Microturbines

2005-04-21 Rolf Gabrielsson, Volvo Aero Corporation Section 3

Microturbines, section 3

MEMS Gas Turbine Engines

Micro-Electro-Mechanical-Systems (MEMS) or Ultra-microturbines. Ref.: Alan H. Epstein, ASME GT-2003-38866

Microturbines Small microturbines Example: IHI remote application MEMS

25 500 kW 1 10 kW

10 - 100 W

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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MEMS Characteristics

MEMS based on manufacturing technologies developed by the semiconductor industry Diameters of millimetres rather than meters with airfoil dimensions in microns rather than millimetres

Shirt-button-sized gas turbine

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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User Pull - Market interest

Small portable electronics - computers, GPS receivers, etc require compact energy supplies Mobile systems such as robots,air vehicles require increasingly compact power and propulsion Hydrocarbon fuels burned in air have 20-30 times the energy density of the best current lithium chemistry-bases batteries Modest system efficiency to compete with batteries Development started mid 1990s Main player: MIT,USA

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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Thermodynamic scaling
Air intake diameter: 100 MW 1 meter 100 W 1 mm However reduced pressure ratio (2:1 - 4:1), TIT and increases losses means reduced specific power Fluid viscous forces Surface area-to volume However, usable strength of material - Increase - Increase - Increase

Manufacturing constraints means: - Reduced cycle efficiency Increased specific fuel consumption - But better thrust to weight ratio. The cube-square law

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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Thermodynamic scaling

Ref.: Gong, Sirakov, Epstein, Tan Aerothermodynamics of Micro-turbomachinery, GT2004-53877, ASME Turbo Expo 2004, Vienna
Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson
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Mechanical scaling
Viscous forces larger film heat transfer coefficient increases Temperature gradients in the structure reduced Helpful reducing stress but makes thermal insulation challenging Possibility to use ceramic materials due to size dependent fault-possibility Single-crystal semiconductor materials. Usable strength increase with reduced size Thermal shock resistance improved
Ref: Epstein, ASME GT-2003-38866

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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MEMS Gas turbine design for demo-MEMS

Microturbine technology applies to Silicon, Si Si loses strength above 950K Fuel: H2 Shaft power: 17 W Design characteristics: = 2:1 TIT = 950K Dcompressor = 8 mm Dturbine = 6 mm Rotor speed = 1.2 Mrpm
Ref: Epstein, ASME GT-2003-38866

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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MEMS Manufacturing
Old-school designer Dont let the manufacturing people tell you what you cant do MEMS design philosophy: Design for manufacturing Primary fabrication processes: - Etching of photolithographically planar geometries - Bonding of multiple wafers Electronics, motors and sensors - Embedded sensors - Alternating insulation and conducting layers - Vapour deposition or sputtering approaches

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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Manufacturing / complete stack

Ref: Epstein, ASME GT-2003-38866

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson
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Turbine design
Si prototype turbine TIT < 950 K - (MIT has designed for 1600 K) Possible turbine performance - = 4:1 - Tip speed = 500 m/s - Efficiency, total-to static = 50-60% (compare Microturbine turbine efficiency approx = 85%)

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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MEMS combustor
Fuel : H2 (methane, propane) Reaction rate - H2 = 90% - Methane = 60% - Compare large Gt: 99.9%

Ref: Epstein, ASME GT-2003-38866

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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Bearings and rotor dynamics

Electromagnetic and air bearings have been considered Electromagnetic bearings up to now not promising Gas bearings have advantages such as - No temperature limits - High load - Relatively simple manufacturing Gas bearings used in microturbinesin the range 30 70 kW and turbochargers. Also in gyroscopic instruments

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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Examples of hydrodynamic and hydrostatic air bearings

Ref: Epstein, ASME GT-2003-38866

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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MEMS materials

Si Max temperature Cost 950 K 1

SiC 1500 K 100

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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MEMS Generator
Permanent magnetic high speed generator

Ref: Epstein, ASME GT-2003-38866

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson

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Ongoing technical development

No reported MEMS operations up to date Demonstration of component technology at MIT Possible improvements as recuperated cycles with heat exchangers MEMS performance:

Ref: Epstein, ASME GT-2003-38866

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Economics and the future

What is required to make millimetre-scale turbines real? Answer: - Technical feasibility - Must fulfil societal needs Power production in short term is aimed at portable applications due to: - Very much larger energy density of hydrocarbon fuel compared to lithium batteries In short term, 5 10% overall system efficiency is sufficient

Ref: Epstein, ASME GT-2003-38866

Microturbine lecture, section 3, 2005-04-21, Rolf Gabrielsson
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