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B.A.R.C-1291
>
30
O
1985
B.A.R.C- 1291
GOVERNMENT OF INDIA
ATOMIC ENERGY COMMISSION
Descriptors
REVIEWS
MEDIUM TEMPERATURE
HIGH TEMPERATURE
TWO-PHASE FLOW
RANKINE CYCLE
BRAYTON CYCLE
RESEARCH PROGRAMS
INDIA
MHD CHANNELS
SODIUM ALLOYS
POTASSIUM ALLOYS
SODIUM
LIQUID METALS
SIMULATION
MERCURY
AIR
ECONOMIC ANALYSIS
FEASIBILITY STUDIES
SOLAR ENERGY
Liquid Metal MHO (LMMHO) Generator ByatSUB ere becoming
increasingly important in apace and terrestrial applications due to
their compactness and versatility. ThiB report gives the current
status and economic viability of LMMHD generators coupled to solar
collectors, faat breeder reactors, loui grade heat aources end conven-
tional high grade heat sources. The various thermodynamic cycles in
the temperature range of 100°C - 2Q00°C have been examined. Tha
report also discusses the present understanding of various leas mecha-
nisms Inherent in LMMHD systems and the techniques for overcoming these
losses.
- i -
ANL t Argonne National Laboratory, Illinois, USA
CC t Closed Cycle
OC : Open Cycle
£ S Jill fill
Page No»
CHAPTER 1 INTRODUCTION 1
REFERENCES
- iii -
1. INTRODUCTION
The extensive JPL program lasted for more than ten years and
TABLE 1.1
Facility Dorking Medium Total Thermal Magnetic Inlet Inlet Power Remarks
Mass Flow Input Field Pressure Tempera- Output
Liquid Gas/ Rate bar ture Electri-
Uapour cal
kg/S KU kliie
In the late 1960s and early 1970s,- a large MHD program M9J
included system studies and experiments, basis flow experiments uith and
without magnetic field,- tuo-phase flow experiments^ material studies and
induction generator modelling and experiments*
Soviet Union
STATUS OF TECHNOLOGY
KHD SEPARATOR
MIXER
GEN.
PRIMARY y / \ MWOSBR
HSAT
EXCHARGSR
LW PDKP
LIQUID METAL
R5J3BNERATCR
WATER FUflF
I--
•/vwwwv-
/TDRBIlffi
/ 6AS \
/OTRBIBB\
AIR-CCCI22) REJECT
HEAT-8XCRAHGER
but differs from it in using an open rather than a closed gas cycle. The
cycle diagram is ehoun in Fig. 2.3. Here the combustion gas (from coal or
metal, moat likely copper or copperalloy,' thereby eliminating the need for
vortex type combuator and most of the slag ia drained off at the bottom.
The combustion products go from the combuator to the LMMHD mixer, uihers
they are mixed with the liquid metal; thus the liquid is heated by the
combustion gas in the mixer. The tbio-phase flow occur in the mixer-
is cycled back to mixer. The combustion product leaving the LMMHD loop,
has the remaining energy used in a conventional boiler plant,- a gas turbine
COPPER
PURIFIER
STACK
GAS
COMPRESSOR STEAK PLABT
WASTE
SHAPT WCPX SHAFT WORK OUT HEAT
IV
COOLIHG
TOWER
LMMHO ere compared with that of other systems. The near term cycle
Fir], 2.5, The mixer exit temperature is fixed at *i23 K and the condensor
temperature is varied. fllaD in Fig, 2,5, the generator exit void fraction
concentrating collectors. The moat suitable fluids for this cycle aie
sodium and helium. The calculation are done for these fluids and further
The effects of the generator exit void fraction (0,85, D.9) t the regene-
rator effectiveness (0.9, 0.95) and pump efficiency (0.8,- 0.S5) on ^ycle
efficiency for a mixer exit temperature of Oil K are shown in Fig. 2.6.
15
CAP.NOT
Nrarterm perf.
Advance" perf.
target
Advance
Development
with process I
10
heat i
500 1500 2500
PEAK CYCLE TEMPERATURE(*F>
, Reohexane
, Reohsxane
014
010 A 0.9
0.95
§ 006 Separator
u.
loss • 0.3
0 « B . eft, - .75 \
NOBSI* %f.x» * .75 y^i o
O-O2 Pump e f f , » .75
e f f . « .70 \
,jr_« , . . f
0 300 340 380
CONDENSER TEMP ( K )"
0-3
bl
g0.2
u.
ui
bl
Gen.Exit
Void Frae.
0.1
0.85
0.85
0.85
0.9
05 06 07 0-8 09
MIXER EXIT VOID FRACTION-
limited preliminary studies uere explored for the adaptation of the LMMHD
Rankine and Brayton cycles to LHFSRs and compared with conventional cycle.
systems at boiler temperature 730 K and 5GD K and at pressures 15.3 MPa
and 7.10 MPa were obtained fco be around 0 4 30 nnd 0«3'» respectively j <tj .
For the Rankine-Cycle LMMHD system for LMFBRs, ANL have done
LMFBR steam plant j^ kj (using steam at 15»3 MPa and 730 H) and a lou-
temperatura LMFBR steam plant Cusing 3ame steam [inraneters : 7.10 MPe and
for the conventional Rankine and the LMMHD Rankine cycles are shoun and
compared in Table 2,1 for turn LMFBR conditions. The low-temperature LMFBR
steam plant hna received attention because it uses existing components and
a 12*/. improvement over high temperature LMFBR steam cycle and Q 57.
TABLE 2.1
R e f . 20
fractions would yield even higher efficiencies for the LHMHD system.
The LMMHD Rankine cycle thus yields higher efficiencies than conven-
tional steam cycle for the same top steBm temperature and offers conai-
versions are attractive for LMFBRs viz, LMMHD with a gos turbine and
LHMHO uith steam bottoming plant. Doth would U S E sodium and helium ns
the working fluids in the LMMHD components. The LMMHD-gsa turbine system
(auxilliary power source were not considered) for the LMMHD-steam and
with the conventional Rankine cycle. It may be noted that higher LMMHD
The concept appearB attractive for plHnt sizes greater than 10 MWe.
0-6 Coabnstor Teap. • 2222 K
Nossle Exit pressnre * 1 at*
ALPHA MIXSB
u
z
Ul
« 0-5
UL.
U.
Ul
0-4t
10 20 30
COMBUSTOR PRESSURE (otm)
0-5
u
il
u.
Coabustor pressure (ata)
0-4
Till now,- detailed analysis have been carried out only on solar
power LMMHD system. At ANL,- Piereon and Herman I 22j have made economic
analysis of 25 Mil),- high temperature (1099-1255 K) Brayton-cycle syatem
coupled to a llquld-metal-cooled solar power tower. They have compared
LMMHD system with photovoltaic systems. Three coat comparisons uere made!
a) LMMHD versus photovoltaics for electrical power only and without
cogeneration,- b) LMMHD cogeneration versus a combined system using photo-
voltaica for the electrical power and a solar power tower for the heat,-
c) LMMHD cogeneration versus a combined system uaing photovoltaics for the
electrical power and a fossil fuel (oil) for the heat. They have assumed
the operating and maintenance coats to be same for all systems. Also
there ere no fuel costs for the a.) and (b) cases,- so only capital costa
uere used. The third comparison,' (c),- Included fuel costa and was made on
a life-cycle basis. Capital costs for (a) and (b) uere plotted in Fig. 2.9,
Clearly,- LMMHD has substantial economic benefits for both the existing
and the anticipated mature technology. The cost savings is greatest
without cogeneration,- and decreases with the degree of cogeneration because
in the limit of no Electric power,- the power tower cost ia the same for
both systems. For third comparison,- the capital costa are shown in
Table 2.2.
o
o
? 5 MW LMMHD
0-4 08
USEFUL HEAT TO PROCES APPLICATION
TABLE 2.2
market prices for magnet,' heat exchanger^ pumps end liquid metal etc. he
M
arrived the coat Df the MHO system to be * 30,000, The coat of S O I B P
components in the LMMHD 3yatem are the generator, mixer, two-phase nozzle,
like end losses, viscous and electrical short circuiting, slip Call these
rator studies have been concentrated on individual losses,- two phase flows
014
010
o
<E
u
Ul
Ui
002
TABLE 2y3
Viscous losses
Slip
generator and the cycle. In the initial tests at AIML,- the slip ratio
(gas to liquid velocity ratio) mas large but has decreased aa the electro-
temperature generator Bhous that at higher liquid flow rate,- the slip
ratio approaches unity,' as desired }_3DJ . Data from the ANL high-
Floui studies
LMMHO systems. The BGuTJ experimental p n gram haa focussed on single and
BGUN for designing generator, tD process the data for interpretation and
32
of local nan-slip flow also fits very well with ANL data 138 I .
with experience and for the recent channel (LT-^t) is higher Bt the high
void fraction Df interest for power systems a3 shown in Fig. 2.11. Al9o
were obtained with a small generator (20 kue) which had no provision
(such as vanes) to minimise end losses. Thus ye 3ee that these results
2,'t.2 Separator
plate separators were studied at JPL J39J and excellent agreement obta-
ined between the test results Bnd theoretical prediction. Novel separators
are being considered for LMMHD. JPL tested an impinging jet separator
O
\
*
30
P
\
•*• 5 \
\
ti
i «s> a *-^ /I
\
x>
S3 o O
Ol 1 """»
H « <* 2 D 7 _ 1
[197
O •
O*J 3
• 9
O CO
1 «••
B MO ^^
1
24
30
to
E
20
111
o
ec
ui
o
o.
10
JPL,' Biphase Energy Systems and ANL. Fundamental studies of liquid layers
free liquid layer can be established and maintained and the kinetic enercjy
rotary separator that IIBVB blades to recover the energy otherwise lost in
For the flat-plate separator,' JPL work has shDun 997. liquid flow
(void fraction ci 0.6) at the outlet with kinetic energy loss of less
than 0.4 in 1968 T 41J . Though the loss in kinetic energy is large,
with newer designs developed since,- 1968, it is expected that the perfor-
factors,- and were used for the conceptual design of a mixer for an LMMHD
systems. JPL studied gaa-liquid mixer and developed designs for their
component teats
lower and hence losses from the collector (radiation etc.) are minimized
much steeper temperature gradients versus exposure time to the sun. The
latter fact means that a system with liquid-metal cooled collectors can
start operating earlier in the morning and hence produce extra amount of
electrical energy.
nitrogen gas was tested in JPL I'*GJ . The moat significant enpects of
the test were smooth and stable operation and absence of unexpected elect-
built Bnd tested at BGUN using mercury and flefrigerent 113. ThiB is a
very small-scale facility with moot of the partn made of glass. However,-
it is the first complete LMMHD system having all the elements of a real
today are summarized in Table 2a<r# We see that ue are at the threshold
of building LMMHD systems,- specially Bolar coupled systems*
TABLE 2.k
1 Generator
Efficiency o.a 0.7 0.6 ANL This is with end lasses. Once
(Channel end lasses can be controlled
LT-4) one can obtain easily <^ 0*8.
Exit void
fraction 0.95 0.85 0,8 ANL Higher than 0.8 could have
been achieved but far limita-
tion of higher gas flow rate
in the facility. Also using
surfactants, upta 0.95 may be
attainable.
Mixer
Pressure 5 atm Air-*iater experiments were con-
drop ducted at ANL. The results
indicate element and contract-
ion geometry design are most
crucial and with this design
uie can achieve the goal.
Separator
Liquid void 0.5 Q.6 OPL The kinetic loss uas less than
Fraction at D.i*. The separation uas done
exit by flat plate separator
Piffuser
Efficiency 0.9 Q.fl D.8 OPL The inlet void fraction was
0.5
SCOPE OF UORK
The wide scope and versatality of LHMHD syBtemB and the major
setting up a pilot LMMHD facility is made,- takincj into view the following
considerations.
collectors,' FBRs and other low temperature systems. Solar LMMHD systems
develop design capability for lBrge power systems 5D klde-5 MWe for
The Industrial Unit (PhBse 3 program) will be taken up during the next
plan period (1990-95) and under the present plan (1985-90) only the
flow pattern under various flow conditions and fluctuations in the MHO
voltage due to non-uniform floui. Since mercury has very high density,-
MHO effects are expected to be low. The schematic diagram of tha faci-
liquid nitrogen trap for mercury vapours. The inlet pressure of the air
mixer,- accelerates the mercury and the two phase fluid passes through
the MHO generator giving rise to MHO voltage. The two phase fluid Is
Dlffuaa*
Two Phaaa
Flow
Separator ir
Liquid Nltrogan
Trap
N MHD
Channel
Marcury
r i m Matar
Mlxar
Maroury
Tank
Air Camprestor
phere through a liquid nitrogen trap. The mercury falls through the
separator due to gravity and enters the mixer. Besides measuring MHD
voltage,- currents,' air flow rate,1 mercury flow rate, the facility will
high speed camera,- the material chosen uas perspex and transparent epoxy
separator are completed. They are given in Figs. 3.2, 3.3,- 3,'* and 3,5
separators are shown in Figs. 3.6,' 3.7,- 3.8 and 3,9 respectively.
9oh-i iMHO
GOVERNMENT OF INDIA
BHABHA ATOMIC RESEARCH CENTRE
-o- - \ --e-
31 — — - » . . — — . _ . i* .
j 135
-•t
-c- - -o
' '•*• •:' i
0- <•-.. K,
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e :
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3 •iii
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ECT
a;
• ^
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dr i if
! • • ; ^
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i SiSii ! £ i
N I ,
J. 4-t—i i ' t
1 I 1 :
i
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T"li
jill! 1?!
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Ftq. 3.it Dlffuser Design Details
48
1
r _ij
« ••* (I ^
•••i\o
0
Y" • '
. <-!
..i1 .,• =
*>
,•
J
1 B
r -——**
: — i
! Ii i(
;r
(••:•.-•..) »
M ;:: • :§>
:
i i !i
\\ 1 1 I I i i
'I •
11 i ' ' • _ ; - u
/
' •>
i i I •i .
I)
•Ill'
'
'O
H
-1
a L_
! W , \i f
3
TABLE 3.1
first part of the programme,- studies will be carriad out for the flow
loui tqrade heat source,- leu temperature heat exchanger,- diffuser etc* L I U I
be added.
During initial stares,- the liquid metal pump accelerates the ljq.iio
.Introduce! rmd necessary two phase flou is obtained in the mixing ckw•'::•••.-..
ThB two phase liquid flaws thrnuqh HMD charing!,- (c:nn5iritJno of r-iri'-,-.• •'.
into tank. During next stage,- the liquid metal pump is removed and solar
metal loop. Suitable organic fluid loop with condensor and pump are
introduced in place of N,, gao. The thennodynamic cycle Df the vapour l'<
stiobin in Fig, jji.i, Trv jprious stages of thRi-nadynamic state the vnn^Mi
unrfergoe:; durir.ij thf: coi'ipl.-'tr? ryele and the rui-pt-ntive iDCafclon!) in the
jnop .:;-2 identified by numbers 1 to 4 in both the t'lnurea,- i.D» F"in« 3.10
parameters :
PHASE 1 Liquid Metal Loop
™*P H* Out •*—
I
J Two Pha-
se flow Separa-
3 MHD Channel tor
PRASE 2
S
I *- "
I
I Solar Punp Condenser
I Collecto Alterna-
I te Heat
Source Vapour
loop
Diffueer
Liquid Metal Loop
I f
Critical Point
Saturated Saturated
Liquid Curve Vapour Curve
- P Conat
ui
B 2
fct
a.
a T Const.
ENTROPY
TABLE 3.2
Length I 30 cm
Average velocity of
i 0 to 8 M/B
two phase flow
Expected current : 0 to 12 x ID 4 A
Magnetic Induction t 0 to 1 T
Electrical nnnr!iir:t. i vi ty
of the tiiio ptiusc flow : 2.<t x 10 mho/m (max.)
58
- Load resistance
• Channel configuration
following parameters :
far this,
Wr by venturimcter.
used.
tively.
59
2) Data interpretation
entrance of the channel for various vanea and for different position. The
all components are designed for the prototype 10 kWe LMMHO syatem. This
code Is also used for designing large scale LMMHD systems for FBRs.
LMMHO,- low tempnrature solar based system (near turm) antj design large
scale LMMI-IO for FBR (lonn. term). In order to achieve this,- Bn infra-
Also prnr,[>nU;d in this Chapter,- mercury air LMMHD system presently being
CHAPTER 4
SUMMARY
and proposal for setting i/p of a LMMHD facility by Advanced MHO Group .
In literature three major cycles have been proposed depending upon the
FBTR, LWR, geothermal energy etc. Rankine LMMHD (between 370 K to 950 K)
and Brayton LMMHD cycle (between 500 K to SOD K) are proposed. For high
based lnu temperature systems both for Rankine and Brayton LMMHD cycles.
I\la or Na-K appears to be one of the most versatile liquid metal for both
cells and other competing cycles. Studies conducted at ANL indicate that
detailed performance hava been conducted for open-cycle LMMHD systems but
studies indicate copper or copper alloy is the most suitable liquid metal
for solar coupled LMMHD systems both for large power generation
energy is made.
APPENDIX A.I
LMMHO generator. Most of the designers use their own schemes \ 3Oj
an ideal gas
configuration)
(3)
P - *
CO
uhere u, P, a arc the velocity, pressure and void fraction of the two
is
phase liquid, x la coordinate along flow, x stress due to the
walls. Subscripts 1 and g corresponds to liquid and gas. § is the
density, a t t are electrical conductivity of the fluid end load
67
=. B 1
i
Brsnover determined the value of p, to be l,l<t from ANL data and p and
f}^ sre related to p. as follous j
The equations are transformed into more suitable farm far computation
purpose and are expressed as Follows :
68
-1
The matching has to be done by trial and error. Once PQf- {^ and p
are specified,- one can calculate P(x) from equation (10) and void fract-
ion from equation (9). The flow velocity from equation (2) and the output
current from equation (11). The load voltage is given by V.,= IR and
APPENDIX flg
TABLE A2.1
PROPERTIES OF MERCURY
CC°> (kg/m ) 3
(J/kg K) (W/mK) (x ID"8)
20 135W.0 139.53 - -
50 - - 98.«.
60 - - 9,671 -
120 •* - 10.927 -
160 - - 11.6B1 -
220 - - 12,686 -
TABLE A2.2
TABLE A2.3
REFERENCES
6. Branover,- H.t- Borde,- I.,- El-Boher, A.,- and Leitner,- On the possible
use of MHO generator in solar energy systems,- MHD flouts and turbulence,-
Prac* of the Second Bat-Sheva International Seminar,- Beersheva,
March 28-31,- 1978.
7. Lee, Ja. H. and Hohl,- P., Solar driven liquid metal magnetohydrodyna-
mic generator,- NASA technical memorandum 61965,- May 81.
76
8, Conuiay,- A,,- Small cool MHO generators could power the industrial
and the third world,- MPS review,- Modern Power Systems,- Vol. 1,- No.4,
1981.
Authority,- 1975.
11. Branover,- H.t- Gurshon,- P., and Vakhot,- A.,- MHD turbulence and two
12. Sranoveiy H.,- Method and system for converting solar energy into
electricity,- U.S. Patent Wo. h$- 191,- 901,- March *»,• I960
13. Branover,- H., El-Boher,' Leitex,- A,, Qorde,- 1.,- and Yakhot, A.,- Use
and E.S. Piersan,- I.C.E. Conference report, Scries No. *t, P 38-42
15. Broun,- G.A. and Lee,- M.S.,- A liquid-metal MHD power generation
16. Prem,- L.L. and Parkins,- W.E.f Outlook far binary pouter plants using
liquid-metal MHDr- IEEE Spectrum,- Hay 197D f p 35-^it.
17. Roue,- I.,- Sixty-cycle test results of the cascade generator,' 9th
symp. on Engg. Aspects tif MHD p. 171,- Aug. 1966,- UTSI,- Tullahoma,-
Tennessee.
20. Piersonf E.S.,- New liquid-metal MHD concepts for Solar and Coal,-
American Pouter Conference,' Chicago,' Illinois,- April 23,' I960.
23. Mos2ynski^ 3.R.,- Reduction of elc;; t'-ical end losses in MHD genera-
tor channels by insulating vanes,- ANL-718fl, AWL,- Arganne,' Illirais,-
Sept. 1967.
7B
24, Petrick,-- M.f and Roberts,- Jo|- Analytical and experimental studies of
25. Hsu,' C.f Petrick,- M.,- and Piersori,- E,S,j- A study of factors perti-
metal MHD generator system,' Proc. of Sth Int.Canf, on MHO Elec, power
26. Gherson^ P.j- Lykoudis,- P,S, and Lynch,' R,EOf- Analytical study of
27, Branover^ H,,' and linger,' Y.,' Experimental study of MHD generators
29, LyKoudis,- P.S,,- Liquid-metal MHD generators with shunt layer in MHO
30, Fabris,' G,,- Pierson,- E.S,, Pollack, I,,- Dauzuardis, P.U. and Ellis,-
31, Dunn,- P.F.,- Pierson,' E.S., Staffon,' 3.D.,' Pollack,- I,,' and Oauzuardis,-
32, Branaver, Ho»' El-Bohr,- A.,- Hoeh,- £.,-• Unger,- Y.j- Yakhat,- A,,- and
Negev,- Beer-Sheva
33, Elkins,- III,-- R.E,,- Trovillion,- T.,- Kurzway,- V«H,,- and Lindgren,- E,R,,-
34, Tanatsugu,- |\l,,- Fuji!,- E,y,,- and Suita,- T,,- Electrical conductivity
J, Nuclear Science and Technology,- _9,- No, 12,- p 753-755, Dec, 1972,
35, Saita,' M#t- Inove,- S,,- and Fuji!,- E,V,,- Gas-liquid slip and MHD press-
36, Fabris,- B,,- Dunn,- P.F,,- Gauor,- J,f- and Pierson,- E,S.,- Local measure-
kZm Fabris,- G.,- Chow,- J.C.F.,- and Dunn,- P.R»f On formation of Homogenous
l»ft» Qranover, H.,- Yakhot,- R»,- El-Qoher,1 A,,- Solar pouered Liquid-Metal
nozzle with potassium,' Freon and water,- 5th Int.Conf, Dn MHD elec.
'>7, Branovei-,' H.,- El-QDhcr,- A.,- and Yakhot,' A.,- Testing of complete
!»Q. Petrick,' M, and Lee,- K.Y.,- Proc, of Second Int*Symp, on MHD elec.
KB, Satyamurthy,- P.,- VenkBtrBmani,- IV. and Rohatgiy U.K.,- Design and
analysis of a Liquid-Metal MHD generator,- BARC/I-B16,- Bhabha Atomic
Research Centre,- Bombay,- 196<fs
Published by Head, Library & Information Services, DARC, Bombay 400 085, India.