EDGE™

Concept Level Project PlanP08451 / P09451 - Feasibility of Energy

Recovery from Thermo-Electric Module for Large Scale Systems

Samuel Haas (ME)

Syed Ashraf (ME)

Robert Hudson (ME)

EDGE™

Planning

Mission Statement:

The scope of this project is to design, test and characterize a scaled prototype thermoelectric heat recovery unit for use with Dresser-Rand Turbo Machinery.

Objective:

This project is aimed at using thermoelectric devices to recover wasted energy exhaust from Dresser Rand VECTRA 40 Gas Turbines. The team will create at least X watt scaled prototype, proof-of-concept heat recovery unit to help educate RIT and Dresser-Rand on sustainable energy systems and technology for remote locations.

EDGE™

TE Module Characterization∆T vs Efficiency

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

40.00%

45.00%

0 100 200 300 400 500 600

∆T (K)

Eff

icie

nc

y

ZT=.8

ZT=1

ZT=2

ZT=3

ZT=5

ZT=10

ZT vs Efficiency

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

40.00%

0 1 2 3 4 5 6 7 8 9 10 11

ZT ave

Eff

icie

nc

y ∆T=400

∆T=300

∆T=200

∆T=100

The efficiency of a thermoelectric system is based on the First Law of Thermodynamics and the Carnot Efficiency:

hot

coldavg

avg

hot

coldhot

TT

ZT

ZT

T

TT

1

11

Efficiency graph for current and future TE Modules Effect of temperature difference on TE module efficiency

EDGE™

Phase 0: PlanningStaffing Requirements

Mechanical Engineers 4Tasks will include thermoelectric system design focusing mainly on waste heat flows from turbo machinery and transfer of heat to thermoelectric units. Students will make use of their academic training in thermal-fluids, heat transfer, materials, and data acquisition in this project.

Electrical Engineers 2Students will participate in circuit design, system integration and characterization of voltage/current in the prototype unit. Familiarity of semiconductor devices, materials, microcontrollers, and LABVIEW would be a great asset to the team.

Industrial and Systems Engineers0There is no foreseeable need for ISE students.

Computer Engineers0There is no foreseeable need for CE students.

Business Majors0This project is for Dresser – Rand Corporation. As for now we see no need for business students.

EDGE™

Staffing

Name Discipline Role / Skills

Dr. Robert Stevens ME Faculty Consultant, Assist with project scope and requirements as well as technical support through the lifetime of the project.

ME Student ME Project Manager

ME Student ME Heat Transfer / Fluids Analysis and Design

ME Student ME Heat Transfer / Finite Element Analysis

ME Student ME Structural Design, Drafting, Manufacturing

EE Student EE System Integration, DAQ

EE Student EE System Integration, Characterization of Voltage/Current

ISE Student ISE Data Acquisition

EDGE™

Work Breakdown StructurePerson Week 0 to 1 Task Week 1 to 2 Task Week 3 to 4 Task

ME Student 1 Review of Thermo-electrics, project specifications, heat

transfer / fluids

Tour DR facilities, Determine module specifications, heat

exchanger / fin design.

Contact vendors concerning module pricing and ordering

options. Gain understanding with existing modules.

ME Student 2 Review of Thermo-electrics, project specifications, heat

transfer / fluids

Tour DR facilities, Research heat exchanger/ fin design. What size

will we need for acceptable performance? What materials are

needed for construction?

ME Student 3 Review of Thermo-electrics, project specifications, Finite

Element Analysis

Tour DR facilities, Research heat exchanger/ fin design. What size

will we need for acceptable performance? What materials are

needed for construction?

ME Student 4 Review of Thermo-electrics, project specifications, drafting

packages

Tour DR facilities, Research TE module interfacing with heat

exchanger or test stand.

EE Student 1 Review of Thermo-electrics, project specifications, Labview

Tour DR facilities, Review data acquisition from P08441,

determine required materials. Continue review of LABVIEW.

Begin developing LABVIEW data acquisition / characterization

program. Work with existing test stands to evaluate progress.

EE Student 2 Review of Thermo-electrics, project specifications, Labview

Tour DR facilities, Review data acquisition from P08441,

determine required materials. Continue review of LABVIEW.

Begin developing LABVIEW data acquisition / characterization

program. Work with existing test stands to evaluate progress.

EDGE™

Dresser-Rand Interview

Interviewed Primary Customer: Dresser-Rand, Paul Chillcott

– Staff Development Engineer (specializing in finite elements, both thermal and structural)

– Proposed several applications:

1) Centrifugal Compressor (~150°C Exhaust)

2) Gas Turbine (~ 516°C Exhaust, healthy flow rate)

3) Expander (Power Turbine)

*Received data packet on both compressor and turbine.

EDGE™

Dresser-Rand VECTRA 40 Gas Turbine

VECTRA 40 Performance Summary

Exhaust Dimensions 60” x 100”

Maximum Continuous Speed: 6,500 RPM

Power: 40,200 HP  30,000 KW

Efficiency: 39.9%

Texhaust 516° C

Mass Flow: 180 lbs/sec

VECTRA Turbine - VECTRA power turbine assembly at the D-R Norway facility.

EDGE™

Fundamentals: Gas Turbine

Picture from Encyclopedia Britannica Online

Basic gas turbine cross sectional view

EDGE™

Phase 1: Concept DevelopmentIdentify Customer Needs - Interpret

Needs Statement:

• Generates Power• Eliminate energy cost of running machinery• Determine feasibility of TE power generation for current and future Dresser-

Rand machinery • Robust, withstands elements (materials)• Interfaces with existing technology (no negative impact)

1) Size Limitations (does not impede exhaust flow)• Low Maintenance• Bring output to Standard Electrical Loads Specifications (define purpose)• Understand how scaled systems will impact desired results (learning)• Ease of manufacture

EDGE™

Phase 1: Concept DevelopmentIdentify Customer Needs - Interpret

Needs Specifications:1. Design Characteristics

1. Robust; Able to withstand extreme and wide range of temperature differences (75°~300°)2. Low Maintenance

1. Ease of Interchangeability of modules (upgrade to next generation modules)3. Ease of manufacture (module mount location on exhaust)4. Safe to work around

1. Needs a emergency shut off switch2. Barriers to protect from intense heat

2. Objective1. Needs to generate at least 150 watts of power 2. No negative impact to existing energy system (efficiency)3. To understand scaling of Thermo-Electric systems

3. Data Acquisition1. Need to be able to quantify power recovered2. User friendly interface

4. Compatibility1. Needs to be able to attach to existing Dresser Rand machinery2. Bring output into standard electrical load specifications3. Provide control station with power while in remote location

EDGE™

Affinity Diagram

Phase 1: Concept DevelopmentIdentify Customer Needs - Interpret

EDGE™

EDGE™

EDGE™

EDGE™