EDGE™ Concept Level Project Plan P08451 / P Feasibility of Energy Recovery from Thermo-Electric Module for Large Scale Systems Samuel Haas (ME) Syed Ashraf (ME) Robert Hudson (ME)

EDGE™ Concept Level Project Plan Project Name –Feasibility of Energy Recovery from Thermo-Electric Module for Large Scale Systems Project Number –P08451 / P09451 Project Family –Sustainable Technologies for the Global Marketplace Track –Sustainable Design and Product Development, Energy & Environment Start Term – confirmed / 2008-? End Term – confirmed / 2008-? Faculty Guide –Dr. Stevens (ME) confirmed Faculty Consultant –Dr. James Moon (EE) confirmed –Dr. Robert Bowman (EE) confirmed Faculty Consultant –John Wellin (ME) confirmed Primary Customer –Paul Chilcott, Dresser Rand Corporation, Title - confirmed –Allan Kidd, Dresser Rand Corporation, Director of Development

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™ Introduction to Thermoelectrics Solid state devices (no moving parts) Two modes of operation 1) Current  temperature gradient 2) Power Generation  temperature gradient to electrical energy Historically materials in TE modules are off the shelf and have been around since the 1960’s. Advancement in nano-scaled materials in the last 5 years has brought attention to power generation applications.

EDGE™ TE Module Characterization The efficiency of a thermoelectric system is based on the First Law of Thermodynamics and the Carnot Efficiency: Efficiency graph for current and future TE Modules Effect of temperature difference on TE module efficiency

EDGE™ Phase 0: Planning Mission Statement Product Description 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. Key Business Goals The primary business goals of this product are to Develop experience and expertise for future advanced thermoelectric design Identify facility systems for power generation application Reduce costs associated with powering of turbo-machinery Expose students to Dresser Rand Power Technologies Reduce environmental impact of products Primary Market The primary market for this product is Dresser Rand Corporation. Secondary Market Oil & Gas/ Energy Companies Automotive Industry Manufacturing Facilities Stakeholders Dresser-Rand Corporation RIT (Mechanical and Electrical Engineering programs gaining expertise and reputation) Customers of Dresser-Rand Service Technicians Thermoelectric Community/Academia Environmental Activists

EDGE™ Phase 0: Planning Staffing Requirements Mechanical Engineers 4 Tasks 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 2 Students 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 Engineers 0 There is no foreseeable need for ISE students. Computer Engineers 0 There is no foreseeable need for CE students. Business Majors 0 This project is for Dresser – Rand Corporation. As for now we see no need for business students.

EDGE™ Staffing NameDisciplineRole / Skills Dr. Robert StevensME Faculty Consultant, Assist with project scope and requirements as well as technical support through the lifetime of the project. ME StudentME Project Manager ME StudentME Heat Transfer / Fluids Analysis and Design ME StudentME Heat Transfer / Finite Element Analysis ME StudentME Structural Design, Drafting, Manufacturing EE StudentEE System Integration, DAQ EE StudentEE System Integration, Characterization of Voltage/Current ISE StudentISE Data Acquisition

EDGE™ Work Breakdown Structure PersonWeek 0 to 1 TaskWeek 1 to 2 TaskWeek 3 to 4 Task ME Student 1Review 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 2Review 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 3Review 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 4Review of Thermo-electrics, project specifications, drafting packages Tour DR facilities, Research TE module interfacing with heat exchanger or test stand. EE Student 1Review 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 2Review 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™ Phase 0: Planning Resource Requirements People Dr. Stevens (ME, Faculty Guide) – Assist with project scope and requirements Dr. James Moon (EE, Technical Consultant) Dr. Robert Bowman (EE, Technical Consultant) Paul Chilcott (Dresser Rand Technical Contact) – Identify needs and application at facility Allan Kidd (Dresser Rand Director of Development) Dave Hathaway – Machining, technical help Environment Workspace: Thermoelectric Lab ( ) Thermofluids Lab ( ) Senior Design Lab (09-4xx) ME Shop ( ) Test Systems: P07441 Thermo-Electric Module Test Stand P07442 Thermo-Electric / Vehicle Exhaust Test Bed Equipment Control Unit – Characterizing voltage/ current generated Desktop PC with LABVIEW – Used for data acquisition Materials Several TE Modules (some use of existing modules) Metal Tubing Data Acquisition Device

EDGE™ Phase 1: Concept Development Identify Customer Needs - Interviews Primary Customer(s) Dresser Rand Corporation – conference call conducted on October 4, 2 pm with Paul Chilcott, Dresser Rand Technical Contact. The call took place and was recorded from Dr. Stevens office. Other Stakeholder(s) RIT (Mechanical and Electrical Engineering Departments) – Conducted interview with Dr. Stevens (ME faculty guide). Learned the basics behind thermoelectrics and their applications, project needs, and direction where the project is headed. Recorded interview and compiled notes. Plan on speaking with the EE Faculty, specifically Dr. Moon and Dr. Bowman. Past Senior Design Team(s) Spoke with Emil Sandoz-Rosado (P07441 Project member). Gave insight on work with thermoelectrics and granted access to electronic project file database. Plan on speaking with Senior Design Team P P07440, Thermo-Electric Family of Projects (basic resource for thermo-electrics) P07441, Thermo-Electric Module Test Stand P07442, Thermo-Electric Demo Device/ Vehicle Exhaust Test Stand

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 Dimensions60” x 100” Maximum Continuous Speed:6,500 RPM Power:40,200 HP 30,000 KW Efficiency:39.9% T exhaust 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 Development Identify Customer Needs - Benchmarking Competitive or Cooperative Solutions Thermo-Electric heating/cooling (wine coolers, etc.) Power Generation Devices (space applications) Thermo-Electric module (testing using test stand at RIT, currently have) Internet Search (extensive compiled list of resources including benchmarking, research, developers, codes and standards) Technical Literature Search Government: DOE, NASA University: MIT, UTexas, Clarkson, MSU ASHRAE Standards ASME (Heat Exchangers) UL Testing Standards IEEE Power Generation Standards

EDGE™ Phase 1: Concept Development Identify 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 Development Identify 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 switch 2.Barriers to protect from intense heat 2.Objective 1.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 Acquisition 1.Need to be able to quantify power recovered 2.User friendly interface 4.Compatibility 1.Needs to be able to attach to existing Dresser Rand machinery 2.Bring output into standard electrical load specifications 3.Provide control station with power while in remote location

EDGE™ Affinity Diagram Phase 1: Concept Development Identify Customer Needs - Interpret

EDGE™ Phase 1: Concept Development Identify Customer Needs - Interpret Objective Tree Thermo Electric Heat Recovery Constraints Design Characteristics RobustInterchangeabilitySafetyObjectiveLocation No Negative Impact Understanding Thermo-Electric systems Data Acquisition User Friendly Interface Quantify ResultsCompatibility Standardize Electrical Load Resources Past Senior Design Teams & Test Stands Dresser RandRIT Faculty Economics Reduction of Energy Costs Tax Deductions Scope Critical Needs to Create Power Standardize Electrical Load Non-Critical Experience in TE Field Real Time Data Technology TE DevicesPower Controller Test Stands for TE

EDGE™ Phase 1: Concept Development Identify Customer Needs - Interpret Establish the Relative Importance of the Needs NeedProductNeeds toImportance 1.1TE SystemBe RobustHigh 1.2TE SystemLow MaintenanceMedium 1.3TE SystemBe Easy To ManufactureLow 1.4TE SystemSafeHigh 2.1TE SystemBe located ProperlyHigh 2.2TE SystemGenerate PowerHigh 3.1DAQQuantifiable OutputLow 3.2DAQUser Friendly InterfaceMedium 4.1TE SystemAttach to Existing MachineryHigh 4.2Power ControllerStandardize the OutputHigh

EDGE™ Phase 1: Concept Development Identify Customer Needs - Analysis Identify Potential Issues and Risks The team will most likely find the following issues during the project: Not having enough modules to test early in the design phase of the project Not being able to quantify the output of the modules early on during the project The test stands not functioning properly The test stands are not able to produce the correct situation that the prototype will function in Spending too much of the overall budget on the modules and not having enough to purchase other materials Purchasing the correct modules for the design (wrong materials can create a series problems)

EDGE™ Future Plan Where do you go from here? Determine the tasks for the project in general and then work out the finer points for each task. We then will create a timeline to help create the task lists for each person in the project. This will be done with Microsoft Project. We will have to meet with Dr. Stevens to help define the tasks that will be necessary to complete the project. We then have to update the information on the website to show our most current progress. Also we need to search for potential students with interest and knowledge in the studies of thermo-electrics and other sustainable systems.