DESIGN AND MANUFACTURE OF A FUEL-LESS GENERATOR
ABSTRACT
The fuel-less generator is a flywheel energy storage system (FESS) which has attracted new research attention recently in applications like power quality, regenerative braking and uninterruptible power supply (UPS). As a sustainable energy storage method, flywheel energy storage has become a direct substitute for batteries in UPS and other electrical applications. The flywheel energy storage system is also known to act as a fuel-less generator working under the original idea of Chas Campbell, as further explained by Lee Tseung’s lead out theory. This project work however, presents an overview of the applications of FESS in power system and microgrid (MG), and also analyses the design parameters in order to improve the energy density of the fuel-less generator. The aim is to improve its value and enhance its applications in numerous fields such as renewable power generation and practical demonstration of the dynamics of flywheels to undergraduates. At the end of the project work, it was discovered that the flywheel energy storage system (the fuel-less generator), possessed a great power density (983.4kw/kg), capable of producing 3.5kw of electricity supply, although its energy density intensity (3.71kwh/kg) remains minimal, it however cripples it sustainability. The machine was also found out to be 75.9% efficient. From the research and results, certain parameters such as increasing the flywheel’s energy density have been discovered to enhance the machine’s sustainability. Thus, if these parameters are carefully implemented on the subsequent related works, we can tend towards achieving the self-sustainability and greater efficiency of the fuel-less generator using flywheel.
LIST OF FIGURES
Figure 3.1 Conceptual Rendition of a Fuel-Less Energy Generator Using Flywheel
Figure 3.2 Flywheel Fitted With Bearings
Figure 3.3 Block diagram of the fuel-less generator
Figure 3.4 An AC Generator
Figure 3.5 An AC Motor
Figure 3.6 The 50kg flywheel
Figure 3.7 The v belt drive
Figure 3.8 The roller bearing
Figure 3.9 Dimensions of the Frame
Figure 3.10 The measuring tape
Figure 3.11 The arc welding machine
Figure 3.12 The Bench Type Drilling Machine
Figure 3.13 Other tools used
Figure 3.14 The Fabrication Flow Chart
Figure 4.1 A graph of generated voltage against speed
Figure 4.2 A graph of power against speed
Figure 4.3 A graph of power against efficiency
Figure 4.4 A graph of efficiency against power when overloaded
Figure 4.5 A graph of electric load and generator speed
Figure 4.6 Comparison of the systems weight
Figure 4.7 comparison of the systems lifetime
Figure 4.8 Comparison of the system specific energy
Figure 4.9 comparison of the system specific power
LIST OF TABLES
Table 3.1 Breakdown of components and materials used
Table 4.1 Input Parameters for the Analysis
Table 4.2 Output Parameters for the Analysis
Table 4.3 Results from the Fabricated System
Table 4.4 Measured values from the fabricated design
Table 4.5 Comparisons between the systems
Table 4.6 Bill of Engineering Measurement and Evaluation
LIST OF ABBREVIATIONS
ABBREVIATION MEANING
AC Alternating Current
DC Direct Current
EDLC Electric Double Layer Capacitor
FESS Flywheel Energy Storage System
MG Micro-Grid
UPS Un-interruptible Power Supply
CHAPTER ONE
INTRODUCTION
1.1 Background of the Study
The desire and search for knowledge by man has brought about growth and development in all ramifications of life. The influence of technology on the growth and development of various aspects of human life cannot be overemphasized. However, the advent of technology has increased over time, and various aspects of human life have been positively impacted. One of the major outcomes of technology is the production of electrical power. The exert nature of electricity is not known but investigation indicate that it consist of small negative charge called Electron. When these electrons are static, static electricity is said to be developed, and when they are in motion, dynamic electricity is said to be developed. Power generation and distribution has been an indispensable factor in the progress of an economy, ranging from manufacturing, banking, media, health care, and aviation (Cibulka, 2009).
Since power has been defined by Knight (2004) as the rate of doing work; this simply means that the productivity of a country will largely depend on the availability of power from different source. The majority of problems of Nigeria are traceable to the erratic power supply nature of the country, where many activities has been paralyzed due to the power outrage. Analysis has clearly shown that Nigeria lose up to about ₦220 billion annually, due to unstable nature of the country power supply which has posed a threat, hence reducing the capacity of industries to increase productivity (James, 2005).
Environmental pollution which leads to degradation or depletion of ozone layer is one of the major problems caused by the use of generator with fossil fuels. Other problem includes land and water pollution, noise pollution, and fluctuating increase in price of fossil fuel. The fuel-less generator is the only way out of these discrepancies facing Nigeria today (Cibulka, 2009).
The fuel-less engine usually runs very smooth and quiet and the best part of the design is that it is free from air pollution, since there is no emission of dangerous gas like Carbon monoxide (CO), carbon-dioxide (CO2), etc. The speed are adjustable or can be built to run at one speed with engine which does not run on any type of gasoline, oil or other combustible fuel. The free electrical energy produced by the fuel-less generators is replaced back into the motor and reused by the motor (James, 2005).
Fuel-less generator are used to operate electrical equipment from the power produced by a car or boat battery or renewable energy sources, like solar panels or wind turbines. DC power is what batteries store, while AC power is what most electrical appliances need to run, so generator is necessary to convert the power into a usable form. The wave form of the generator is pure sine-wave. In pure sine-wave, the output voltage of a sine-wave generator has a sine wave-form like the sine wave-form of the mains / utility voltage. In a sine-wave, the voltage rises and falls smoothly with a smoothly changing phase angle and also changes its polarity instantly when it crosses 0 Volts. Fuel-less generators are used to operate sensitive electronic devices that require high quality waveform with little harmonic distortion. In addition, they have high surge capacity which means they are able to exceed their rated wattage for a limited time. This enables power motors to start easily which can draw up to seven times their rated wattage during start up. Virtually any electronic device will operate with the output from a pure sine fuel-less generator. There are primarily four properties that make the flywheel attractive for use as energy storage: High power density; Long cycle life; No degradation over time; easily estimated state-of-charge.
1.2 Types of Fuel-Less Generators
According to Morita et al. (2002), the fuel-less generator can be categorised into;
• Off-grid fuel-less generators: used in isolated systems where the inverter draws its DC energy from batteries charged by solar arrays and/or other sources, such as wind turbines, hydro turbines etc. Normally these do not interface in any way with the utility grid, and as such are not required to have anti-islanding protection.
• Grid-tied fuel-less generators: These systems match their phase with a utility-supplied sine wave. Grid-tie Fuel-less generator is designed to shut down automatically upon loss of utility supply (referred to as anti-islanding protection). They do not provide backup power during utility outages. In Ontario, any solar arrays that feed the utility grid (under the FIT/micro-FIT programs for example), are required to have anti-islanding protection.
• Battery backup: These are special Fuel-less generator which are designed to draw energy from a battery, manage the battery charge via an onboard charger, and export excess energy to the utility grid. These inverters are capable of supplying AC energy to selected loads during a utility outage, and are required to have anti-islanding protection.
However, Perry, (1997) also classified the fuel-less generator under two types; the wet and dry type fuel-less generator.
• The wet-type fuel-less generator - as the name implies, is a type of fuel-less generator that makes use of any component that contains liquid( e.g. battery) to enhance the production of electric power. It mainly consists of an electric DC motor, an electric generator, couplings and battery.
• The dry-type fuel-less generator – it is an environmentally friendly type of generator that does not make use of battery. These systems basically consist of an AC electric motor, flywheel, pulleys, belt drives, shafts and an electric generator.
1.3 Problem Statement
Many energy generating means such as wind turbines and photovoltaic cells suffer losses of energy when at their peak intensity, also in various denominations such as the academic institutions and churches, there are bound to be abrupt failure in power supply, hence the fuel-less generator is developed to address those issues by conserving or storing energy which is then released to be used during the failure periods, therefore enhancing un-interruptible power supply and fuel economy.
1.4 Aim of the Project
The aim of this project is to recover energy stored in flywheel by using principle of energy recovery system from flywheel and generating sufficient energy to run the project set up and also little additional energy to run external power supply.
1.5 Objectives of the Project
The objectives of this project work are;
• To fabricate the fuel-less generator using locally available materials.
• To analyze the input and output characteristics of the designed generator.
• To utilize a gravitational energy from the flywheel.
• To use the energy generated by the flywheel generator to power a load bank.
• To give a comparative overview of flywheel versus other technologies for energy storage systems.
1.6 Expected Benefits of the Project
The importance of the fuel-less generator cannot be overemphasized and are demonstrated thus;
• It is environmentally friendly as it produces no noise (noiseless operation) and emissions. In fact, it is possible for the machine to be kept indoors.
• It requires very low maintenance.
• It can be used in academic institutions; Akwa Ibom State University to be specific for powering the lecture halls and staff offices especially during the night hours where there is no power supply from the school.
• It can be used to enhance un-interrupted power supply, in power generating facilities that may fail.
• The fuel-less generator (FESS) can be incorporated in vehicle engines to enhance fuel economy as powers which were supposed to be lost are used to generate electricity to power the electronic facilities.
• FESS can be used at the landside of electrified railways to help regulate the line voltage thus improving the acceleration of unmodified electric trains and the amount of energy recovered back to the line during regenerative braking, thus lowering energy bills.
1.7 Scope and Limitations
The fuel-less generator for this project work stores kinetic energy, after which the kinetic energy is magnified in terms of its intensity. This magnified kinetic energy is converted into electrical energy according to Lee Tseung’s lead out theory to produce electrical power. The fuel-less generator can be used as a backup power generator for facilities powered by electric supply in cases where the source of the electrical power supply fails, thus enhancing un-interruptible power supply. It can be used as an energy storage device for renewable power applications.
However, the project setup cannot operate over a long period of time, because of the low energy density of the flywheel. It is also not self sustainable. Finally, the whole system is subjected to many losses such as losses due to air friction and mechanical losses from the mechanical bearings, which in turn reduces its efficiency.
1.8 Project Justification
The need to switch from the use of synthetic fuels due to the effect of global warming caused by the use of fossil fuels among other reasons has necessitated exploration of other means of energy generation. Although several attempts have been made to come up with a means of energy generation like this, these fuel-less generators are easy to build and operate, and are likely to be one of the most appropriate for developing countries as a source of decentralized power supply to rural communities and industries (FAO, 1986). Hence, the experimental scale fuel-less generator is needed for studies into how its efficiency can be improved and adapted to meet the local requirement of developing countries. This small scale fuel-less generator should serve as a model for the development of industrial scale fuel-less generators. Nigeria, whose dependence rests exclusively on the fossil fuels (crude oil), would undoubtedly benefit from this project as it explores the use of basic electrical and mechanical components in the country. Also, the large energy need or demand in the country can be met by employing the technology of this fuel-less generator.
1.9 Structure of the Report
Chapter 1 gives brief information about the fuel-less generator, its uses and its limitations. Chapter 2 reviews some literature on the fuel-less generator, and establishes the gaps in the literatures. Chapter 3 shows the different materials that were used to fabricate the project design, while the materials are chosen and methods that were obtained to fabricate the project design. Chapter 4 shows the different results and analysis that were obtained from the model calculations and the fabricated project. Chapter 5 emphasizes on the conclusion made and recommendations in order to make the manufacture of the project design a success.
