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Dr. J. Michael Mcquade Senior Vice President, Science & Technology United Technologies Corporation

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Dr. J. Michael Mcquade Senior Vice President, Science & Technology United Technologies Corporation Materials for Energy Efficiency / Energy Efficient Materials Dr. J. Michael McQuade Senior Vice President, Science & Technology United Technologies Corporation February 1, 2012 Agenda UTC Overview UTC Examples of the Impact of Materials Science Elevators Membranes Catalysts Materials Processing and Energy Additive Manufacturing Machine Modeling Materials Design/Manufacturing 2 United Technologies Business units Pratt & Whitney aerospace systems power Sikorsky Carrier solutions UTC Power Hamilton Sundstrand UTC Fire Otis & Security building systems 3 United Technologies - 2011 Revenues: $58.2 billion Business unit revenues Pratt & Whitney Carrier 23% 21% UTC Fire & Hamilton Security Sundstrand 12% 11% Sikorsky ( 'LQYHVWPHQW«%LQ 13% Otis ($ Billions) 21% 4.0 3.0 Customer Funded Customer Funded Segment « 2.0 54% Commercial & Industrial Company Funded 1.0 Company Funded 46% Aerospace 0.0 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 4 UTC Sustainability Roadmap Operations Products Advocacy UTC launches the UTC energy efficient products UTC is leading voice in advocacy 2015 Sustainability Goals and programs Otis launches the Gen2® elevator system establishes a LEED requirement U.S. Green Building Council (1993) for new construction UTC Power introduces 400 kW PureCell® system World Business Council for 6XVWDLQDEOH'HYHORSPHQW¶V(QHUJ\ Pratt & Whitney flight tests PurePowerTM Efficiency in Buildings project PW1000G engine with Geared Turbofan (2006-2009) technology Energy Use 1997-2010 Water Use 1997-2010 5 Materials Science ± Enabling Technology ³7KHKDOOPDUNRISURJUHVVLQHYHU\DJHKDVEHHQWKHZD\ µPDWHULDOVHQJLQHHUV¶ZRUNHGWRLPSURYHWKHXVHIXOQHVVRI PDWHULDOV´ Iron and bronze Aluminum and stainless steel Plastics and synthetic fibers Nanostructured materials ³0DWHULDOVhave enabled advancements in railroads, automobiles, aircraft, telecommunications, defense, and medicine, even if PDWHULDOVGLGQRWE\WKHPVHOYHVVHWWKHSDFHRILQQRYDWLRQ´ 2ILQWHUHVW³7KH$GYDQFHG0DWHULDOV5HYROXWLRQ´ Sanford L. Moskovitz, Wiley, 2009 6 87&¶V%DVLVRI&RPSHWLWLRQLV7HFKQRORJ\ ³(YHU\GD\87&HQJLQHHUVDQGVFLHQWLVWVDURXQGWKHZRUOGZRUNWR overcome two basic forces of nature ± JUDYLW\DQGZHDWKHU´ former CEO George David, 2006 ³87&FRPSHWHVRQWKHEDVLVRILWVWHFKQRORJ\2XURSHUDWLQJ system matters, our customer interactions matter, but in the end people buy products, services and solutions from us because they run faster, operate hotter, weigh less, make less noise, last longer, DQGXVHOHVVHQHUJ\´ Fundamental drivers for materials technology insertion at UTC Durability Weight Cost Temperature Embodied energy Operating energy Enhanced features 7 SOME EXAMPLES 8 Elevators Cost reduction Weight reduction Material systems for brakes and safeties Electrical efficiency Super hi-rise lifting systems 9 Elevator Systems Enabled By Materials Technology Conventional rope systems require Large machine size due to rope torque Rope diameter drives turning radius drives sheave diameter Lubricant systems Otis Gen2® Elevator System Flat polyurethane-coated steel belts 3 mm x 30 mm belt Eliminates lubricants 10 Elevator Systems Enabled By Materials Technology Gen2 ® Elevator System Up to 70% reduced machine volume Reduced torque from smaller radius sheave (480 mm to 100 mm) 12mm dia rope vs. 1.6 mm dia. cord in flat belt Improved packaging; machine roomless 75% machine weight reduction Power consumption reduced by 50% 11 Gen2 ® Elevator Material Challenges Material interactions in CSB cords Advanced magnetics for motor drives Silicon FET GaN Equiv. Materials for power electronics Gen2® regenerating drive system achieves 75% improved energy efficiency Rail interactions and lifting 12 Elevator Topology Optimization Material saving Reduced distinct parts Reduced operations Optimal topology Baseline Design space Engineering (stress, deflection product and load/BCs interpretation (10 load cases) and frequency CAD drawing constraints) 13 Otis«Ultra High Rise Buildings Technology challenges... Elevator hoistway space 1100 Dispatching and elevator access 1000 Rope sway and elevation control 900 Ride comfort and energy consumption 800 Building evacuation and safety 700 600 500 Rise (m) 400 300 200 100 0 Al Burj Burj Shanghai Pentominium Russia Chicago Incheon China Dubai World Trade (Dubai UAE) (Dubai UAE) Center (Dubai UAE) Tower Spire Towers 117 Tower 4 (NYC) (Shanghai SH) (Moscow) (Chicago) (South Tower (Dubai UAE) 417 m Korea) (TJ China) Emerging ultra high rise buildings have needs beyond the capabilities of many of the components we produce today. 14 Where Does It End - The Space Elevator A cable anchored to the Earth's equator, reaching into space. (Tsiolkovsky, 1895) A counterweight at the end keeps the center of mass above the level of geostationary orbit. Inertia ensures cable remains stretched Above the geostationary level, climbers have upward centrifugal force. The cable must be made of a material with a large tensile strength/density ratio > 100,000 kN/(kg/m). Optimize EM energy harvesting versus statics / potential differences. 15 Membranes and Catalysts World Market (MM $US) Process 2002 2004 2006 2008 RO / NF 1716 1934 2222 2571 Ultrafiltration 1441 1653 1927 2265 Microfiltration 2091 2449 2928 3517 Liquid Separations 1786 2138 2605 3200 Gas Separations 453 547 679 846 Total 7487 8721 10361 12399 Source: Profile of the International Membrane Industry, Elsevier Ltd.,3rd Ed. Global membrane separation technologies market to reach US $16 Billion by 2017 (Global Industry Analysts, Inc.) 16 Membranes Market Overview Market growth between 2003 - 2008 Key drivers are energy efficiency and environmental footprint rd Source: Profile of the International Membrane Industry, Elsevier Ltd.,3 Ed. 17 Membrane Technology Development Materials Polymers Ceramics Metals Flat sheets Pressure-driven Pleated papers Concentration-driven Tubular/hollow fiber Electrical potential Structure Process 18 Membrane and Catalyst Applications at UTC Buildings Industrial CO separation for power plants Air dehumidification 2 Waste-heat driven membrane distillation Batteries and fuel cells 39% 33% 28% Aircraft Fuel tank inerting Fuel deoxygenation 19 Principles of FSU Operation Membrane-based deoxygenation prevents coke formation Deposition as a function of oxygen level Coke formation prevents heating jet (20 mL / min flow rates) fuel to high temperature 2.5 104 /kg 2 104 2 Pyrolysis g/cm P 1.5 104 1 104 Autoxidation Acceptable level micrograms Deposition, 5000 Coke deposition, Coke Deoxygenated 0 200 400 600 800 1000 0 0 10 20 30 40 50 60 70 80 T fuel (F) Dissolved O Concentration, ppm 2 O2 concentration gradient provides driving force Porous Support Membrane Membrane Porous support Jet Fuel Fuel In Fuel Out < 6 ppm O2 70 ppm O2 O2 vacuum or O2 oxygen-free gas 20 Principles of FSU Operation Membrane-based deoxygenation prevents coke formation O2 out Bottleneck: oxygen transport from bulk flow to membrane surface Fuel in O2 out Fuel Leakage 0.025 ³6HDODQWOD\HU´ Membrane 0.020 Backing 2 0.015 gr / hr / in 0.010 Support 0.005 0.000 Conventional Modified Gen1 Gen2 Construction Construction Oxygen Permeability 10X lower fuel leakage 300.0 250.0 5X higher oxygen permeance 200.0 150.0 2X lower membrane mfg. cost 100.0 Oxygen Permeability (GPU) 50.0 40% less membrane needed 0.0 Conventional Gen1 ModifiedGen2 Construction Construction 21 CO2 Separation Membrane ± Simulation Study Membrane module Synthetic analogue/ polymer thin-film Porous substrate Membrane properties mapping Simulated separation system (simplified) 22 CO2 Separation Membrane N , H O, O CO2 2 2 2 CO2 N2, H2O, O2 ~ 0.2 Pm Current: Desired: Thin, dense polymer films with CO2 WUDQVSRUWIDFLOLWDWHGE\³FDUULHUV´ preferential CO2 affinity within a barrier film Low selectivity for CO2 Fast and reversible interaction sites 23 PEM Fuel Cells Membrane Attributes and Challenges Function Transport protons Separate the reactants (H2, O2) Available membranes Desired attributes PerFluoro Sulphonic High proton conductivity Hydrocarbon Low gas cross-over High chemical / mechanical durability Challenges Sufficient proton conductivity at low RH Stability at high temperature operation Trade-offs in durability and performance Cost 24 PEM Fuel Cells Membrane critical to fuel cell life and performance Chemical stability Mechanical strength Micro porous layer Improved performance resulting in Anode Cathode Macro porous porous Macro higher power densities Bipolar Plate Bipolar Membrane Catalyst Voltage (V) 1 layer 0.9 H+ 0.8 AIR H2 AIR H2 0.7 2010 0.6 2004-2009 0.5 <2004 0.4 0.3 0 500 1000 1500 2000 Current Density (mA/cm2) 25 UTC Power ± Fuel Cell Bus Durability (mVdc) 700 2008 Fleet Leader 2011 Fleet Leader (in service) Fleet statistics 17 bus fleet 2007 Fleet Leader 2011 second bus (in service) 600 750,000 miles 70,000 hours End of life 2006 Fleet Leader 18,500 start-stops 500 400 0 2000 4000 6000 8000 10000 12000 Load Hours Best in class PEM fuel cell durability enabled by improved systems understanding and advanced cell materials 26 Membrane Durability: Critical Fuel Cell Enabler Membrane failure limits stack life (e.g. 10,000 vs 40,000 hours) H2 Measure in PEMFC effluent (FER) - F H2 O 2 Radical Attack of polymer Anode H2O2 formation formation weak sites OH Material Localized stress Crossover properties promotes cracks, failure Cathode H2O2 degrade fissures occurs H2 O O2 Chemical degradation Mechanical degradation 27 Flow Batteries Flow Battery System Ion exchange Power out Electrolyte membrane flow Renewable Energy Smoothing
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