EDGE™ Concept Level Project Plan P08451 / P Feasibility of Energy Recovery from Thermoelectric 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™ Introduction to Thermo-Electrics Solid state devices 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™ Planning Mission Statement: The scope of this project is to develop a model for a thermoelectric heat recovery unit in the turbulent flow regime, using Nusselt correlations to derive a relationship between RIT's P08442 Auto Exhaust Test Bed and Dresser Rand's VECTRA 40 Gas Turbine. Additionally, the model will be used to design a small scaled system providing experience in TEG systems and further verification of the model. Objective: The team will build a model to relate RIT's P08441 Auto exhaust test bed and Dresser-Rand's VECTRA 40 Gas Turbine in the same flow regime. From this model, a 50 watt prototype, proof-of-concept heat recovery unit will be designed and built to help educate RIT and Dresser-Rand on sustainable energy systems and technology for remote locations. Furthermore, the team will construct a business case to show the feasibility of thermoelectric power generation and market this technology to Dresser-Rand Corporation.

EDGE™ TEG Flow from Auto Exhaust Test Bed (250° C) ΔT decreases as heat is pulled from the exhaust stream TEG Tentative TE Prototype Concept Tentative TE Prototype Concept via talks with Dr. Stevens 4 sides * 3 modules * 4+ watt/module = 50 Watts Will look at how q drops with distance

EDGE™ Cold Side Hot Side TEG TE Module Resistance Modeling Source: IEEE Transactions on Industry Applications, Vol. 43, No. 2 March/April 2007 Seebeck heat transfer through module due to current flow Joule Heating due to back current through module Conduction through the module

EDGE™ Phase 0: Planning Mission Statement Product Description The scope of this project is to develop a model for a thermoelectric heat recovery unit in the turbulent flow regime, using Nusselt number correlations to derive a relationship between RIT's P08442 Auto Exhaust Test Bed and Dresser Rand's VECTRA 40 Gas Turbine. Additionally, the model will be used to design a small scaled system providing experience in TEG systems and further verification of the model. Key Business Goals The primary business goals of this product are to Develop experience and expertise for future advanced thermoelectric design Identify Dresser-Rand products for power generation application Reduce costs associated with powering of turbo-machinery Expose students to Dresser Rand Power Technologies Reduce environmental impact of products Show feasibility of TE power generation

EDGE™ Phase 0: Planning Mission Statement Primary Market This project is aimed at satisfying the needs of Dresser Rand Corporation, in particular the VECTRA 40 Gas Turbine, used in the oil and gas/energy sector. Secondary Market Tertiary Market –Centrifugal Compressors- Oil and Gas / Energy Sector (On and Off-Shore) –Reciprocating Compressors - Automotive Industry –Power Turbine/ Expanders - Manufacturing Facilities Stakeholders –Dresser Rand Corporation (Customer) –RIT (Mechanical and Electrical Engineering programs gaining expertise and reputation) –Customers of Dresser Rand Corporation (Gain a better product) –Service Technicians –Thermoelectric Community/ Other academia and research –Environmental Activists

EDGE™ Staffing NameDisciplineRole / Skills Dr. Robert StevensME Faculty Consultant: Assist with project scope and requirements as well as technical support throughout the lifetime of the project ME Student 1ME Project Manager: Will lead the team through the lifetime of the project by maintaining schedule and assisting sub teams as necessary. Primary responsibilities will include System Level Design and development of a model to show relationship between heat transfer and flow characteristics in prototype and Dresser-Rand VECTRA Gas Turbine. This student should have strengths in heat transfer, thermal fluids and most importantly, project management. ME Student 2ME Heat Transfer / Fluids Analysis and Design: This student will focus on thermal resistance modeling and heat spreader design for the hot side of the TE module. This team member should have a strong background in heat transfer, fluids, and energy systems. Additional knowledge in CFD or ANSYS modeling would be helpful. ME Student 3ME Heat Transfer / Fluids Analysis and Design: This student is responsible for the design of systems responsible for maintaining ambient temperatures on the cold side of the TE module. This student should have a good understanding of heat transfer and thermal fluids. Additional knowledge in CFD or ANSYS would be helpful.

EDGE™ Staffing Continued NameDisciplineRole / Skills ME Student 4ME Thermal Modeler: This student is responsible for understanding behind TE modules and the thermal modeling of their resistances. This student will assist the System Level Designer in development of a model to show relationship between heat transfer and flow characteristics in prototype and Dresser-Rand VECTRA Gas Turbine. This student should have a strong background in heat transfer and thermal fluids. ME Student 5ME Structural Designer: This student should have working knowledge of mechanical design and be proficient with a CAD software package. The student should be excellent at machining and assembling components. This student will be responsible for the design of the structure portion of the prototype. This student should have a good understanding of materials and heat transfer. EE StudentEE Electrical System Designer: This student will assist in characterization of voltage current relationships for TE modules and test systems. This student will also assist in verification of the model through test setup using sensors. Understanding of LABVIEW or another data acquisition software package is necessary. IE StudentIE Feasibility Engineer: This student is responsible for the development of business case to be delivered to the customer. Engineering Economics will be drawn upon to show feasibility of TE power generation and predict where the technology will become competitive to traditional power solutions. This student must be strong in Engineering Economics.

EDGE™ Work Breakdown Structure Person Week 1 Task (Dec 3) Week 2 Task (Dec 10) Week 3 Task (Dec 17) ME Student 1 Team Lead Student will establish contact with team members and setup first meeting. contact information will be collected and distributed to each member. Team leader will provide an introduction to thermoelectrics to team and a basic overview of the mission of the project. This student is responsible for review of heat transfer with ME 2 and 3 for this weeks homework assignment. The team will meet the customer and tour DR facilities. This student will assist ME 4 in researching commercially available TE modules and give a short presentation of findings the following meeting. Student will begin working with ME 4 on the characterization of TE modules using P07441 thermoelectric [bench top] Test Stand. Student will complete characterization of modules with ME 4 and collaborate with ME 2,3,4 regarding resistance modeling of respective systems. Primary focus of this week will be the development of a Nusselt correlation to relate P07442 Automotive Exhaust Test Bed with DR VECTRA 40 in the same flow regime. This student is responsible for delivery of a correlation by the next meeting. ME Student 2 Student will view the introduction to thermoelectrics and follow up by reading P07440, P07441, P07442 project websites to become acquainted with TE technologies. The student will review heat transfer with ME 1 and 3, but focus primarily on fins and heat spreader technologies. The student is responsible for presenting findings to the group during the next meeting. The team will meet the customer and tour DR facilities. Student will become familiar with VECTRA 40 Gas Turbine and P07442 Automotive Exhaust Test Bed and present important findings to the group. The student will begin analysis of the thermal resistance of the hot side of the TE module. The student will collaborate with ME 1,3,4 regarding resistance modeling of respective systems. Student will support ME 1 with development of Nusselt Correlation when necessary. This student will research mounting of modules in a test system (see Hi-z pdf in PRP).

EDGE™ Work Breakdown Structure Person Week 1 Task (Dec 3) Week 2 Task (Dec 10) Week 3 Task (Dec 17) ME Student 3 Student will view the introduction to thermoelectrics and follow up by reading P07440, P07441, P07442 project websites to become acquainted with TE technologies. The student will review heat transfer with ME 1 and 2, but focus primarily on fins and heat exchanger analysis. The student is responsible for presenting findings to the group during the next meeting. The team will meet the customer and tour DR facilities. Student will become familiar with cold side fin / heat exhanger designs used in P07441 and P07442 and present important findings to the group. The student will begin analysis of the thermal resistance of the cold side of the TE module. The student will collaborate with ME 1,2,4 regarding resistance modeling of respective systems. Student will support ME 1 with development of Nusselt Correlation when necessary. ME Student 4 Student will view the introduction to thermoelectrics and follow up by reading P07440, P07441, P07442 project websites to become acquainted with TE technologies. The student will review heat transfer with ME 1, 2, 3 but focus primarily on thermal resistance modeling of a TE module itself (see IEEE tech paper posted in PRP). The student is responsible for presenting findings to the group during the next meeting. The team will meet the customer and tour DR facilities. Student will become familiar with commercially available TE modules and applications and provide a short presentation to the group for the next meeting. Student should look at TE module characterization from P07441 and assist ME 1 with characterization of TE modules using P07441 Thermoelectric [bench top] Test Stand. The student will begin analysis of the thermal resistance of the TE module itself. The student will collaborate with ME 1,2,4 regarding resistance modeling of respective systems. Student will support ME 1 with development of Nusselt Correlation when necessary.

EDGE™ Work Breakdown Structure Person Week 1 Task (Dec 3) Week 2 Task (Dec 10) Week 3 Task (Dec 17) ME Student 5 Student will view the introduction to thermoelectrics and follow up by reading P07440, P07441, P07442 project websites to become acquainted with TE technologies. This student will review materials, mechanics and design of machine elements this week. Student is also responsible for review of CAD package of choice. The team will meet the customer and tour DR facilities. Student will become familiar with P07441 Thermoelectric [bench top] Test Stand and suppliers of commercially available building materials. This student is also responsible for research into module mounting and interface. Findings are to be presented to the team the following meeting. Student will begin identifying [rectangular] duct and interface to be used with existing test stand. Student will help in other areas where necessary. EE Student Student will view the introduction to thermoelectrics and follow up by reading P07440, P07441, P07442 project websites to become acquainted with TE technologies. Student will attend 2 hour LABVIEW tutorial. This student will research sensors necessary for testing of prototype later in the life of the project. This student will present findings back to the group during the next meeting. The team will meet the customer and tour DR facilities. Student will help ME 1,4 with characterization of TE modules on P07441 Thermoelectric [bench top] Test Stand. Begin developing LABVIEW data acquisition/characterization program for use with test setup later in the project. Work with existing test stands to evaluate progress. ISE Student Student will view the introduction to thermoelectrics and follow up by reading P07440, P07441, P07442 project websites to become acquainted with TE technologies. Student will assist team with development and refinement of engineering specifications. Student should focus attention to feasibility study of TE devices and start researching alternative solutions. Attend 2 hour LABVIEW tutorial with EE student. The team will meet the customer and tour DR facilities. Review competitive or cooperative solutions to begin developing business case. Help team with tasks where necessary. Present work you have completed to the group the next meeting. Continue work with development of business case. Research!

EDGE™ 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 Workspace: Thermoelectric Lab ( ) Thermofluids Lab ( ) Senior Design Lab (09-4xx) ME Shop ( ) Equipment Control Unit – Characterizing voltage/ current generated Desktop PC with LABVIEW – Used for data acquisition Data Acquisition Device

EDGE™ Resource Requirements Test Systems: P07441 Thermo-Electric Module Test Stand P07442 Thermo-Electric / Vehicle Exhaust Test Bed

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™ Benchmarking: Alternative Solutions Diesel Generator/ Natural Gas Turbine Many current forms of remote energy comes from diesel generators and NG turbines. These tend to be noisy, large and cumbersome, but relatively efficient. The largest downfall is the need for a fuel source to be readily available, which might not be the case. Photovoltaics Solar energy is available almost everywhere in the world. The cells tend to be inefficient for the size, but technology is increasing very rapidly. Materials are becoming better suited for absorbing the suns energy and turning it into electricity. These also can be semi-mobile, but are normally stationary for large collectors or arrays of collectors.

EDGE™ Benchmarking: Alternative Solutions Thermo-Electric Solutions There are many different manufactures of TE modules. Two of these manufactures are Melcor and Hi-Z. The following is the product specifications for one module sold by each of these manufactures. Competitive Benchmarking Matrix Melcor: 4.2 Watt Module High Z: 14 Watt Module High Z: 2 Watt Module deg C250 deg C 12 < $1200< $1800< $1000

EDGE™ Benchmarking: Research Internet Search (extensive compiled list of resources including benchmarking, research, developers, codes and standards) als1.pdf Technical Literature Search Government: DOE, NASA University: MIT, UTexas, Clarkson, MSU ASHRAE Standards ASME (Heat Exchangers) UL Testing Standards IEEE Power Generation Standards

EDGE™ Benchmarking: Alternative Solutions Average Cost per Kilowatt Solution$/kW Diesel Generator1000 Natural Gas Turbine400 Photovoltaic5000 TE Generator8000

EDGE™ Identify Customer Needs Overall Needs Statement: Create xxxx Watts of electrical power. –To be determined based on model and overall heat transfer analysis. Have a robust design: –must withstand heat, climate variations and vibrations. Attach to current machinery. Not interfere with machine's productivity. Be low maintenance; Must last, on average, life of module. Bring output to standard electrical loads specifications. Understand how scaled system will impact desired results. Be able to be produced commercially. Determine business plan and conduct feasibility study.

EDGE™ Identify Customer Needs P08451 Needs Statement: Create 50 Watts of electrical power. Create model to derive relationship between systems Have a robust design: –must withstand high temperatures only. Attach to test stand. Operate using existing test stand characteristics. Bring output to standard electrical loads. Be within budget, but large enough to be a system (Lab Use Only). Understand how scaled system will impact desired results. Determine business plan and conduct feasibility study.

EDGE™ Identify Customer Needs Design Characteristics –Robust Withstand Temperatures up to 600 deg C Withstand Vibrations and Various Climates –Bring output into standard electrical load specifications Identify possible uses of energy –Safety to System Not going to fall off and get damaged easily –Safety to People No danger due to hot temperatures No danger due to unsecured parts Objective –Generate power Identify best opportunity for heat recovery –Not interfere with DR machinery productivity –Needs to be able to attach to existing Dresser Rand machinery –To understand scaling of thermo-electric systems –Low maintainence Life determined by modules Data Acquisition –Need to be able to quantify power recovered –User friendly interface

EDGE™ Design Characteristics 1.Robust, able to withstand temperatures up to 600 deg c 2.Quantify output : bring output into standard electrical load specifications 3.Safety to System 4.Safety to people Objective 1.Generate Power 2.Not interfere with DR Machinery productivity 3.Needs to be able to attach to existing Dresser Rand Machinery 4.To understand scaling of thermo-electric systems 5.Low maintenance Data Acquisition 1.Need to be able to quantify power recovered 2.User friendly interface Affinity Diagram

EDGE™ 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 ControllerTest Stands for TE

EDGE™ Relative Importance of the Needs Need The Product Needs toImportance DesignSystem Nusselt number correlation of system accurate to DR Machinery Very High RobustTE ModuleWithstand High TemperaturesHigh RobustTE CasingWithstand Vibrations/ClimateVery Low Power OutputTE ModuleOutput load is usableHigh Power OutputSystemQuantifiableHigh Safety TE Module/ Casing Not going to fail due to rough environ.Low CompatabilitySystemNot interfering with DR MachineryMedium CompatabilitySystemAttach to DR MachineryLow CompatabilitySystemAttach to Test StandHigh

EDGE™ List of Metrics Metric No.MetricImportance Marginal value Ideal Value 1 Power Generation 50 WattsHigh> 0 Watts50 Watts 2 Maximum Temperature 250 deg CHigh > 200 deg C > 250 deg C 3 Number of Modules 12 ModulesHigh4 Modules 12 Modules 4 Nusselt Number Correlation < 10%Medium< 50%< 10% 5 Cost of Modules < 25% of Budget High$2500$1500

EDGE™ Future Plan Where do you go from here? The next and final step of the planning is to identify students interested in this project and begin building the team. We have already identified several students with interest to our faculty guide.