Wisconsin Energy Institute Update

Major Customer Council
Bruce Beihoff
Technical Director of Industry Relations
Wisconsin Energy Institute
Mark H. Anderson
Research Professor of Engineering Physics
University of Wisconsin - Madison
• responsiblenergy
• responsibleducation
• responsiblenvironment
• responsibleconomy
• responsiblengagement
Wisconsin Energy Institute (WEI) Welcomes
MGE Major Customer Council
Bruce Beihoff, Technical Director, WEI
Professor Mark Anderson, COE/WEI
Professor Michael Corradini, Director, WEI
Professor Thomas Jahns, COE/WEI
June 9, 2015
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WEI Update
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WEI Overview
Electrical Power Systems – Bruce Beihoff
Thermal-Mechanical Power Systems – Mark Anderson
Tour of WEI Facility – Bruce Beihoff, et al.
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Forward in Energy
The WEI provides an objective forum to exchange ideas on
energy issues and to synthesize and share knowledge regarding
the challenges and needs in energy resources, technology, and
impacts. Specifically:
 Foster collaborative energy projects across sectors and disciplines
 Prepare energy leaders of today and tomorrow
 Enhance public understanding of energy issues
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Our Energy Opportunity
WEI efforts focus on making breakthroughs in key areas of the energy
sector:
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Feedstocks, liquid fuels, and transportation systems
Energy storage (thermal and electrical) and utilization
Carbon-neutral electricity sources
Policy, economics, and societal impact of energy challenges
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Great Lakes Bioenergy Research Center
IMPROVED BIO INDUSTRIAL CHEMISTRY
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Paper and Pulping and Paper-Processing
Industries
 Zip lignin and bio-based GVL technologies that reduce
the cost of deconstructing biomass for conversion into
fuels and chemicals, create new product opportunities,
and potentially transform the economics of the
$5.23B pulp and paper and converted paper product
manufacturing industries
 Production of valuable, bio-based aromatic chemicals
from lignin, a low-value component that is 30 percent of
the biomass processed by the paper and pulping
industry, which also could be a competitive
advantage for Wisconsin’s $2.6B plastics products
manufacturing industry
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Far-Reaching Education Efforts
 University educational programs
 Resources for educators
 Foster relationships with key policy stakeholder and
and advocacy groups
 Educational materials
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Sharing Expertise to Engage
 Public education events
 Campus collaboration
 Energy-related meetings and events
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Transferring Advances to Private Sector
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Evaluate inventions
Derisking and economics
Patent and commercialize
Sponsored research to match technology to platform
Engaging Industry as an External Partner
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WEI FRAMEWORK
MSREC
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WBI/WEI/GLBRC Impact on Wisconsin
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WEI Building
Home of Great Lakes
Bioenergy Research
Center (GLBRC)
and
Carbon-Neutral and Clean
Energy Systems Research
 107,000 gross square feet
 $57M paid by State  LEED Gold
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WEI: Integrated Energy Systems
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ELECTRICAL POWER
SYSTEMS
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Power Systems
Power Systems Engineering Research Center
• Eight Internationally
Recognized Faculty
• 65 Current Graduate Students
• 450 M.S. and Ph.D
• 90 Corporate Sponsors
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Wisconsin Electric Machines and
Power Electronic Consortium
130 Sponsored Projects
4 Labs
Power Systems Dynamics
Electric Machines
Power Electronics
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Utility Power Networks and Techno-Economics
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Microgrids and Advanced Distribution Networks
 Enables greater
efficiency and
resiliency
 Helps address $100B
in business losses
due to power
disruptions
 Deployed at hospitals,
military bases,
factories, and more
 Offers new products
and supply chains for
Wisconsin’s electrical
equipment
manufacturers
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Evolution of Grid Models
Conventional Grid
Power Plant
(~1000 MW)
Future Grid
Power Plant
(~1000 MW)
Transmission
Line (~100 mi)
Transmission
Line (~100 mi)
Smart Switch
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Distribution
Substation
Seamless Separation
Smart re-synchronization
Power Routing &
Protection
Distribution
Line (~10 mi)
Distribution
Transformer
Microgrid
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Functional Combination
Distributed Sources & Loads
Smart Controls
Distributed Resources, Microgrids Will Play Important
Role in Future Utility Grid
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WEI Power Systems Lab
"Small-Scale Models of a Larger Grid"
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WEI Microgrid Test Bed
WEI Madison MicroGrid
WEI Building
 Each source and load has rating of 50 to 100 kW
 Power supplies and dynos controlled to emulate DE sources 23
Microgrids and CHP
Electricity
Fuel
Thermal
Electric
Storage
Combined
Heat & Power
thermal
Thermal
storage
Storage
• Integration of Combined
Heating and Power (CHP)
enables 70% to 85%
efficiency for some
systems
• White House Executive
Order issued in August 2012
calls for 40 GW of new CHP
in the industrial sector by
2020
• Opportunities to integrate
microgrid, CHP, and NG
biofuels
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Beyond Microgrids, Dynamic Distribution System
Best of
Centralized Grid
Best of
Personal Power Plants
Dynamic
provides
promising
approach
for
• NewDistribution
concept System
offers (DDS)
path to
take the
best of
2 extremes
reducing volatility in transmission system
2
5
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Microgrids Next Step ...
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Major Microgrid Demo, Santa Rita, California
DOE award supported successful test of CERTS
microgrid concept at multi-MW level
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Distributed Energy Capabilities/Services
Electricity Reliability
(in "9"s)
(3 ms/yr)
(30 ms/yr)
(0.3 sec/yr)
(3 sec/yr)
(30 sec/yr)
(5 min/yr)
(1 hr/yr)
(9 hr/yr)
(3-4 day/yr)
(1 mo/yr)
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9
8
7
6
5
4
3
2
1
0
Local reliability
Greater need for
sophisticated
energy services
Higher efficiency
Renewables
Smarter components
Interconnected Central
Station Generation
DER-based
Distribution
System
Smart
Distribution
Microgrids
Robust
G&T
Stand-alone
Steam Generation
1900
1950
Year
2000
*EPRI
IEEE PES May2012&Wisconsin Energy Summit Oct2012
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ELECTRICAL ENERGY
STORAGE SYSTEMS
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Johnson Controls Energy Storage System Test Lab
May 5, 2014
 3 thermal chambers up to 32 ft3
 33 test circuits (18V and 100V), including 1000A
discharge
 12 electrochemical impedance spectroscopy circuit
channels
 Sponsored projects connected to cutting edge
industry goals
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Battery Systems Spanning all Applications
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Integrated Battery Management
Future battery packs will benefit from battery management systems including
equalization that is integrated inside batteries
New very high-frequency power converters shrink size of power electronics
A pathway to "smart" batteries with improved cost, reliability, and
ruggedness. < $200/KW at > 20k cycles
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THERMAL MECHANICAL
POWER SYSTEMS
Research Professor Mark Anderson
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High-Temperature Energy Generation and Waste Heat Recovery
Study advanced
energy sources to
increase efficiency
and power output
Reduce waste heat and make
Use or store energy to Study and develop new
make use in different power conversion cycles use of any possible waste heat
that we cannot reduce
applications
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2012 U.S. Energy Use ("Sankey Diagram")
1 Quad =33.434 gigawatt-years (GWy)
1 Quad=970,434,000,000 Cubic feet of natural gas
=1,940 gigawatt-years (GWy)
=1,235 gigawatt-years (GWy)
http://www.energyvanguard.com/knowledge/us-energy-flows-llnl-diagrams/
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High-Temperature Liquid Salts
(Flow loops for thermal hydraulics, property measurements, materials testing, chemical reactivity, system design)
Working with UCB, INL, PNNL, ORNL, SNL, and private industry
Large scale liquid salt flow
loops
Static and flow loop materials testing to 1000 oC - 1832 oF
Study of reaction of salts with water
and hydrocarbons
*Funding: DOE NEUP, Private industry
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Increasing the Temperature/Efficiency of Solar Energy
Solar trough systems
Facilities built to test joints
Collaboration with
national laboratories
and industries to
increase efficiency of
energy generation
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Use of Advanced Fluids for High-Temperature
Sensible and Latent Heat Thermal Energy Storage
Dispatchable modular thermal energy storage system
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In Situ Conversion Process Using Liquid Salts as
Heat Transfer Medium
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Liquid salt used to gradually heat shale subsurface
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Applicable to oil shale and heavy oil refining
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Technology converts "Kerogen" by gradual heating in oil shale
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Results in a high recovery of light hydrocarbon products yielding high-quality transportation
fuels
Modest size
test facilities
to answer
fundamental
questions
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Improved Safety and Increased Output From Nuclear Reactors
Water reservoir
tank
Test
Section
Heat Exchanger
HX Pump
CHF Loop
pump
Ultrasonic Flowmeter
for CHF Loop
Critical heat flux test facility
Passive safety systems for reactor
Small increase in efficiency and power in several reactors
means a lot of additional power. There has recently been
5.7 GWe up-rates to existing nuclear reactors.
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Advanced Power Cycles
There has been 100 years of research and improvement to the
Rankine cycle.
Ideal/Non-ideal Rankine cycle
20%
Rankine cycle with reheat
25%
Rankine cycle with regeneration
30%
Issue: As temp increases, pressure increases
(We have reached the practical limits of Rankine cycle)
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Not suitable for waste heat recovery
Not suitable for load following
Not suitable for high-temperature heat sources
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Supercritical Carbon Dioxide Brayton Cycle
8 MPa
(1,160 psi)
20 MPa
(2,900 psi)
45%
 Use of CO2 above its critical point
o Critical temperature is 31.1ºC (88ºF)
o Critical pressure is 7.39 MPa (1,072 psi)
 Acts as an ideal gas at high temperatures
 Acts like water at low temperatures
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Advantages of the sCO2 Power Cycle
•
Thermal efficiencies on the order of 40 to 50 percent are possible with
relatively simple (and small) turbomachinery with high-power density.
Higher cycle efficiency – lower operational cost
Lower capital costs
Improved environmental electrical production
Potential for several different fuel sources
• No phase change through the turbine, which reduces blade wearing.
Decreased Maintenance
• More compatible with dry cooling than a steam cycle.
Lower Water Usage
• Shorter start-up and ramp due to smaller size.
Improved Load Following
• Simpler system with no water chemistry.
Lower operating and maintenance costs
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Turbomachinery Size
Echogens waste heat recovery
sCO2 system
50 kW (67 HP)
compressor
Wright et al., “Operation and Analysis of a Supercritical CO2 Brayton
Cycle,” Sandia Report, SAND2010-0171, pp. 1-101 (2010)
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S-CO2 Power Cycle Allows for High Temperature Heat and
Waste Heat Recovery, Carbon Capture (Significant Market Potential)
Potential for Natural Gas/Coal
With CO2 Capture Oxy-Fuel Combustion Cycle
Advanced High-Temperature
CSP Energy Generation,
Electrical Power Generation From
Thermal Storage
750C
Advanced High-Temperature
Nuclear Energy Generation
Energy Generation From Waste Heat
NG-Compression and Industrial Processes
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Current Area of Research Related to sCO2 Cycle
 Cycle analysis
o Optimization and configuration
 Turbine design – Fluid dynamics
o Need to scale up system
(100 kW level
100 MW)
 Heat exchangers – Heat transfer
o Heavily recuperated currently
expensive 50% of the cycle
 Safety system, flow-through
valves, seal leakage
 Materials corrosion issues
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Cycle Analysis and Optimization
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Small Scale Test Facilities
sCO2 heat exchanger testing
Valve, seal, high-speed flow test facility
600 ºC /1112 ºF – 3600PSI In 625 sCO2 Loop – 160 GPM
5 separate
sCO2 materials corrosion autoclaves
(800ºC/1472 ºF, 4000 psi)
Heat transfer test facility
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Compact Heat Exchangers for sCO2
S-CO2 compact HX facility
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sCO2 Turbo-Machinery
(Compressor Turbine Seal Issues, Depressurization Rate Study for Reactor Safety Systems)
S-CO2 Radial Turbo compressor design
Axial turbine designs for larger power systems
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sCO2 Materials Research
(Working with several vendors and EPRI to look at advanced alloys.)
sCO2 static autoclave testing
Flow
Applied stress
Component testing
sCO2 flow testing (corrosion/erosion)
Low-speed HX test facility
Valve, seal, high-speed flow test facility
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Supercritical Transformational
Electric Power (STEP) Facility
10MWe Demonstration Test Facility
Cross-cutting support within the
Department of Energy
EERE, FE, NE, and Geothermal
•
Supercritical CO2: Research, development, and
demonstration of sCO2 technologies with broad
potential for higher-efficiency, lower-cost power
generation, including a new STEP demonstration
project ($57M).
Possible site location at the UWMadison Charter Street plant
Collaboration with MGE
U.S. Secretary of Energy Ernest
Moniz discusses President Obama’s
2015 budget March 4, 2014
"Within the Department of Energy
(DOE), SCO2 Brayton Cycle energy
conversion could benefit research
and development efforts in the offices
of Nuclear Energy, Fossil Energy and
Energy Efficiency and Renewable
Energy."
http://energy.gov/supercritical-co2-tech-team
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Concluding the WEI Summary
 WEI research is under way to tackle energy
technology at both component and system levels
 Power electronics, controls, electric machines,
microgrid, and distribution system advances are
combining to pave the way to powerful integrated
electrical grid and energy systems
 New thermal-mechanical power systems promise
major advances in integrated energy systems
 Companies, utilities, and agencies are being
engaged as partners ... Many thanks to MGE
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Small Scale Test Facilities
sCO2 Heat exchanger testing
Valve, seal, high-speed flow test facility
600 ºC / 1112 ºF– 3600PSI In625 sCO2 Loop - 160GPM
5 separate
sCO2 materials corrosion autoclaves
(800 ºC /1472 ºF, 4000psi)
Heat Transfer test facility
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