Microfabricated Power Generation Devices

Transcription

1 Microfabricated Power Generation Devices Design and Technology Edited by Alexander Mitsos and Paul I. Barton WILEY- VCH WILEY-VCH Verlag GmbH & Co. KGaA

2 Contents Preface XIII List of Contributors XV 1 Introduction 1 Alexander Mitsos and Paul I. Barton 1.1 Alternatives to Microchemical Systems Using Manpower Harvesting Environmental Energy Book Outline 3 References 4 Part One Technologies 5 2 Microfabrication for Energy Generating Devices and Fuel Processors 7 Volker Hessel, Günther Kolb and Jürgen J. Brandner 2.1 Specific Issues for Manufacturing of Energy-Related Microdevices Micro Power Device Type and Choice of Microfabrication Techniques-Role of Materials, Sealing, and Dimensions Fabrication Techniques for Minichannels in Monoliths or Mini Fluidic Ducts in Foams Fabrication of Ceramic Monoliths Fabrication of Metallic Monoliths Fabrication of Ceramic and Metallic Foams Fabrication of Plate Heat-Exchangers/Reactors Steel and Metal Material Choice Steel and Metal Plate Sealing Techniques Laser Welding Electron Beam Welding Diffusion Bonding Brazing Fabrication of Microchannels for Microstructured Reactors Steel and Metal Plate Micromachining 13 Microfabricated Power Generation Devices. Edited by Alexander Mitsos and Paul I. Barton Copyright 2009 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim ISBN:

3 Contents Mechanical Precision Machining Micro Electro Discharge Machining Wet Chemical Etching Selective Laser Melting Punching Embossing Rolling Laser Ablation Powder Sintering Steel and Metal Plate Interconnection and Assembly Alignment Bonding Techniques Ceramic Plate Micromachining Slurry-Based Molding and Other Techniques Selective Laser Melting Ceramic Plate Interconnection and Assembly Polymer Plate Micromachining Injection Molding Laser Machining and Micro Stereolithography Polymer Plate Interconnection and Assembly Fabrication of Microchannels for Chip-Like Microreactors Silicon Micromachining Glass Micromachining Membrane Machining (for Hydrogen Separation) Catalyst-Coating Techniques Surface Pre-treatment Slurry/Sol Preparation Slurry/Sol Deposition Temperature Treatment Alternative Coating Techniques Automated Catalyst Coating 31 Acknowledgements 31 References 32 3 Fuel Processing for Hydrogen Generation 39 Kishori Deshpande 3.1 Introduction Hydrogen Generation Reforming Techniques Steam Reforming Partial Oxidation Autothermal Reforming Pyrolysis Ammonia Cracking Related Processes: Hydrogen Clean-Up 43

4 3.4 Alternative Hydrogen Production Techniques Materials Selection Literature Examples Methanol Partial Oxidation Samsung Micro Fuel Processor Summary and Outlook 47 Acknowledgements 49 References 49 4 Micro Fuel Cells 51 Joshua L Hertz and Harry L Tuller 4.1 Introduction Principles of Operation Electrochemical Potential Ohmic Polarization Activation Polarization Concentration Polarization Practical Device Performance Micro Fuel Cells Solid Oxide Fuel Cells Basic Principles Micro Solid Oxide Fuel Cells Polymer Electrolyte Membrane Fuel Cells Basic Principles Direct Methanol Fuel Cells Micro Polymer Electrolyte Membrane Fuel Cells New Concepts for Micro Fuel Cells Single Chamber Fuel Cells Membraneless (Liquid Laminar Flow) Micro Fuel Cell 4.6 Conclusions 76 Acknowledgements 76 References 76 5 Microscale Heat Engines 81 Stuart Jacobson, Hanqing Li and Alan Epstein 5.1 Introduction Challenges Physical Challenges Boundary Layer Effects Heat Transfer Effects Fabrication and Material Challenges Standard Silicon Microfabrication Small-Scale Conventional Machining Microscale Heat Engine Examples MIT MEMS Gas Turbine Generator 87

5 VIII Contents Bearings and Rotordynamics Combustion Turbocharger Electric Generator Self-Sustaining Engine Other Gas Turbine Efforts Rankine Engines Internal Combustion Engines External Combustion Flexing Wall Heat Engine 94 Acknowledgements 96 References 96 6 Thermophotovoltaics 99 Ole Nielsen 6.1 Overview Thermophotovoltaic System Components Photocell Materials Emitters Thermal Management in TPV Systems Scaling of TPV Systems Optics Heat Transfer Conclusion on Scaling Examples of TPV Micro-Generator Systems A Prototype Microthermophotovoltaic Power Generator A Thermophotovoltaic Micro-Generator for Portable Power Applications Conclusion 109 Acknowledgments 110 References Thermal Management and System Integration 113 Benjamin A. Wilhite 7.1 Introduction Discussion of Component Processes Overview Fuels Pre-treatment Desulfurization Vaporization Power Production Components Fuels Reforming Thermal Integration, Combustion Integration Schemes, Methods and Dimensions Horizontal (Zero-Dimensional) Integration Component Integration Strategies 120

6 Cartesian (One-Dimensional) Integration Radial (One-Dimensional) Integration Complex (Two- and Three-Dimensional) Integration Materials of Construction Silicon-Based Materials Metals Ceramics Packaging Strategies Compression Sealing Direct Fluidic Connections Micromachined Mechanical Couplers Adhesive Seals and Brazed Seals Solder-Joint Sealing Summary 133 Acknowledgements 134 References 134 Part Two System Design Selection of Alternatives and Process Design 143 Alexander Mitsos and Paul I. Barton 8.1 Introduction Objectives, Constraints and Alternatives Analysis of Design Objectives Efficiency vs. Energy Density Safety Concerns, High Temperatures and Heat Dissipation Decisions Methodologies A Superstructure-Based Approach Integrated Layout and Thermal Management Case Studies Comparison of Alternatives in Terms of Efficiency and Energy Density Effect of Scale on Process Performance Effect of Fuel Combinations and Layout Nomenclature 163 Acknowledgments 164 References Structural Considerations 167 Brian L Wardle and S. Mark Spearing 9.1 Introduction Structural Design Challenges in Micropower Devices Thermomechanical Design Approach 171

7 Contents 9.4 Concurrent Development in Micropower Device Design 175 Acknowledgments 177 References Microreactor Engineering: Processes, Detailed Design and Modeling 179 Dionisios С Vlachos 10.1 Introduction Process and Catalyst Selection for Microreactors Microreactor Configurations for Portable Power Need for Novel Processes and Reactor Configurations Mixing Catalyst Area Transients Safety Materials Selection Process Intensification via Multifunctionality Integration of Two Reactions via Heat Exchange Recuperative and Regenerative Heat Integration Multiscale Modeling, Design, and Optimization Hierarchical Multiscale Modeling Framework Methodological Steps Minimal Microreaction Engineering Models Catalyst Design Conclusions 193 Acknowledgements 193 References Optimal Design and Steady-State Operation 199 Benott Chachuat 11.1 Introduction Models for Optimal Design and Operation Case Study Intermediate-Fidelity Model Steady-State Simulations Optimal Design and Steady-State Operation for Nominal Power Demand Case Study (Continued) Optimal Design and Operation for a Nominal Power Demand Effect of the Nominal Power Demand Sensitivity to Uncertain Kinetic Rates and Resource Allocation Optimal Design and Steady-State Operation for Variable Power Demand Case Study (Continued) Performance of Nominal Power Demand Design 219

8 Performance of Two-Stage Programming Design 220 Acknowledgment 221 References Design of Hybrid Electrochemical Devices 223 Andrew T. Stamps and Edward P. Catzke 12.1 Introduction Hybrid Electrochemical Systems Simultaneous Optimization of Dynamic Systems Hybrid Power System Optimization Li-Ion Battery Capacitor Fuel Cell Programmable Load Problem Formulation and Results Future Directions 239 Acknowledgments 240 References Control of Microreactors 243 Mayuresh V. Kothare 13.1 Introduction Issues in Control of Microsystems Control Relevant Modeling of Microchemical Systems Continuum Models Model Reduction Empirical Models Feedback Control of Microchemical Systems POD-Based Boundary Control of Thermal Transients in Microsystems Wafer Temperature Profile Control Receding Horizon Formulation Receding Horizon Control Using POD Simulation Results Empirical Model-Based Predictive Control of Microflows COMSOL (FEMLAB) Simulation Model Predictive Control (MPC) Simulation Results Hardware Embedded Model Predictive Control for Microchemical Systems Embedded MPC on a Motorola Processor Embedded MPC on Customized Hardware Conclusions 265 References 266 Index 271