Experimental and Numerical Performance Survey of a MW-Scale Supercritical CO2 Compressor Operating in Near-Critical Conditions

Closed power cycles based on carbon dioxide in supercritical conditions (sCO2 in the following) are experiencing a growing scientific, technical and industrial interest, due to the high energy conversion efficiency and components compactness. Despite these advantages, the use of a working fluid operating in proximity to the critical point, especially for the compressor, entails multidisciplinary challenges related to the severe non-ideality of the supercritical fluid, which includes the potential onset of phase change at the impeller intake. On the technical and industrial grounds, the phase-transition might dramatically affect the aerodynamics, the performance and the rangeability of the compressor. On the scientific ground, the modelling of two-phase flows in transonic/supersonic conditions still remains an open issue that demands a thorough experimental assessment. This work illustrates the results of a wide experimental campaign focused on the evaluation of the operative map of a MW-scale high-load sCO2 compressor operating in plant-representative conditions, i.e. in proximity to the critical point (P = 79.8 bar, T = 33°C), designed in the frame of the sCO2Flex project, EU Horizon 2020 funded program (grant agreement #764690). In the design process, the machine had been object of a thorough computational investigation, performed by using a homogeneous equilibrium model equipped with a barotropic equation of state, which revealed a significant impact of the phase change on the compressor aerodynamics and on its rangeability for flow rates higher than the design one. Such phenomena are connected to the sudden drop of the speed of sound, originated when the fluid thermodynamic condition crosses the saturation line, and they weaken as the compressor loading reduces. Experiments carried out on a first of a kind 5 MW sCO2 prototype compressor manufactured and tested by Baker Hughes in 2021 remarkably well matched the predicted compressor performance and, especially, the anticipated and sudden choking of the compressor at nominal peripheral Mach number. Results demonstrates experimentally, for the first time ever, the effects of the phase-change on the operation of a realistic sCO2 compressor, also providing significant insights on the predictive capabilities of the physical models employed for the calculation of two-phase flows in this class of machines.