Magnetocaloric Refrigerator Freezer - Energy.gov...How Magnetic Refrigeration Works . The magnetic refrigeration cycle is essentially a Brayton cycle with the potential for continuous
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Ayyoub M. Momen, momena@ornl.gov Oak Ridge National Laboratory
Magnetocaloric Refrigerator Freezer 2017 Building Technologies Office Peer Review
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Project Summary Timeline: Start date: August 1, 2013 (FY 2014) Planned end date: January, 31, 2017
Key Milestones 1. Evaluation of MCM microchannels through
collaboration with GEA (6/30/2016) 2. Improve the regenerator structure (9/30/2016) 3. Final optimization, testing and drafting final
report (12/30/2016)
Budget: Total Project $ to Date: • DOE: $1588k • Cost Share: $1689k Total Project $: • DOE: $2049k • Cost Share: $2189
Key Partners:
Project Outcome: The main objectives of the magnetocaloric refrigerator project were to achieve: 100 watts of cooling 100°F temperature span
General Electric Appliances
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Purpose and Objectives Problem Statement: Decades of R&D efforts have gone into making a high performance, magnetocaloric refrigeration machine. Developing such a machine presents many challenges including material, flow hydrodynamics, rotating components, heat transfer limitation, and system cost. This project focuses on “developing the new manufacturing processes required to make microchannels from magnetocaloric material (MCMs).”
Target Market and Audience: The principal target market is residential and commercial refrigerators (>200M units). In addition, the technology has the potential to be used in larger-scale HVAC, drying, and industrial heating/cooling applications.
Impact of Project: Cooling/heating systems utilizing the magnetocaloric effect can be significantly more efficient than today’s refrigeration systems. • Final product will be a full scale magnetocaloric refrigerator-freezer. • The success criteria includes achieving a 100°F temperature span and approximately 100
watts of cooling capacity at 25% better efficiency. – Near-term: develop a feasible design with emerging MCM materials – Intermediate-term: design a magnetocaloric refrigerator-freezer – Long-term: introduce the technology to the market
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Approach
Approach: • Develop a manufacturing process for forming MCM microchannels • Enhance the heat transfer rate, which translates into a higher system capacity • Develop a high-efficiency magnetocaloric system design Key Issues: • Solid/liquid interstitial heat transfer limits the performance of the machine • Manufacturability of MCM to make the shapes is a big challenge Distinctive Characteristics: • Develop unique additive manufacturing followed by a sintering process to
fabricate MCM microchannels • 3D MCM microchannels through non-traditional manufacturing • Solid-state magnetocaloric machine
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Progress and Accomplishments
Accomplishments: • MCM successfully 3D printed in the form of microchannels • Magnetocaloric microchannel successfully developed using a novel approach • Patent 1: MCM microchannel has been patented • Patent 2: Fully solid-state magnetocaloric machine has been patented • Patent 3: Process of 3D printing of MCM microchannels • Multiple publications/presentations • GEA has developed several configurations of the prototype machines
Market Impact: This project can potentially save 0.75 quads of energy
Awards/Recognition: Recognized research by former EERE Assistant Secretary
Lessons Learned: Pressure drop of MCM particulate regenerator is one of the primary loss sources of the MCM system. R&D needs to be devoted to this area.
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How Magnetic Refrigeration Works
The magnetic refrigeration cycle is essentially a Brayton cycle with the potential for continuous regeneration that can approach Carnot efficiency.
• Cycle starts with MC material (MCM) at T0. • MCM is placed inside a higher magnetic field
resulting in MCM temperature increase to T0 + ΔT. • Heat is rejected from the MCM to ambient while
inside the higher magnetic field, reducing its temperature to T0.
• MCM is removed from the higher magnetic field, resulting in reduced temperature to T0 – ΔT.
• Heat is absorbed by MCM from a refrigerated compartment; increasing its temperature to T0 and the cycle is repeated.
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Achieving Large Temperature Span • Use different MCM alloys with different curie temperatures and layer
atop one another.
Layered bed
ΔT a
db
ΔT a
db
Tc1
Effective operating
range, material 1
Temperature
Effective operating range, material 1
Effective operating
range, material 2
Temperature Tc1 Tc2
0°F 100°F
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Impact of Finding a Way to Fabricate Microchannels from MCM
If we could develop a manufacturing process to make microchannels from MCM, then we could get a better heat transfer rate at the acceptable range of pressure drop and achieve a higher COP machine.
In competition between pressure drop and heat transfer, microchannels will win over a packed particle bed.
J. Tian, T. Kim, T.J. Lu, H.P. Hadson, D. T. Qucheillilt, D.J. Sypeck, H.N.H. Hadky. Int. J. Heat and Mass Transfer, 2004.
State of the art
Our goal
Heat
tran
sfer
/ pu
mp
powe
r ~
Message of the study: • Heat transfer in porous media
is mainly a function of ε, area. • Pressure drop in porous
media is mainly a function of ε, area, orientation.
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Approach 1: Resolution in printing Irregular Powder Regular Powder
Developing Manufacturing Process to 3D Print MCM Microchannels
Two MCM powders were printed with two different particle shapes
150-200 microns microchannels printed with one of these powders
Enhanced structures printed
Parameters studied: • Particle shape • Particle size • Orientation • Process and more
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Developing Manufacturing Process for Sintering and Pressing MCM
Sintering and pressing MCM is very challenging and a necessary, intermediate manufacturing process in MCM microchannel development. Note: Sintering is the process of compacting and forming a solid mass of material by heat and/or pressure without melting it to the point of liquefaction. After 8 months of R&D effort: • MCM die was successfully pressed • Mold-cast MCM parts were successfully sintered to
high densities (up to 99% of material density)
Findings: • Sintering conditions, including the right atmosphere,
temperature, oxygen level, and type of furnace were realized.
• Final densities of 97–99% were achieved.
Very Challenging Process
Restoring MCE properties is still a challenge
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Approach 2: MCM microchannels
Developing a Novel Manufacturing Process for Making 3-Dimensional Microchannels
ORNL is working on an innovative way to produce random elongated microchannels. This solution significantly reduces the pressure drop and provides very high interstitial heat transfer rates. It has the potential to produce random microchannels as small as 20–100 µm, which cannot be achieved by other manufacturing processes.
It is a propriety low-cost method which is different from the printing process.
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MCM microchannels
• Up to 10% enhancement of magnetization is achieved.
• Significant improvement in the hydrodynamic characteristics of MCM microchannel is reached.
A slice of the fabricated structure
1 mm
Pressure drop across the MCM before and after microchannel formation
Developing a Novel Manufacturing Process for Making 3-Dimensional Microchannels
The graph shows the temperature span across the three-stage, 3-dimensional microchannel AMR.
GEA performed 1000 cycles in its prototype magnetocaloric refrigeration unit to achieve this temperature span.
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GEA’s Recent Simulation will be the Guideline for Future Multi-stage Regenerator Development
Baseline as received powder
New process can do this
Competitive with VC systems
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Solid-State Magnetocaloric Refrigerator
8x improvement on heat transfer could be achievable after including the air gap thermal resistance. This is equivalent to 8x faster machine or 8x larger capacity or 8x reduction in size.
Approach 3: ORNL/GE estimate
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Prototyping: GEA’s Prototype Development Progress
Prototype 1 - early 2014 Prototype 2 - 2014
Prototype 3 - 2015 Prototype 4 - 2016
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Prototype Development Progress
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Project Integration: Three collaborating patents, with GEA weekly meetings between ORNL team members: • Bi-weekly meeting between ORNL and GEA • ORNL and GE have quarterly site visits Past successes in similar CRADAs show that such close collaboration with manufacturers is the best path to success.
Partners, Subcontractors, and Collaborators: GE Appliances for machine design ORNL for component improvement
Communications: • Two conference papers • ASHRAE presentation in 2016 • Google Hangout http://www.youtube.com/watch?v=uDF_COU1OJI • Several visitors from public, private, media, industry, DOE
Project Integration and Collaboration
http://www.youtube.com/watch?v=uDF_COU1OJI
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REFERENCE SLIDES
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Acknowledgments
ORNL Team
Building Eqpt. Res. Center
Additive Manufacturing
Material Sciences
GE Appliances Team
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Project Budget: DOE total $1588k Variances: None Cost to Date: $1689k Additional Funding: $286k
Budget History
FY 2016 (past)
FY 2017 (current)
FY 2018 (planned)
DOE Cost-share DOE Cost-share DOE Cost-share $539k 1-1 $360k 1-1 $286k 1-1
Project Budget
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Project Budget Project ScheduleProject Start: 01-Aug-2013 (FY13)Projected End: 30-Sept-2016
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Past Work
Descrip.hypothetical manuf. to shape regenerators Development of at least 3-stage regenerator using at least one of the selected manufacturing processes.
Developing complete regenerator via the selected manufacturing process.
Indentify testing procedures for comparable bed testingTesting, fabrication MCM microchannels by collaborating with GEAImprove preformance of regenerator strructureFinal optimization, testing and drafting the final reportCurrent/Future Work
Completed WorkActive Task (in progress work)Milestone/Deliverable (Originally Planned) use for missed Milestone/Deliverable (Actual) use when met on time
FY2015 FY2016 FY2017
Sheet1
Project Schedule
Project Start: 01-Aug-2013 (FY13)Completed Work
Projected End: 30-Sept-2016Active Task (in progress work)
Milestone/Deliverable (Originally Planned) use for missed milestones
Milestone/Deliverable (Actual) use when met on time
FY2015FY2016FY2017
TaskQ1 (Oct-Dec)Q2 (Jan-Mar)Q3 (Apr-Jun)Q4 (Jul-Sep)Q1 (Oct-Dec)Q2 (Jan-Mar)Q3 (Apr-Jun)Q4 (Jul-Sep)Q1 (Oct-Dec)Q2 (Jan-Mar)Q3 (Apr-Jun)Q4 (Jul-Sep)
Past Work
Descrip.hypothetical manuf. to shape regenerators
Development of at least 3-stage regenerator using at least one of the selected manufacturing processes.
Developing complete regenerator via the selected manufacturing process.
Current/Future Work
Indentify testing procedures for comparable bed testing
Testing, fabrication MCM microchannels by collaborating with GEA
Improve preformance of regenerator strructure
Final optimization, testing and drafting the final report
Current/Future Work
Slide Number 1Project SummaryPurpose and ObjectivesApproachProgress and AccomplishmentsHow Magnetic Refrigeration WorksAchieving Large Temperature SpanImpact of Finding a Way to Fabricate Microchannels from MCMApproach 1: Resolution in printingDeveloping Manufacturing Process for Sintering and Pressing MCMApproach 2: MCM microchannelsMCM microchannelsGEA’s Recent Simulation will be the Guideline for Future Multi-stage Regenerator Development Solid-State Magnetocaloric RefrigeratorPrototyping: GEA’s Prototype Development ProgressPrototype Development ProgressProject Integration and CollaborationSlide Number 18AcknowledgmentsProject BudgetProject Budget
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