Syllabus: MAE 446/598: Energy Systems Design
Spring 2012
1. Course:
MAE 446: Energy Systems Design: Spring 2012
MAE 598 Energy Systems Engineering: Spring 2012
1:30 – 2:45 TTH
Tempe ECG 236
2. Designation:
Capstone Design Course for Energy & Environment Students
Elective Design Course for MAE Graduate Students
3. Description:
This course will address the design of energy systems that include some or all of the
following elements: source conversion, transmission, storage and use conversion. The
emphasis of the course is learning and demonstrating the use of the Integrated Product
Design (IPD) process. This is accomplished through lectures, homework problems, case
studies and team design projects. The outcome of the course is for students, through their
team projects, to demonstrate their mastery of the ABET criteria for graduating
mechanical engineering students. For graduate students, a higher degree of mastery of
the ABET criteria in the areas of design, testing, teamwork and communications is
expected.
Topics covered in lecture and required for successful team projects are as follows: Types
of Energy Systems, Integrated Product Development, Teamwork, Analysis, Testing,
Trade Studies, Modeling, Optimization, Equipment Selection, Cost Estimating,
Engineering Economics, Product Commercialization and Communications.
This is a team performance-based course. The student’s grade is primarily determined by
the performance of their team. Therefore, team selection and management is critical to
student success.
4. Student Teamwork and Time Requirements
Successful teams will have teammates that invest at least 6 hours outside of class each
week. This is a minimum. Many students may need to spend considerably more time to
review prior coursework and/or complete team project tasks. Students who are weak in
thermodynamics and cycle analyses should plan on additional study time. All students
are expected to be active team members who do the following:
1. Attend all team meetings
2. Engage in team analyses and decision making
3. Complete all team assignments on time and provide them to members prior to
the team meeting.
4. Review the work of others prior to the team meeting
Students are expected to have read, outlined, and mastered the major concepts of all
reading assigned prior to the next lecture. Pop and scheduled quizzes may be given over
this material.
Many of the course deliverables must be accomplished by consistent, daily work over an
extended period of time. This course requires students to be self-managing. There is not
enough instructor time to monitor students to insure that they are not waiting until the last
day to do an assignment that should have been done over an extended period of time.
The instructor may at any time impose quizzes, notebook inspections, etc. to determine if
students are completing work in a timely manner. Students who are not staying
current may have points deducted by the instructor from the 1000 points possible.
5. Prerequisites:
MAE 340 Thermofluids II and MAE 482 Thermodynamics
6. Textbooks: None.
7. Lectures:
Students are responsible for all information covered in class. Some information will be
on slides that will be posted to Blackboard. Other information may be given orally in
class. Students are responsible for taking notes on this information.
8. Instructor: Steve Trimble, Professor of Practice
a. Room: ECR 385
b. Telephone: 623-229-9070
c. Office Hours:
MW: 3:45 – 5:15 PM
TTh: 3:15 – 4:15 PM
Other times by Appointment
d. Email: steven.trimble@asu.edu
9. Teaching Assistant: Maryam Khordishi
10. Course Outcomes:
The purpose of this course is for students to demonstrate that they have met the
ABET criteria for mechanical engineering students. The level of mastery for
undergraduate students working on their Capstone Projects is in accordance with
ABET requirements. The level of mastery for graduate students is determined by the
instructor. The course outcomes and levels of mastery are shown in the following
table.
Table 1. Course Outcomes and Level of Mastery Based on ABET Criteria
ABET Mechanical Engineering Program
Outcome
Capstone
Team
Level of
Mastery
(a) an ability to apply knowledge of
mathematics, science, and engineering
Applicati
on
Select the appropriate physical laws, make simplifying
assumptions, show trends, understand limitations,
make inferences from analysis results.
Analysis
Test plan based on requirements, FMEA and technical
approach. Test procedures, data collection and
instrumentation, data analysis, and application to
design. Ability to do POC, development and validation
testing. Ability to troubleshoot.
(b) an ability to design and conduct
experiments, as well as to analyze and
interpret data
1
Graduate
Team
Level of
Mastery
MAE 446/598 Outcomes
Design of overall energy system and then
design/develop the system or a component in the
system into a working prototype. Use the following
tools and processes: IPDS; Voice of Customer; technical
approach; functional block diagrams, engineering
requirements; options; trade studies; configuration
block diagrams; parametric models and optimization;
development; validation.
(c) an ability to design a system, component
or process to meet desired needs
within realistic constraints such as
economic,
environmental,
social,
political, ethical, health and safety,
manufacturability, and sustainability
Analysis
(d) an ability to function on multidisciplinary teams
Applicati
on
Form and sustain team. Hold team members
accountable. Resolve team conflict. All team
members cognizant of the work presented in design
reviews and reports. Hold regular team working
meetings with documented minutes.
(e) an ability to identify, formulate, and
solve engineering problems1
Analysis
For each IPDS phase, T of C for analyses, each analyses
documented with issue, approach, principles used,
simplifying model and assumptions, limitations of
analysis, select solution to problem based on analysis
and engineering judgment.
(f) an understanding of professional and
ethical responsibility
Applicati
on
Reference all work of others. Follow ASU academic
honor code.
(g) an ability to communicate effectively
Applicati
on
Project Plan, Design reviews, Final Report, notebook,
final presentation, team meeting minutes, analysis
reports, test reports, communications with customers,
users, and suppliers.
(h) the broad education necessary to
understand the impact of engineering
solutions in a global, economic,
environmental, and societal context
Compreh
ension
(i) a recognition of the need for, and an
ability to engage in life-long learning
Applicati
on
In final presentation and final report introduction,
discuss why project was chosen and its societal impact.
List literature and experts researched in final report
and document findings in notebook.
This outcome includes the ability to create physical and mathematical models for engineering systems
and/or components.
(j) a knowledge of contemporary issues2
(k) an ability to use the techniques, skills,
and modern engineering tools
necessary for engineering practice.
Applicati
on
Discuss in final presentation and final report
introduction how this project addresses a
contemporary issue.
Applicati
on
Solid modeling, FEA, computer performance modeling
and optimization, project management—project plan,
budget, schedule and performance monitoring,
variance resolution, bring project in on-time, inbudget, meeting all requirements. Manage student
labor.
11. Class Schedule: 75 minutes of lecture/class activity two times a week
12. Grading:
Homework
Quizzes
Project Plan
Design Review 1
Design Review 2
Final Design Review
Report
Notebook
Final Presentation
Total Points
130
50
50
25
25
20
300
200
200
1000
Grade Ranges:
1000 to 915 points
A
914 to 900 points
A899 to 885 points
B+
884 to 815 points
B
814 to 800 points
B799 to 700 points
C
699 to 600 points
D
Note: A+ grade may be earned by extra-ordinary performance and will be given at
the discretion of the instructor.
Students who are not staying current may have points individually deducted by the
instructor from the 1000 points possible.
13. Honors Projects:
Honors Projects can be accomplished for this class. These projects are separate from the
grade earned.
2
This outcome refers to contemporary issues within the discipline or within engineering in general.
14. Attendance



Attendance in class is required. Impromptu quizzes may be given.
Excused absences (quiz make-up allowed) will be accepted for the following:
o Illness with medical proof
o Job interviews
o Engineering organization events (approved by instructor)
o Other legitimate reasons approved beforehand by the instructor
Whether the absence is excused or not, the student is responsible for the material
covered. Students should get notes regarding what was covered in class from a
fellow classmate.
15. Written Assignments
Homework, papers and all other written work will be neat, organized and easy to read.
Homework problems must show all work and the answers must be boxed. (In industry,
showing how you arrived at the answer is as important as the answer. There is no answer
at the back of the book, so the reviewer must determine if your logic and calculations
have yielded the right answer.)
16. Schedule
The class schedule is provided in an Excel file posted on Blackboard. It is subject to
change based on course needs.
17. Honor Policy
The Student Academic Integrity Policy of Arizona State University requires
each student to act with honesty and integrity and to respect the rights of others in
carrying out all academic assignments (see:
http://www.asu.edu/studentaffairs/studentlife/judicial/).
Violations of academic integrity include, but are not limited to, cheating, fabrication,
tampering, plagiarism and/or facilitating such activities. A discussion of professional
ethics that is especially relevant to FSE students can be found at
http://www.fulton.asu.edu/fulton/departments/acad_affairs/integrity.php.
18. Purpose of Team Projects
The primary purpose of the team projects is for students to learn and
then demonstrate that they can design using the processes covered in
this course. Clever and imaginative designs are encouraged, but they cannot make-up
for not following the processes prescribed in this course.
19. Capstone Team Projects
Capstone Projects were started in MAE 482. The teams will remain as started in that
course. Prior work will be re-formatted in accordance with the documentation
requirements for this course. Projects started in MAE 482 that are too large for the time
and material cost constraints of this course MUST be reduced in scope. Teams that
reduce their scope must meet with the instructor for approval. All Capstone Projects
must result in prototype hardware that meets the design requirements.
20. Graduate Student Projects
The graduate students will complete their entire project in this course. A major challenge
for these students is to quickly form effective teams and select a project from the list
provided. More than one team can select the same project, but the teams cannot
collaborate with each other. The graduate team projects cover only conceptual and
preliminary design. No overall system prototype hardware will be built. However,
proof-of-concept (POC) testing may be needed. The system modeling and optimization
tasks will be more extensive for the graduate teams as compared to the Capstone design
teams.
21. List of Candidate Graduate Team Projects
Solar Thermal-to-Electric Power Plant with Thermal Storage
The goal of the study is to complete the preliminary design of a solar power plant based
on idealized solar input and guaranteed electric power output profiles as given in the
following figure. The effect of clouds, wind and other weather effects will not be
considered. The ultimate heat sink is a large lake with a constant temperature of 80
degrees F. The ambient temperature and relative humidity will be assumed to be a
constant 70 deg F and 10%, respectively. The plant is to be viewed as three subsystems:
solar input to working fluid A, thermal storage system, and power block. The power
block receives thermal energy from a working fluid A or B and then converts this energy
to electric power via a heat engine that rejects its waste heat to the lake. Supplementary
fuel firing is not allowed. The plant is to be optimized for the lowest initial cost-ofelectricity. During conceptual design various solar thermal storage techniques and
thermal energy-to-electricity power conversion plants must be considered. Various solar
concentrator designs must also to be considered. The final conceptual design will have
the basic plant configuration defined. The plant will be rated according to the maximum
electric output of the power block.
The preliminary design will select the thermal storage material and the operating state
points (temperature, pressure, flow) for each major component. The power block will be
defined to the major component level. A computerized COE performance model will be
prepared and used to optimize the plant for the lowest COE. An FMEA for the system
will also be provided. For the COE calculations, use the following: FCR = 10% and CF
= 30% based on the rated power of the plant. The O&M will be estimated based on the
O&M of a typical steam plant being $0.01/kWeh.
Maximum Solar Insolation
1000 W/sq m
Guaranteed
Output = 100 MWe
Midnight
6 pm
Noon
6 am
Midnight
Cogeneration Plant for Ethanol Production Facility
An ethanol production facility requires xx lbs/hr of 80 psia saturated steam and XX MWe
of electric power. The facility must generate its own steam and electrical power.
Natural gas is available at the site for $4/MMBtu. The plant usually runs at 100%
capacity; however, the plant must have at least x lbs/hr of steam and x MWe of electric
power at all times to prevent damage to the plant. The plant operator is only willing to
risk a maximum probability of 5 % that the plant will be without the minimum amounts
of steam and electricity. The team is to identify the lowest cost way of providing the
needed steam and electricity. The plant must last for 20 years. A FCR of 0.12 should be
assumed and a plant CF = 90%.
The conceptual design will consider a number of energy system heat engines and steam
generation devices. At the end of conceptual design, a baseline system will be defined in
terms of a process flowchart with state points and types of components identified. Each
candidate system will be configured such that it never has a probability of less than 95%
that the plant will be able to meet its minimum steam and electric power requirements.
The preliminary design will refine the baseline conceptual design and optimize the
component selections and operating state points to minimize the overall cost of providing
electricity and steam to the plant. The final preliminary design will include a flowchart
with components and state points. It will also include a bill of materials with the
components listed along with their estimated costs and predicted performance. An
FMEA will be prepared for the system. A computerized performance model that
optimizes the design for minimum cost will be prepared. It will include cost models for
the components and the required thermodynamic equations to establish state points for
the system.
Engine/Thermal Battery Heat Source for an Unmanned Underwater Vehicle (UUV)
An underwater vehicle must have a propulsion power system that delivers 150 kWe for
5 hours. The propulsion system consists of a heat engine and an insulated carbon block
heated to a high uniform block temperature, Tblock max. The carbon block has cooling
passages to transfer the thermal energy to a re-circulating helium gas loop that interfaces
with the heat engine. The seawater at 40 deg F is the heat sink. The heat engine drives an
electric power generation device that delivers 150 kWe to the UUV propeller motor.
Assume that adequate heat transfer is obtained if axial cylindrical passages are drilled
into the face of the cylindrical carbon block. Further assume that 50% of the face of the
carbon block is carbon and the remainder is holes.
The conceptual design will identify the carbon block and insulation configuration,
insulation material(s) and heat engine type. It will also include a method of tempering
the temperature of the helium gas that interfaces with the heat engine. The method of
initially heating the carbon block is not part of this design.
The preliminary design will identify the specifics of the heat source and heat engine
design including size, weight, and components. State points for the major components
will be determined. An FMEA will be prepared for the system. A computerized
performance model that optimizes the design for minimum cylindrical packaging volume
of the heat source plus the heat engine will be developed, validated and used to optimize
the design. There is no restriction on overall envelope diameter or length.
Flashed-Steam Geothermal Power Plant
Geothermal water at 200 deg C is available at a slightly pressurized condition at the
geothermal well head. The cost of the water is $ xx per million gallons. Assume the
water will not cause fouling or corrosion. A 5 MWe output electric power plant with
input energy for the geothermal source is needed. Assume the heat sink is ambient air at
80 deg F and 30 percent relative humidity.
For the conceptual design consider various methods of power conversion including
Rankine cycles based on 1) flashing the water to steam and 2) using an organic Rankine
cycle working fluid. For the power block heat sink consider both evaporative and dry
cooling. For the evaporative cooling, assume the cost of water to be $XX per million
gallons. The plant must last for 20 years. The baseline conceptual design should include
a cycle diagram with the major components and state points identified.
The preliminary design will refine the baseline conceptual design and optimize the
component selections and operating state points to minimize the overall cost-ofelectricity (COE). The COE model will be computerized and include both
thermodynamic and cost algorithms. Assume a FCR = 0.12 and a CF = 90%. As a basis
for estimating the O&M costs, a regular 5 MWe steam plant is assumed to have operating
and maintenance costs equal to $0.02/kWeh. The final preliminary design will include a
flowchart with components and state points. It will also include a bill of materials with
the components listed along with their estimated costs and predicted performance. An
FMEA will be prepared for the system.
Optimized, Low-cost Air Conditioning Ssystem for Emergency G3Box Clinic
The G3Box is a 40-foot long shipping container converted into a mobile clinic for
disaster areas. The project is to design an affordable air conditioning system for this
clinic that meets the needs of the clinic. The project involves interfacing with the G3Box
team at ASU and arriving at a list of design requirements. The use of fossil fuel will be
minimized. The conceptual design activity will include the identification of candidate
approaches for meeting the requirements and a comparison of candidates followed by the
selection of a final baseline design. The air conditioning system must consider air
quality, temperature, humidity and circulation.
The preliminary design will include the creation of a computerized optimization program
that will optimize the design for low cost and minimum fossil fuel usage while meeting
all the design requirements. An FMEA will also be accomplished. The ventilation
method will be modeled with CFD analysis to verify that adequate circulation under
various ambient conditions will be achieved.
Heat of Compression Recovery System for Compressed Air Energy Storage
One method of storing electrical energy generated by wind farms at night is to use the
electricity to power air compressors. The compressed air is then stored in a vessel or an
underground cavern. During peak times of electric power demand, the compressed air is
then introduced into a solar receiver where it is heated to a high turbine inlet temperature.
The high-temperature air is then expanded in a turbine that drives a generator.
The round-trip efficiency of energy storage is dependent upon the heat of compression
being recovered. The main emphasis of this project is to identify an efficient and cost
effective method of recovering this heat.
The conceptual design will include the overall modeling of the compressed air storage
system and the identification of a baseline compression system. Candidate methods of
recovery the heat of compression will be identified and evaluated. A final candidate
baseline conceptual design will be defined.
The preliminary design will include the creation of a computerized tool for optimizing
the heat of compression recovery system. This model will include both cost and
thermodynamic models to predict performance in terms of cost-of-compression. For
these analyses the following will be ass