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ADVANCES IN ANODE AND ADVANCES IN ANODE AND CATHODE BLOWERS CATHODE BLOWERS
99thth Annual SECA WorkshopAnnual SECA WorkshopPittsburgh, PAPittsburgh, PA
Sponsor: Sponsor: Department of Energy Department of Energy
Presented by: Presented by: Dr. Giri Agrawal Dr. Giri Agrawal R&D Dynamics CorporationR&D Dynamics Corporation
Date:Date: August 7, 2008August 7, 2008
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OutlineOutline
1. R&D DYNAMICS OVERVIEW
2. CATHODE BLOWERS
a. Prototype Units
b. Development Programs
– Low Cost Unit
– High Temperature Recycle Blower
3. ANODE BLOWERS
– Warm Recycle Blower
– Hot Gas Recycle Blower
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Design, Develop and Production Manufacture Oil-Free, Efficient, and Affordable High-Speed Turbomachinery
OUR BUSINESSOUR BUSINESS
R&D Dynamics, Bloomfield, CT
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BackgroundBackground
Started in 1990
23,000 sq. ft. space
47 employees
50% development programs
50% production programs
Quality system approved by FAA
ISO 9001:2000 / AS9100 registered
Major facility expansion planned for 2009
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ExperienceExperience
Fuel Cell Blowers
Motor driven gas compressors
Turboalternators
Turboexpanders for air separation plants
Hydrogen turboexpander
Refrigerant centrifugal compressors
High temperature turbochargers
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Foil Air/Gas BearingsFoil Air/Gas BearingsAdvantages of Foil Air/Gas Bearings include….–Increased Reliability–No Oil/Grease Contamination–Higher Speed Capability–Smaller Size/Weight–Increased Performance–Quieter Operation–No Scheduled Maintenance–Lower Life Cycle Cost
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CATHODE BLOWERSCATHODE BLOWERS
Prototype UnitsPrototype Units
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Prototype UnitsPrototype UnitsAccomplishmentsAccomplishments
Blowers have been tested by various SECA members and
others on 5 kW to 80 kW fuel cell systems
Blowers have passed all major tests including…
– Endurance > 2000 Hrs
– Start/Stop > 10,000 Cycles
– Vibration & Shock
– Before and After Performance
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Cathode Air Blower for Automotive ApplicationCathode Air Blower for Automotive Application
60ºC Air Inlet Temperature
Integrated Motor Drive
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Fuel Blower for Stationary Fuel CellFuel Blower for Stationary Fuel Cell
160ºC Inlet GasHermetically Sealed
Stainless Steel Construction
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ATR Reformer Air Blower for ATR Reformer Air Blower for Automotive ApplicationAutomotive Application
40ºC Air Inlet Temperature
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Cathode Air Blower for Cathode Air Blower for Automotive ApplicationAutomotive Application
45ºC Air Inlet Temperature
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Cathode Air Blower for Cathode Air Blower for Automotive ApplicationAutomotive Application
60ºC Air Inlet Temperature
Liquid Cooled
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CATHODE BLOWERSCATHODE BLOWERSDevelopment ProgramDevelopment Program
A Low Cost Unit A Low Cost Unit
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A Low Cost UnitA Low Cost UnitAccomplishmentsAccomplishments
Design for 5- 10 kW SOFC completed…– Novel design
– DFMA techniques used
– New materials
Blower needs to be built and tested
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Low Cost Cathode Blower Design Blower Cut-Section View
Impeller
Upper Half Housing
Lower Half Housing
Controller
Collector
Thrust Bearing
Journal Bearing 1Motor Stator
Motor Rotor Journal Bearing 2
Shaft
Air Inlet
Compressed Air Outlet
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Low Cost Blower Cross-SectionNumber of Parts = 16
Collector
Controller
Thrust CapThrust Cavity
Diffuser Vanes
Housing
Motor Stator
Motor Rotor
140 mm
152 mm
Weight = 1.45 kg
Cooling Air Outlet
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Innovative Low Cost Split Housing DesignSingle Piece Upper Half
Housing
Single Piece Lower Half Housing
Single Piece Collector
Rotating Assembly
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Technical Summary
Blower Type CentrifugalMechanical Speed 80,500 rpmFlow 1500 SLPMPressure Ratio 1.2Weight 1.45 kg (3.2 lbm)Bearings Foil Gas BearingsMotor Type Permanent Magnet MotorController Type Sensorless ControllerInput Electric Power 769 wattOverall Efficiency > 62 %Total Blower Cost $105.11 [@ 50,000 units/year]Life >40,000 hrs
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CATHODE BLOWERSCATHODE BLOWERSDevelopment ProgramDevelopment Program
A High Temperature Recycle BlowerA High Temperature Recycle Blower
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A High Temperature Recycle Blower A High Temperature Recycle Blower AccomplishmentsAccomplishments
Preliminary Design Completed
− To improve efficiency of Fuel-Cell-based coal-fueled power generating stations
− To be used in 5 MW POC Plant
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High Temperature High Temperature Cathode Recycle BlowerCathode Recycle Blower
Design Summary− Flow 11.2 kg/sec
− Inlet temperature 802 oC
− Pressure Rise 3.0 KPa
− Axial flow fan
− Speed 9,244 rpm
− Input power 131 kW
− Overall Efficiency 72 %
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High Temperature High Temperature Cathode Recycle BlowerCathode Recycle Blower
330 cm
228 cm
Weight = 680 kg
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ANODE BLOWERSANODE BLOWERS
Warm Recycle BlowerWarm Recycle Blower
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Warm Anode Recycle Blower Warm Anode Recycle Blower AccomplishmentsAccomplishments
Successfully field tested
Suitable for 10 kW SOFC
Rated inlet temperature 250 oC
Flow 14 g/sec (corr.)
PR 1.15
Turndown 10:1
Prototype blowers are being manufactured forvarious SECA members and others
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Warm Fuel Recycle Blower for Warm Fuel Recycle Blower for Automotive ApplicationAutomotive Application
250ºC Inlet GasHermetically Sealed
Stainless Steel Construction
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ANODE BLOWERSANODE BLOWERS
Hot Anode Gas Recycle BlowerHot Anode Gas Recycle Blower
(ARGB) (ARGB)
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Hot Anode Gas Recycle BlowerHot Anode Gas Recycle BlowerAccomplishments Accomplishments
Lab tested up to 718 oC inlet temperature
Successfully field tested by U.S. Navy
Design improvement in progress ~ 850 oC inlet
Design is scalable
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Anode Gas Recycle Blower for Anode Gas Recycle Blower for SECA ProgramSECA Program
850ºC Inlet GasHermetically Sealed
Scalable to Larger Sizes
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Technical RequirementsTechnical Requirements
Low Cost
High Temperature Capability (~ 8500C)
High Efficiency
High Reliability
Compact
Maintenance Free
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Additional Requirements by SECA MembersAdditional Requirements by SECA Members
Design for scalability.
No gas leakage.
No sulfur leak into fuel stream.
No free silica exposure into fuel stream.
No heavy metal leakage into fuel stream.
Prefer DC voltage operation flexibility below 150 VDC.
Design for 40,000 hour lifetime (flexible on maintenance interval).
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Additional Requirements (ContAdditional Requirements (Cont’’d)d)
No cooling available from system other than from process fluid (air).
All power consumption needs to include cooling.
Purge gas is undesirable.
Mechanical type seals do not last.
Hydrogen around motor may be safety concern.
Corrosion/carbon deposition issues with high temperatures.
Metal out gassing at high temperatures with certain metals e.g. chrome.
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AGRB CrossAGRB Cross--Section Cut VerticallySection Cut Vertically
Volute Housing
Air Inlet
Impeller
Left Insulation Shield
Right Insulation Shield
Outer Housing
Inner Housing
Inner Housing
Fins
Fan Ring
Spacer (6)
Thrust Runner
Tie Rod
PM Motor Rotor
Stator & Windings
O-ring Seal
Outer Plate
Thrust Shim
Diffuser Shim
Heat Shield
Washer Shaft (2)
Nut Shaft (2)
End Cover
Thermocouple Connector
Speed Probe
Connector Speed Probe
Power Connector Wiring Outlet
Diffuser Vanes
Motor Journal Bearing
Compressor Journal Bearing
Compressor Shaft
Thrust Shaft
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AGRBAGRB Cut Away ViewCut Away View
Volute Housing
Left Insulation
Shield
Right Insulation
Shield
Heat Shield
Diffuser Vanes
Impeller
Spacers (6)
Inner Housing
Outer Housing
Compressor Journal Bearing Lamination
Stack
Motor Journal Bearing
Motor Stator & Windings
Thrust Bearings
Thrust Bearings
Shims
Outer Plate
Thermocouple Connector
End Cover
Shaft Assembly
Speed Probe
Assembly
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Technical SummaryTechnical Summary
Blower Type Centrifugal
Mechanical Speed 98,600 rpm
Pressure Ratio 1.025
Weight 4.26 kg (9.38 lbs)
Volume 0.565 liter (34.5 cu. in.)
Bearings Foil Gas Bearings
Motor Type Permanent Magnet Motor
Controller Sensorless
Operating Temperature 850º C (1562º F)
Overall Efficiency 45%
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Innovative High Temperature AGRB
Design Packaging
187 mm
186 mm
169 mm
Total Assembly Weight = 4.26 kg
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AGRB Tested in 3 Different ArrangementsAGRB Tested in 3 Different Arrangements
1. Testing at ambient conditions
2. Testing at moderate (~430 oC) using heat gun as heat source
3. High temperature testing using heat furnace
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AGRB Instrumented
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AGRBAGRB Test Rig Setup at Ambient Conditions Test Rig Setup at Ambient Conditions (Arrangement #1)(Arrangement #1)
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AGRBAGRB Map at Ambient Conditions Map at Ambient Conditions (Arrangement #1)(Arrangement #1)
1
1.01
1.02
1.03
1.04
1.05
1.06
1.07
1.08
1.09
1.1
1.11
1.12
1.13
1.14
1.15
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.01 0.011 0.012 0.013
Corrected Flow (kg/s)
P.R
60.4 krpm
71.7 krpm
79.2 krpm
90.4 krpm
98.9 krpm
105.9 krpm
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AGRBAGRB Fully Insulated Open Loop Rig Setup Fully Insulated Open Loop Rig Setup using Heat Gun (Arrangement #2)using Heat Gun (Arrangement #2)
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AGRBAGRB Closed Loop High Temperature System Closed Loop High Temperature System (Arrangement #3)(Arrangement #3)
The test cycle is based on closed loop system.
Hot air is circulated via Furnace heated up to 850 0C.
Flow to the compressor measured through bell mouth flow meter.
Back pressure valve is used to back pressure the compressor to generate compressor map.
All the plumbing connections and pipings are fully insulated for a minimal heat loss.
The blower hot side is enclosed in an insulation box for minimal heat loss.
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AGRB Fully Insulated High Temperature Rig Setup AGRB Fully Insulated High Temperature Rig Setup (Arrangement #3)(Arrangement #3)
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AGRB Cost Reduced DesignAGRB Cost Reduced Design
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Work in ProgressWork in Progress
Upgrade of materials and design in progress to run AGRB at 850 oC
Cost reduction is being worked on in parallel
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Conclusions
Component and SECA member system testinghave shown that foil bearing supported blowerswill meet…
− High efficiency
− Low volume/weight
− High reliability
− Oil free operation
− Maintenance free operation
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Conclusions (cont’d)
DFMA analysis have shown that production costtarget of SECA members will be met
Pricing of limited production units will requirepartnership among…
R&D DynamicsSECA MembersDepartment of Energy
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Acknowledgement
R&D Dynamics would like to thank DOE
and SECA members for their support