10900-01320

CO2 Compression Using SupersonicShock Wave Technology

Project NT42651

March 26, 2009

Shawn LawlorRamgen Power Systems

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Forward Looking Statement

Some of the information contained in this document contains “forward-looking statements”. In many cases you can identify forward-looking statements by terminology such as “may,” “will,” “should,” “expects,” “plans,” “anticipates,” “estimates,” “predicts,” “potential,” or “continue,” or the negative of such terms and other comparable terminology. Forward-looking statements are only predictions and as such inherently include risks and uncertainties. Actual events or results may differ materially as a result of risks facing Ramgen Power Systems, LLC (“Ramgen”) or actual results differing from the assumptions underlying such statements. These forward-looking statements are made only as of the date of this presentation, and Ramgen undertakes no obligation to update or revise the forward-looking statements, whether as a result of new information, future events or otherwise. Your decision to remain and receive the information about to be presented to you shall constitute your unconditional acceptance to the foregoing.

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The Company – Brief Background

• Privately held since 1993, headquartered in Bellevue, WA• Development and test of supersonic turbo-components for process

gas and power generation applications• 1998-present, $30 M in private funds and $25.0 M in DOE, DOD

and CEC PIER support• 2008-Dresser-Rand investment of up to $49M to commercialize

supersonic compression technology• Novel technology permits high pressure ratios and efficiencies• Recent DOE Funded tests validate capability of compression stage• 26 full-time employees

− Ingersoll-Rand, CAT/Solar, P&W, Boeing, Honeywell, Rocketdyne− 3 PhD & 9 MS Degreed Engineers

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Project Overview

• Funding (DOE and Cost Share)– Total Funding – Current Contract $16,109,211 (DE-FC26-06NT42651)– DOE – $9,494,456– Ramgen – $6,614,665

• Overall Project Performance Dates– May 10, 2006 – January 9, 2011

• Project Participants– DOE– Ramgen

▪ Dresser-Rand – Integrated demonstration tests▪ Naval Post Graduate School Turbo Machinery Laboratory – static component testing▪ Consulting engineering organizations

• Overall Project Objectives (SOPO)– Incorporate lessons learned from previous Ramgen shock compression test

programs and recommendations from industry partner Dresser-Rand to define and execute improvements in development plan for large scale demonstration of novel CO2 compression technology

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World Class Test Facilities

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Technology Fundamentals/Background

F-15 Inlet Cross Section

RampressorRotor

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Rampressor 3-D Geometry & Flowfield

• Compressive flowpaths integrated onto rim of rotor at shallow helix angle

• Strakes form sidewalls for shock compression ducts & separate high pressure discharge from low pressure suction

Mrel = ~1.6M = ~0.5Mrel = ~1.6M = ~0.5

3-D Euler CFDStatic Pressure

Contours

ObliqueShocks

Rotor RimStatio

nary Case

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• Shaft power (stages 1-2)– Gas-path power = 29,072 kWmech

– Total shaft power = 29,964 kWmech

• Heat of compression– Total rejected into coolers (stages 1-2) = 50,989 kWth

– Total recoverable1 = 28,986 kWth

Ramgen 2-Stage Process – Discrete Drive

Notes:1) 60ºF Cooling Water / 9ºF Approach / 69ºF Interstage2) Recovery to 200ºF

14,3

00 k

Wm

ech

Pgas=15,200 kW

17,269 kWth

ηad=0.85

P=23.5 psiaT=69 F

P=230.7 psiaT=442.5 F

P=2,220 psiaT=462.2 F

1

2

13,872

0.85

PR=9.810

9.814P=226.2 psiaT=69 F 15

,664

kW

mec

h

33,720 kWth

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1

10

100

1,000

10,000

-100 0 100 200 300 400 500

Temperature (F)

Pres

sure

(bar

)

PT Diagram & Supercritical Phase

Suction

Cooling

LP Compression

HP Compression

Discharge

Cooling

Separate Phases Visible-Meniscus Clearly Observed

Increase in Temperature-Diminished Meniscus

Further Increase in Temperature-Gas & Liquid Densities more Similar

At Critical P & T-Distinct Gas & Liquid Phases no Longer Visible “Supercritical Fluid” with Properties of Both Liquids & Gases

• Compression process transitions from superheated to supercritical phases

• Avoids liquid (sub-cooled) phase

solid

Liquid

gas

Supercriticalfluid

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• Shaft power (stages 1-8)– Gas-path power = 27,862 kWmech

– Total shaft power = 29,636 kWmech

• Heat of compression– Total rejected into coolers (stages 1-8) = 45,614 kWth

– Total recoverable2 = 224 kWth

Advantages Over Conventional Designs3,770 kWth

6

7,52

9 kW

mec

h

5

0.70

3,553

3,523

0.65

6,263 kWth

4,689 kWth

P=218.7 psiaT=69 F

P=127.4 psiaT=160.3 F

7,28

3 kW

mec

h

4

3

0.79

3,378

3,470

0.75

4,233 kWth

3,816 kWth

P=71.1 psiaT=69 F

P=124.5 psiaT=69 F

P=223.1 psiaT=144 F

P=392.0 psiaT=169.5 F

P=387.0 psiaT=69 F

P=693.8 psiaT=172.8F

P=40.8 psiaT=69 F

Pgas=3,307 kW

3,757 kWth

ηad=0.83

P=23.5 psiaT=69 F

P=42.2 psiaT=156.1 F

7,08

5 kW

mec

h

P=73.1 psiaT=158.4 F

1

2

3,356

0.81

PR=1.793

1.793

1.793

1.792

1.793

1.793

7,73

9 kW

mec

h

8

7

4,201

0.56

0.60

3,073

5,055 kWth

0 kWth

P=688.8 psiaT=69 F

P=1,234.7 psiaT=166.8 F

P=1,234.7 psiaT=166.8 F

P=2,220.0 psiaT=285 F

1.798

1.793

Notes:1) 60ºF Cooling Water / 9ºF Approach / 69ºF Interstage2) Recovery to 200ºF

- Total shaft power = 29,964 kWmech

• Ramgen (stages 1-2)

- Total recoverable2 = 28,986 kWth

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• Combined PR, turndown and specific speed effects limit maximum achievable stage pressure ratios (PR ~1.7 – 1.9)

• Increasing suction pressure and rotor pair speed matching results in decreasing rotor sizes through system

• Decreased rotor sizes result in decreased efficiency – Reynolds number effects become dominant

Conventional Design Practices

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Ramgen CO2 Compressor

Benefits - Reduce CC(C)&S COE Penalty

• 10-stage 6000 hp– $8.0 million $1350/hp– Pr 200:1 1.70 per stage

• 8-stage 20,000 hp– $15.0 million $750/hp– $23.0 million installed $1150/hp– Pr 143:1 1.86 per stage

MAN Turbo

• Pr 10+:1 per stage; Intercooled• 1/10th the physical size• 50-60% of the installed capital cost• Same shaft input power requirements• Recover of 80% of the input Btu at 500°F

– Improve CCS efficiency– Reduce power plant de-rate

MAN Turbo CO2 Compressor

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Progress/Current Status – Rampressor 2

Drive Turbine

RotorExhaust Collector

Facility Air Supply Plenum

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Ram 2 Results• Achieved breakthrough rotor pressure ratio of ~7.9:1

• Demonstrated tip speeds up to ~2,200 ft/s and Mrel’s up to ~ 2.7

• Full flow path 3-D viscous CFD modeling successful

• Performance prediction/design tools match test– Pressure ratio– Mass flow

• Benign surge characteristics

• Data gathered for preliminary compressor maps

• Developed & demonstrated bearing designs suitable for product application

• Have not optimized all available technology “knobs” to increase efficiency

Test results fully traceable to CO2 productTest results fully traceable to CO2 product

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Working HP Stage Cross Section• Key stage features

– Suction (inflow)– Discharge (outflow)– Boundary layer control (injection)– Starting recycle– Rotor

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Demo Unit Performance StatusIGV

Product Goal

Current Status

Analysis Type

Total Pressure Recovery

97% 95% 2D & 3D CFD

2D & 3D CFD Aero Analyses Indicate Component Performance Levels Are Near Product Levels

Product Goal

Current Status

Analysis Type

Total Pressure

Ratio5.38 5.05 2D CFD

Rotor - SHOCK COMPRESSION

Product Goal

Current Status

Analysis Type

Total Pressure Recovery

92% 90% 2D & 3D CFD

Stationary Diffuser

Product Goal

Current Status

Analysis Type

Total Pressure

Ratio2.1 1.9 2D & 3D

CFD

Rotor - EXDUCER

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Future Testing/Commercialization

Static Component Tests

10 khp CO2 Demonstrator Rig

CFD Validation

IGV/Diffusers

FY 2008 FY 2009 FY 2010 FY 2011

Performance-Improving Retrofit

Improved IGV/Diffusers

Field Demonstration

DesignRisk Reduction

Test

DesignFab.

Testing at D-RFabrication/Procurement

Fab.Test

Design

Design

TestFab.

Fab.

Planning / Interface ControlDetailed Preparation

Field Demo

FY 2012

Equip / Build out / CommissionTest Facility Ramgen Rotating Test Capability

Design

Naval Post Graduate School Static Test Facility

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Ramgen Heat Recovery - Availability• HP stage has significantly more heat available due to non-ideal nature of CO2

10:1 discharge

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Ramgen Heat Recovery - AmountLow Pressure Stage High Pressure Stage

22 - 220 psia 220 - 2200 psiaCompressor Shaft Input Work 90.6 Btu/lbm 87.0 Btu/lbm

Discharge Temperature 489 °F 509 °FLower Recovery Temperature 100 °F 100 °F

Recovered Heat 92.4 Btu/lbm 178.8 Btu/lbmRecovered Heat/Compression Work 102% 205%

• Heat available in the HP hot discharge CO2 is more than double the compressor shaft work

• 153% of the combined LP + HP shaft work is available as heat in the discharge CO2

10

100

1,000

10,000

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340Enthalpy, Btu/lb

Pre

ssur

e, P

si

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• Shaft power (stages 1-6)– Gas-path power = 23,090 kWmech

– Total shaft power = 23,441 kWmech

• Heat of compression– Total rejected into coolers (stages 1-6) = 44,648 kWth

– Total recoverable2 = 0 kWth

6-Stage Process (DOE Baseline)5,098 kWth

6

5,41

3 kW

mec

h

5

0.84

3,812

1,520

0.84

12,103 kWth

10,359 kWth

P=545.0 psiaT=69 F

P=253.0 psiaT=174.2 F

8,63

1 kW

mec

h

4

3

0.84

4,407

4,095

0.84

6,288 kWth

5,423 kWth

P=113 psiaT=69 F

P=248.0 psiaT=69 F

P=550.0 psiaT=191 F

P=1205.0 psiaT=197.2 F

P=1,200 psiaT=100 F

P=2,220.0 psiaT=164.7F

P=52.0 psiaT=69 F

Pgas=4,743 kW

5,377 kWth

ηad=0.84

P=23.5 psiaT=69 F

P=53.7 psiaT=192.7 F

9,39

7 kW

mec

h

P=115.8 psiaT=189.3 F

1

2

4,513

0.84

PR=2.281

2.227

2.239

2.218

2.211

1.850

Notes:1) 6 stage concept assumed in DOE1) 60ºF Cooling Water / 9ºF Approach / 69ºF Interstage2) Recovery to 200ºF3) Constant Stage η=0.84