DOE OSTI2017
Hydro power has been used since the early days of electricity, but is generally limited to very large facilities. There remains a vast array of untapped locations, either rivers, tidal currents, or also man-made facilities where energy harvesting is technically feasible, but still too costly. E-Motors, in partnership with MTI, is developing an integrated design aimed at facilitating manufacturing, installation, and retrofitting. The integrated design includes a rim on the outside of the turbine runner to house the electrical generator rotor, a so-called rim drive. With this approach, a compact, in-line assembly can be produced and placed in straight pipes, without having to resort to elbows, shafts, and outside generators, thus improving efficiency and facilitating assembly. The long term goal of the project is to develop a realistic prototype for market development and start of manufacturing. During this Phase I grant, in collaboration with the University of Wisconsin-Milwaukee (UWM), the team pursued two objectives: First, design and test a small (3”) system in a laboratory at UWM, and second develop a prototype design at higher power between 50 and 100 kW. The tests showed the potential for integrating the generator rotor with the turbine runner. Output power is so far limited due to test conditions, but CFD calculations show good efficiency potential. With the larger system, a number of possibilities were explored, including: a generator design matching the turbine output, and capable of generating a peak of 86 kW from a flow of 136 cfs at 9’ of head; various intake tube geometries, showing that an elliptical shape is quite favorable; removing the hub, something made possible with a rim design, which can improve efficiency by about 10 percentage points.