A StarDrive Dynamo Application Case Study

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Date: 9/24/03
to:  Dr. Robert Langgons
      Icefire Systems, Inc.
      Corinth, Mississippi

from:  Mark R. Tomion
           Archer Energy Systems, Inc.

Hello, Dr. Langgons:

   In response to our phone conversation of this morning, here's the EDF Generator thermal plant data and estimated pricing you requested:
         It is desired as proposed to build a liquid-cooled EDF Generator plant having
      between 350,000 and 500,000 gallons per day (gpd) of desalinization capacity,
      such plant to also be entirely self-sufficient for electrical power in operation,
      at a total budget of under $3,000,000.

   This project could be approached in a number of ways, but the prime consideration must be whether the intake water to be purified is brackish groundwater, raw seawater, or super-heavy brine from which the reclaiming of precious metals is intended. We assume that the output product is to be fully potable. For greatest flexibility of end-user application, the requisite dynamo size we selected is a 10 MW unit of 52.5" in diameter. We feel that we can build this dynamo model for about $450,000, given the relative ease with which the device itself can be linearly scaled (based on the production specifications for our 30"-dia. air-cooled prototype).
   However, the liquid-sodium primary coolant loops and heat exchanger system required to extract 10 MW in thermal energy from that dynamo will likely cost appr. $750,000 once it's been fully prototyped. Our most accurate current estimate for the installed price of an Aquatech desalination subsystem that requires 10 MW of heat energy input is  $1.625 million  for a multi-stage flash (MSF) distillation facility with an output capacity of 396,000 gpd of potable water – from any of the said sources. Using such an MSF subsystem would be essential  in order to produce potable water from super-heavy brine while at the same time allowing the recovery of any precious metals. With a custom gain output ratio of 4.2, as opposed to a "turnkey" package's GOR of 10.5, company engineers assure us that such a subsystem would not require any cooling tower.*  [Note: Precious metals recovery is perhaps best accomplished using an Ionics Calandria Crystallizer, whose cost is not included in this estimate.]
   * Technical details regarding verification of the 10 MW dynamo coolant system's thermal delivery capability as designed are provided at the end of this letter.
   If electrical self-sufficiency is desired or required for such a plant, a single Power Paragon 838-kW inverter would suffice to run all of the electrical equipment involved, at a current unit price of $160,000. Therefore, the total cost of the plant described thus far would be  $2,985,000. The basic specifications for this inverter are also provided hereinbelow.
   It must be stressed, however, that such a plant leaves over 90% of the electric power output capacity of the dynamo unit untapped! Moreover, producing potable water directly from a source other than super-heavy brine can be far more cost-effectively achieved using modular commercial reverse osmosis (RO) subsystems with standard-duty or seawater membranes (as necessary).
   For instance, the 10 MW dynamo unit using the same single inverter quoted would readily provide both the starting and run electrical loads presented by a total of 56 EHP Hydrosphere RO units, each having a 21,000 gpd seawater treatment capacity and an installed price of appr. $29,000. The total cost of such an EDF Generator plant would then still be  $2,985,000  but the output product capacity would rise to 1.176 Mgpd! In this case, the entire thermal output of the plant would still be available for use in any of a number of 'cogeneration' capacities, but extra expense may of course be incurred in arranging for the end utilization of the heat byproduct (which must be extracted proportional to the square of the no-load power resistor current).
   In selecting final plant design parameters to meet the requirements of your desired application(s), it should be noted that each such RO subsystem should be allocated 25 kW of inverter capacity to cover start current surge (given the 7.5hp pump moter used therein).
   In any event, this should provide you with most of the information you need to assist us in specifying the overall design of a complete StarDrive Dynamo utility plant to meet any of the various prospective applications you've mentioned in our earlier conversations. Please feel free to contact me at any time, though, if you have any further questions or concerns, and of course if you would like to proceed with construction of the 10 MW pilot plant under discussion.

Mark Tomion                                  
Archer Energy Systems, Inc.         

 NOTE A:  We have run the coolant flow rate computer spreadsheet for the 10 MW dynamo unit, and the necessary thermal delivery capability of the sodium piping system as designed has been verified for the following specifications.
      individual thermal conduits (total of 72):  0.241" ID:  pressure = 14.7 psi;
      manifolds (total of 12):  0.582" ID;  pressure = 41.7 psi;  and
      mainlines (total of 2):  1.388" ID;  pressure = 70.3 psi.

   The mass flow rate (liquid sodium) is 517.3 g/sec per conduit, with a conduit laminar flow velocity of just over 21.1 m/sec. Total mass flow G (for both mainlines) is 37.243 kg/sec. [These figures assume 85% overall thermal efficiency.]

 NOTE B:  Basic specifications for the modular DC-to-AC grid-synchronous solid-state power inverter unit that was designed specifically for  Archer Enterprises  (by Power Paragon, Inc. of Anaheim, CA)  are provided in the attached pdf Auxiliary Specifications document.

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