel 250 7,14 100 % Waste Scenario (VS)
Gearbox Stainless steel 3,5 0,1 90 % Reuse
10 % Waste Scenario (VS)
Foundation Concrete 14400 411 50 % Landfill
50 % Waste Scenario (VS)
Peak demand Piston
engines 3x
(combined)
Engine block Cast Iron 110,5 3,16 90 % Reuse
10 % Waste Scenario (VS)
Coil Copper 40,4 1,15 90 % Reuse
10 % Waste Scenario (VS)
Others Stainless steel 50,2 1,43 90 % Reuse
10 % Waste Scenario (VS)
Profiling
-4
-3
-2
-1
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Life cycle analysis current situation normalised
Assembly
Usage
Disposal
-6
-4
-2
0
2
4
6
8
10
Climate change Human toxicity Photochemical
oxidant
formation
Particulate
matter
formation
Terrestrial
acidification
Terrestrial
ecotoxicity
Marine
ecotoxicity
Natural land
transformation
Metal
depletion
Fossil depletion
kg CO2 eq kg 1,4-DB eq kg NMVOC kg PM10 eq kg SO2 eq kg 1,4-DB eq kg 1,4-DB eq m2 kg Fe eq kg oil eq
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Current situation characterized
Assembly
Usage
Disposal
Profiling
24
Study of Emissions
Assembly
Disposal of sulfide residues
Disposal of Nickel slags
Mining of Copper
Usage
Burning of heavy fuels
Mining of lignite
Off/onshore oil rig
Disposal
Incineration / landfill urban waste
Incineration of steel
+ reuse of materials
The original inhabitants of this land had a saying
Every time you take something from the earth,
you must give something back.
25
Profiling
-2
-1
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4
5
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Life cycle analysis new situation normalised
Assembly
Usage
Disposal
-6
-4
-2
0
2
4
6
8
Climate change Human toxicity Photochemical
oxidant
formation
Particulate
matter
formation
Terrestrial
acidification
Terrestrial
ecotoxicity
Marine
ecotoxicity
Natural land
transformation
Metal depletion Fossil depletion
kg CO2 eq kg 1,4-DB eq kg NMVOC kg PM10 eq kg SO2 eq kg 1,4-DB eq kg 1,4-DB eq m2 kg Fe eq kg oil eq
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LCA new situation characterized
Assembly
Usage
Disposal
26
Study of Emissions
Assembly
Mining of lignite
Dumping of sulfuric waste
Off/onshore oil rig
Disposal
incineration/landfill urban waste
incineration of steel
+ reuse of materials
The original inhabitants of this land had a saying
Every time you take something from the earth,
you must give something back.
27
Checking Assumptions
Recycling concrete even
smaller differences
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kg CO2 eq kg 1,4-DB eq kg NMVOC kg PM10 eq kg SO2 eq kg 1,4-DB eq kg 1,4-DB eq m2 kg Fe eq kg oil eq
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Different transport distances
100km
without lorry
3500km
3850km
7000km
28
Evaluation
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Life cycle analysis new and current situation normalised
New Situation
Current
Situation
29
New installation has
lower environmental
impact

Turning point:
6x usage of salt
Improvement Analysis
Usage of oil instead of salt
Disadvantage oil max. 400
o
C
Using less salt
Salt recycling
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kg CO2 eq kg 1,4-DB eq kg NMVOC kg PM10 eq kg SO2 eq kg 1,4-DB eq kg 1,4-DB eq m2 kg Fe eq
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Salt
Oil
30
Transmission
Design a coupling to connect the turbine to the
generator
8000 rpm 3600 rpm (60Hz)
8000 rpm 7200 rpm
Fixed coupling: flexible discs
Releasable coupling: SSS-coupling
Fixed coupling: Flexible disc coupling

31
Fixed Coupling
Flexible disc coupling
Metal discs
Minor axial and angular
misalignment
High power
High torque
32
Releasable Coupling
Ability to disconnect
Synchro-self-shifting
clutch
80T SSS
33
Material Selection
Input shaft generator = 133 kNm
Input shaft gearbox = 199 kNm
Roloff Matek table 1.1
C40E was used in design calculations
41Cr4 as final material
=
34
Gears
Generator: 7200 rpm Turbine: 8000 rpm
= 8000/7200=1,11
Double Helical (herringbone) gears
Silent Smooth No axial forces Cost effective
35

Gears
m = 19.2 m = 20
Dimensions turbine side: d = 400mm z = 20
Dimensions generator side: d = 460mm z = 23
Safety factor 3
Width 180 mm
Width 350 mm
Experimenting with different widths
36
Drive Shaft
Normal stress, Shear stress by torque & shear stress by shear
force

Dominant factor: shear force by torque

Final diameter = 180mm


37
Bearings
Rolling element bearings
Cylindrical bearing
Current _=180 mm lifespan 600 hours
Higher C value
New dimensions: _= 260 mm _= 570 mm
NU 2352 ECMA 1300 hours
38
Floor specifications
Mortar Floor

3-component, solvent free floor

Epoxy resin with mineral fillers

Misalignment : 0,20

Foundation: Concrete
39
Conclusion
Bearings bigger than gears
Short lifetime: 1300 hours (54 days)
Upscale gears: 1.5x
New dimensions: d= 620, z=31 & d= 700, z =35
New bearings:

= 240

= 500
Lifespan: 13200 hours (550 days)
40
Recommendation
Develop a new metal disc coupling
Research into manually releasable clutch
41
Summary
New installation with salt cycle and modified rankine
cycle
MED used for water desalination
LCA: HFO and molten salt have big impact
Designed transmission
SSS-clutch, 3 metal-disc clutch, gearbox
Increased gear size
42
Overall conclusion
Higher efficiency than PS10
Decreased environmental impact
100% renewable energy
& recommendation
Investigate waste scenario South America
Research into salt alternatives
Old Installation New Installation Sevilla (PS10)
Thermal
Efficiency
29.0% 29.2% 22.2%
Utilization
factor
64% 73.7% 22.2%
43
Thank you for your attention
44

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