Publications

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The supercritical carbon dioxide (S-CO2) Brayton Cycle has gained significant attention in the last decade as an advanced power cycle capable of achieving high efficiency power conversion. Sandia National Laboratories, with support from the U.S. Department of Energy Office of Nuclear Energy (US DOE-NE), has been conducting research and development in order to deliver a technology that is ready for commercialization. Root cause analysis has been performed on the Recompression Loop at Sandia National Laboratories. It was found that particles throughout the loop are stainless steel, likely alloy 316 based upon the elemental composition. Deployment of a filter scheme is underway to both protect the turbomachinery and also for purposes of determining the specific cause for the particulate. Shake down tests of electric resistance (ER) as a potential in-situ monitoring scheme shows promise in high temperature systems. A modified instrument was purchased and held at 650°C for more than 1.5 months to date without issue. Quantitative measurements of this instrument will be benchmarked against witness samples in the future, but all qualitative trends to date are as to be expected. ER is a robust method for corrosion monitoring, but very slow at responding and can take several weeks under conditions to see obvious changes in behavior. Electrochemical noise was identified as an advanced technique that should be pursued for the ability to identify transients that would lead to poor material performance.

The Sandia S-CO₂ Recompression Closed Brayton Cycle (RCBC) utilizes a series of gas foil bearings in its turbine-alternator-compressors. At high shaft rotational speed these bearings allow the shaft to ride on a cushion of air. Conversely, during startup and shutdown, the shaft rides along the foil bearing surface. Low-friction coatings are used on bearing surfaces in order to facilitate rotation during these periods. An experimental program was initiated to elucidate the behavior of coated bearing foils in the harsh environments of this system. A test configuration was developed enabling long duration exposure tests, followed by a range of analyses relevant to their performance in a bearing. This report provides a detailed overview of this work. The results contained herein provide valuable information in selecting appropriate coatings for more advanced future bearing-rig tests at the newly established test facility in Sandia-NM.

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The systematic development of microstructure, solidification characteristics, and heat of solidification with composition in copper-silicon-magnesium alloys for thermal energy storage is presented. Differential scanning calorimetry was used to relate the thermal characteristics to microstructural development in the investigated alloys and clarifies the location of one of the terminal three-phase eutectics. Repeated thermal cycling highlights the thermal storage stability of the transformation through multiple melting events. In conclusion, two near-terminal eutectic alloys display high enthalpies of solidification, relatively narrow melting ranges, and stable transformation hysteresis behaviors suited to thermal energy storage.

The supercritical carbon dioxide (S-CO2) Brayton Cycle has gained significant attention in the last decade as an advanced power cycle capable of achieving high efficiency power conversion. Sandia National Laboratories, with support from the U.S. Department of Energy Office of Nuclear Energy (US DOE-NE), has been conducting research and development in order to deliver a technology that is ready for commercialization. There are a wide range of materials related challenges that must be overcome for the success of this technology. At Sandia, recent work has focused on the following main areas: (1) Investigating the potential for system cost re duction through the introduction of low cost alloys in low temperature loop sections, (2) Identifying material options for 10MW RCBC systems, (3) Understanding and resolving turbine degradation, (4) Identifying gas foil bearing behavior in CO₂, and (5) Identifying the influence of gas chemistry on alloy corrosion. Progress in each of these areas is provided in this report.

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In this study, the performance of Y₂O₃-stabilized ZrO₂ (YSZ), Y₂O₃, and Al₂O₃ plasma sprayed coatings are investigated for their ability to prevent attack of Haynes 230 by a near-eutectic Cu-Mg-Si metallic phase change material (PCM) in a closed environment at 820 °C. Areas where coatings failed were identified with optical and scanning electron microscopy, while chemical interactions were clarified through elemental mapping using electron microprobe analysis. Despite its susceptibility to reduction by Mg, the Al₂O₃ coating performed well while the YSZ and Y₂O₃ coating showed clear areas of attack. These results are attributed to the evolution of gaseous Mg at 820 °C leading to the formation of MgO and MgAl₂O₄.

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This report outlines the thermodynamics of a supercritical carbon dioxide (sCO₂) recompression closed Brayton cycle (RCBC) coupled to a Helium-cooled nuclear reactor. The baseline reactor design for the study is the AREVA High Temperature Gas-Cooled Reactor (HTGR). Using the AREVA HTGR nominal operating parameters, an initial thermodynamic study was performed using Sandia's deterministic RCBC analysis program. Utilizing the output of the RCBC thermodynamic analysis, preliminary values of reactor power and of Helium flow rate through the reactor were calculated in Sandia's HelCO₂ code. Some research regarding materials requirements was then conducted to determine aspects of corrosion related to both Helium and to sCO₂ , as well as some mechanical considerations for pressures and temperatures that will be seen by the piping and other components. This analysis resulted in a list of materials-related research items that need to be conducted in the future. A short assessment of dry heat rejection advantages of sCO₂> Brayton cycles was also included. This assessment lists some items that should be investigated in the future to better understand how sCO₂ Brayton cycles and nuclear can maximally contribute to optimizing the water efficiency of carbon free power generation

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