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Design optimisation of a micro turbine combined heat and power rotary shaft


Project Description

Problem Description:

SP spent 4 million pounds to date to design the CHP boiler. The boiler comes with a small size micro gas turbine mounted inside the boiler. The micro turbine’s rotary shaft should maintain 170,000 RPM. The life time for the boiler is 10 years while the life time of the rotary shaft is lower than the boiler life time warranty. It has been found the rotary shaft has inferior design compared to other components of the micro turbine.

Challenges

The mCHP rotary shaft made of typical steel material, but the use of combined high-performance materials is aimed. A new metal-ceramic hybrid design has been proposed to be replaced with the current rotary shaft.
On the other hand, to maintain a constant operating temperature for the shaft, design a cooling system has been suggested.

Project managment

The main technical objective of this project is to design a rotary shaft which will be tested in an integrated prototype of the mCHP application. Prototypes of the rotary shaft will be built tested under UH team leadership.

The project will require new design, fabrication and assembly expertise from the partners to produce. A proven methodology adapted from the automotive industry with adequate control and verification steps with staged EP and VP allow for flexibility to achieve a robust end product. SP involves the aero-thermal analysis of the high efficiency air-cooled turbine, gas compressor and combustor. We shall do FE of the shaft and CFD analysis of the cooling system. Rotor dynamic analysis will be done along with preparation of test cell.
A quarterly meeting will review the team performance, risk status, existing issues and update the lesson learned log. The project outcomes will be presented in Q1 journals.

Potential market

There are about 26 million boilers in the UK only. The annual boiler market size reaches 1.6 million boiler installation per year.

Potential fund

There is a potential to apply for 400,000 from the Innovate UK.

Application Web Page

Applicants must apply using the online form on the University Alliance website at https://unialliance.ac.uk/dta/cofund/how-to-apply/. Full details of the programme, eligibility details and a list of available research projects can be seen at https://unialliance.ac.uk/dta/cofund/

Funding Notes

DTA3/COFUND participants will be employed for 36 months with a minimum salary of (approximately) £20,989 per annum. Tuition fees will waived for DTA3/COFUND participants who will also be able to access an annual DTA elective bursary to enable attendance at DTA training events and interact with colleagues across the Doctoral Training Alliance(s).
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under the Marie Skłodowska-Curie grant agreement No 801604.

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