high temperature anode recycle blower for solid oxide fuel ...€¦ · hydrogen pipeline compressor...
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High Temperature Anode Recycle Blower for Solid Oxide Fuel Cell
Department of Energy Award No.
DE-FE0027895
Prepared for DOE
By Mohawk Innovative Technology, Inc.
P.I.: Hooshang Heshmat, PhD
18th Annual Solid Oxide Fuel Cell (SOFC) Project Review MeetingPittsburgh Airport Marriott Hotel
Pittsburgh, PAJune 12-14, 2017
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Project Team
MITI
• Hooshang Heshmat, PhD• Principal Investigator
• Jose Luis Cordova, PhD• PM/Thermal Management
• James F. Walton II• Rotordynamics
FCE
• Hossain Ghezel Ayagh, PhD• FCE Director
• Stephen Jolly• Systems Design Engineer
• Micah Casteel, PhD
• Mechanical Engineer
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DOE Program Manager: Arun Bose, NETL
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Team Background
• MITI Specializes in High-Speed, High-Temperature Oil-Free Rotating Machinery Technology• Blowers, Compressors, Turbo-alternators,
Gas-Turbine Engines, Flywheel Energy Storage, and more.
• FCE Integrated fuel cell company that designs, manufactures, installs, operates and services stationary fuel cell power plants.
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MITI’s Oil-Free Turbomachinery
4
ORC TurbogeneratorHydrogen Pipeline Compressor
Hydrogen Blower Fuel Cell CompressorAir Cycle Machine
65 kWe @ 30,000 rpm
120,000 rpm360,000 rpm
60,000 rpm 60 kWe @ 60,000 rpm
Flywheel Electromechanical Battery
120,000 rpm
Micro Machining
500,000 rpm
High Temperature Anode Recycle Blower for Solid Oxide Fuel Cell
8 kW Turbogenerator
184,000 rpm
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Fuel Cell Energy, Inc. 200 kW SOFC
• Develops Solid Oxide Fuel Cell (SOFC) for power generation and electrolysis.
• 200 kW SOFC selected as commercialization platform.
• Thermally integrated modules enable compact and lower cost system.
• Unattended Operation with Remote Monitoring• >60% Electrical Efficiency• >5000 hours of operation
• Heat recovery capability for > 80% total thermal efficiency.
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Project Objectives
• Develop Scalable Oil-Free High Temperature Anode Recycle Blower for SOFC Power Plants• Design of a scalable oil-free high
temperature SOFC recycle blower• Experimental validation• Demonstrate commercial viability
• Reduce BOP and Increase Efficiency• Recycle anode off-gas• Reduce external water supply
used for fuel reforming• Small footprint
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Project Structure and Timeline
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Task 2: Operating Conditions (Specs)• Three sets of operating conditions specified with input from FCE:
• Start-Up Transient• Nominal Operation• Rated Operation
• These require a high turn-down ratio engine• Temperature: Up to 180oC• Flow Rate: 0.02 to 0.04 kg/sec• Pressure Increase: ~8 kPa• Gas composition: Varialble Mix, of Water, CO2 and H2 (Primarily)
• Water content requires encapsulation of magnet and stator element
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Task 2: Key Design Requirements
• Net Power Input < 1.5 kW
• Oil-Free Design• No Internal Liquid Cooling or
Lubrication
• High Efficiency
• Air Cooling
• Economical Design• Low Capital/Operating Cost
• Maintenance-Free
• Long Life
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Task 3: Blower Design Process
Oil-Free System Design Elements
• Motor/Power Electronics
• Fluid/Thermodynamic Analysis
• Aerodynamic Design
• Rotor-Dynamic Analysis
• Foil Bearing Design
• Thermal Management
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Task 3: Aerodynamic Design Summary
Chosen Design• Type = Centrifugal• Diameter = 50 mm• Operating Speed Range
• 55 krpm < N < 80 krpm• Flow
• Efficiency > 85%• Material Selection:
• Aluminum 2618-T61
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Task 3: Centrifugal Wheel Performance
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Task 3: Blower Performance
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Task 3: Anode Recycle Blower Layout
Design Features
• Hermetically sealed
• One moving part
• Radial outflow
• Encapsulated permanent magnet/stator
• Process fluid lubricated and cooled system
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Task 4: Hardware Fabrication and Integration
• Fabricate Parts and Assemble Prototype Blower
• Instrument Prototype• Temp/Pressure/Flow/Power
• Monitor Rotor Motions
• Preliminary Tests• Verify Instrumentation Operation
• Verify Motor/Drive Operation
• Confirm Rotor Smooth Operation
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Task 4: Rotating Elements
100% of rotating components fabricated
• Integrated shaft/permanent magnet assembly
• Blower impeller
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Task 4: Oil-Free Foil Bearings
Bearing Components Fabricated• Bearing Housings
• Bearing Shells/Plates
• Foil Components
Fabricated Journal Bearings
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Task 4: Motor Stator and Drive
Stator and drive/power electronics have been built.
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Task 4: Housings and Volute
All housings fabricated Volute parts fabricated—to be welded
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Task 4: Thermal Management
• Natural Convection Based Blower Cooling
• Cooling Fins Under Fabrication (Casting)
• Secondary Flow for Cooling/Lubricating Bearings
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Task 4: Instrumentation
LabView-based continuous monitoring
Transducer List:
• 8 pressure transducers
• 13 thermocouples
• 4 or 5 shaft displacement probes
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Task 5: Test and Evaluate
• Demonstrate full speed operation• Rotordynamic stability
• Thermal stability
• Measure flow/pressure/temperature with similitude gas
• Map performance
• Compare measured and design performance
• Identify possible improvements
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Task 6: Assessment and Plan Forward
Scalability for higher capacity SOFC applications assessed
• MiTi Design Capability Demonstrated for 100 kW to Multi-Megawatt Systems
• MiTi has Demonstrated Oil-Free Blowers from 1 to 200 kW
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Recently-Developed Oil-Free Blower by MiTi
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Task 6: Notional 50 kW Blower—10 MW SOFC
24
High Efficiency Centrifugal Impeller• Speed: 50 kRPM• Diameter: 125 mm
• ṁ = 3.5 kg/s
• CDP = 18 psia
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Task 6: 100x Scalability Assessment
100 kW Present Design
• Type = Centrifugal• Diameter = 50 mm• Operating Speed Range
• 55 krpm < N < 80 krpm• ṁ ~ 35 g/sec• CDP ~ 100 kPa• Power < 1.5 kW
• Efficiency > 85%• Material Selection
• Aluminum 2618
10 MW Scaled Design
• Type = Centrifugal• Diameter = 125 mm• Operating Speed Range
• N ~ 50 krpm• ṁ ~ 3.5 kg/s• CDP ~ 126 kPa• Power ~ 50 kW
• Efficiency > 87%• Material Selection
• Stainless Steel
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Task 6: Cost Considerations
• Total Program Cost: $758,855.00
• Government Share: $598,855.00
• MiTi’s Cost Share: $ 160,000.00
• Estimated Cost After Development for First 10 Units
• 1.5 kW: $10k - $15k / unit
• 50 kW: $40k - $60k / unit
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Risk Management
Main Risks Identified (R) and Planned Mitigation Strategies (M):• R: Thermal management: External natural air cooling may be insufficient at SOFC
startup operating condition• M: Introduce auxiliary forced convection• M: Closed loop water/glycol
• R: Schedule of long lead items: Motor Magnet procurement may cause prototype fabrication delay• M: Risk Managed. MAGNET ASSEMBLED INTO SHAFT
• R: Prototype Fabrication Cost: Initial prototype low-volume cost may be high.• M: Reduce motor size from 1.5 to ~1 kW• M: Minimize part count • M: Casting of as many parts as possible• M: Material substitution
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Technology Readiness Level
•Prototype will be a high TRL 5 at end of Phase I
•Will achieve TRL 6 at end of Phase II
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Progress Summary and Program Status
• Design Requirement Review: Completed
• Preliminary/Detailed Design: Completed
•Manufacturing/Assembly Currently Underway• 90% of parts fabricated
• Testing to commence late September 2017
•Program is on budget and on time
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Questions and Discussion
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Thank you for your support and attention!