Samuel Haas (ME) Syed Ashraf (ME) Robert Hudson (ME)

1. Concept Level Project PlanP08451 / P09451 - Feasibility of Energy Recovery from Thermoelectric Module for Large Scale Systems Samuel Haas (ME) Syed Ashraf (ME) Robert Hudson (ME)

2. 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 • 2007-2 confirmed / 2008-? • End Term • 2007-3 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

3. 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.

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

5. 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.

6. TEG TEG TEG Flow from Auto Exhaust Test Bed (250° C) TEG TEG TEG ΔT decreases as heat is pulled from the exhaust stream 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

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

8. Phase 0: PlanningMission 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

9. Phase 0: PlanningMission 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

10. Staffing

11. Staffing Continued

12. Work Breakdown Structure

13. Work Breakdown Structure

14. Work Breakdown Structure

15. 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 (09-2240) Thermofluids Lab (09-2230) Senior Design Lab (09-4xx) ME Shop (09-2360) Equipment Control Unit – Characterizing voltage/ current generated Desktop PC with LABVIEW – Used for data acquisition Data Acquisition Device

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

17. Dresser-Rand VECTRA 40 Gas Turbine VECTRA Turbine - VECTRA power turbine assembly at the D-R Norway facility.

18. Fundamentals: Gas Turbine Picture from Encyclopedia Britannica Online Basic gas turbine cross sectional view

19. 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.

20. 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

21. Benchmarking: Research Internet Search https://edge.rit.edu/content/P07440/public/home (extensive compiled list of resources including benchmarking, research, developers, codes and standards) http://www.swri.org/3pubs/IRD2002/03-9322.htm http://www1.eere.energy.gov/industry/imf/pdfs/16947_advanced_thermoelectric_materials1.pdf http://peswiki.com/energy/Directory:Thermal_Electric Technical Literature Search Government: DOE, NASA University: MIT, UTexas, Clarkson, MSU ASHRAE Standards ASME (Heat Exchangers) UL Testing Standards IEEE Power Generation Standards

22. Benchmarking: Alternative Solutions Average Cost per Kilowatt

23. 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.

24. 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.

25. 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

26. Affinity Diagram • Data Acquisition • Need to be able to quantify power recovered • User friendly interface • Design Characteristics • Robust, able to withstand temperatures up to 600 deg c • Quantify output : bring output into standard electrical load specifications • Safety to System • Safety to people • Objective • Generate Power • 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 maintenance

27. Objective Tree

28. Relative Importance of the Needs

29. List of Metrics

30. Future PlanWhere 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.