THE UNIVERSITY OF QUEENSLAND Bachelor of Engineering Thesis Conceptual Design and Simulation of a Microturbine; An Electric Car Range Extender Application Student Name: Adam HEAD Course Code: ENGG4011 Supervisor: Professor David J. Mee Submission date: 03 June 2011 A thesis submitted in partial fulfillment of the requirements of the Bachelor of Engineering degree in the specialization Mechanical and Aerospace Engineering UQ Engineering Faculty of Engineering, Architecture and Information Technology i Adam Joseph Head 18 Jacobs Well Road Stapylton QLD 4207 30/05/2011 Professor D. J. Mee Head School of Mechanical & Mining Engineering University of Queensland Queensland 4072 Dear Sir, I hereby submit my Thesis titled “Conceptual Design and Simulation of a Microturbine; An Electric Car Range Extender Application” for consideration as partial fulfillment of the Bachelor of Engineering degree. All the work contained within this Thesis is my original work except where otherwise acknowledged. I request that this thesis be kept confidential for a minimum period of 5 years from the date of submission. Please refer to the copy of the confidentiality agreement which is enclosed. Yours sincerely Adam Joseph Head Student ID: 41244432 ii A design report developed in collaboration with Microturbine Technology (MTT), Technische Universiteit Delft (TUD) and Toegepast Natuurwetenschappelijk Onderzoek (TNO) MTT/ TUDelft/ TNO The Netherlands (June, 2011) Copyright ©Adam Joseph Head, 2011 Author: Adam Joseph Head Supervisors: Wilfried Visser Prof. ir. J.P. van Buijtenen Dr. Arvind G. Rao Professor David J.Mee iii Abstract The microturbine seems to be a viable option for implementation into Hybrid Electric Vehicle (HEV) systems. A microturbine was constructed in the Gas Turbine Simulation software GSP in order to assess its viability for a low-power range extender. Due to the small magnitude of the turbine, scale effects need to be incorporated into the performance models. A microturbine has various advantages over other heat engines (Wankel, Piston, or Fuel Cell), and the capabilities in terms of range extension of the HEV are potentially superior. Through the use of the Engineering Design Process, a new microturbine design was developed that allows the system to be implemented into the HEV system. Aspects such as geometric size, weight, cost, availability, and ease of production were used to compare the different concepts and determine their feasibility. Empirical loss models previously researched were adapted and implemented into scheduling components of the microturbine base model. The model was used to simulate the required output data (Mechanical/ Electric Power, 퐶푂2 emissions, Fuel flow rate, Exhaust gas temperature and Exhaust gas mass flow) for a range of predefined design powers (9, 15, 22, 30, 36 kW). Power-to-weight ratios and component dimensions were also calculated and sent for analysis. The data above was generated under two control schemes (fixed and variable speed) and at three power codes; maximum power (100%), part load (60%) and idle (20%). The HEV model used this data to configure and size its own system. Simulations of design and optimization are important as it restricts the size of the HEV. The results suggest that the variable speed control scheme will extend the life of the system and reduce emissions substantially. If the microturbine is operated at or below ISA conditions the scheme offers numerous other advantages. However the control system is far more complex and will cost more to develop. Recommendations have been highlighted for model configuration improvement and focus on the control system is important for continued programme development. iv Acknowledgements For most I wish to thank Wilfried Visser, my industrial supervisor, for the continuous support and invaluable supervision. I would like to extend my eternal gratitude for the guidance and knowledge offered. The experience mastered will be of great use in the engineering industry. I would also like to offer thanks to Arvind Rao, my TU university supervisor, for the kind assistance and suggestions which greatly improved the quality of my work. I wish to offer thanks to my UQ supervisor David Mee, whose continued constructive comments improved the quality of my report and authority allowed me to conduct this thesis. A brief thanks to Savad Shakariyants and Colin Rodgers for their personal support, suggestions and help with various aspects of the assignment. I would like to thank the following PhD students for their help with various issues throughout my internship. Thanks to Michel Verbist, Adeel Javed and Mattia Olivero for providing their resources in literature. Iliane Dountchev for his help with the GSP working environment. I would also like to offer a special thanks to Fatma Cinar (international coordinator) for making my stay here in Delft possible. A brief special thanks goes to Wolbodo, the studentenvergeneging and my friends within for providing me with a wonderful experience here in the Netherlands. I finally wish to thank my parents Benjamin J. Head and Kathryn F. Head for supporting me financially and emotionally throughout my stay in Delft. v Special Notes This thesis is a master thesis topic and was issued by the TU delft, The Netherlands. It was chosen and completed as a bachelor thesis for qualifications awarded by the University of Queensland, Australia. It was conducted at a company called MTT within the city Eindhoven. Three months of work was conducted prior to the start of the bachelor thesis; Chapter 2.2.3 contains empirical size effect correlations adapted to experimental data which is further elaborated on in Appendix E.6. The author sincerely hopes you enjoy reading through the study. Enjoy! Key Words: Microturbines, Hybrid Electric Vehicles, Capstone C30, Geometric Size and Weight, Cost, Fuel Analysis, Performance, Carpet Plot, Flat Rating, Power code, Effect Graphs. vi Table of Contents Abstract ....................................................................................................................................... iv Acknowledgements ....................................................................................................................... v Special Notes ............................................................................................................................... vi List of Figures ............................................................................................................................. xi List of Tables ............................................................................................................................ xiii Nomenclature ............................................................................................................................ xiv Chapter 1 Project Background and Goals ........................................................................................ 1 1.1 Mission Statement .................................................................................................................. 1 1.2 Background – context, problem, scope .................................................................................. 1 1.2.1 Project Description and Formal Statement of Work ....................................................... 1 1.2.2 MTT (Microturbine Technology) ................................................................................... 3 1.2.3 Scope ............................................................................................................................... 5 1.2.4 Stakeholders .................................................................................................................... 6 1.3 Chapter Summaries ................................................................................................................ 7 1.4 Appendices ............................................................................................................................. 8 Chapter 2 Literature Review ............................................................................................................ 9 2.1 PART 1: Microturbine Development and History in Industry ............................................... 9 2.1.1 Introduction ..................................................................................................................... 9 2.1.2 Primary Configurations of Microturbines ..................................................................... 11 2.1.3 C30 Microturbine Configuration .................................................................................. 12 2.1.4 Advantages/Disadvantages ........................................................................................... 17 2.1.5 Microturbine Parameters and Issues ............................................................................. 18 2.1.6 Market for Microturbines .............................................................................................. 19 2.1.7 Emissions and Pollution ................................................................................................ 19 2.1.8 Economics of Microturbines ......................................................................................... 20 2.1.9 Hybrid Electric Vehicle ................................................................................................ 21 2.1.10 Conclusion .................................................................................................................. 31 2.2 PART 2: Turbomachinery;