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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