Innovative Phase Change Thermal Energy Storage Solution for Baseload Power Phase 1 Final Report

The primary purpose of this project is to develop and validate an innovative, scalable phase change salt thermal energy storage (TES) system that can interface with Infinia’s family of free-piston Stirling engines (FPSE). This TES technology is also appropriate for Rankine and Brayton power converters. Solar TES systems based on latent heat of fusion rather than molten salt temperature differences, have many advantages that include up to an order of magnitude higher energy storage density, much higher temperature operation, and elimination of pumped loops for most of Infinia’s design options. DOE has funded four different concepts for solar phase change TES, including one other Infinia awarded project using heat pipes to transfer heat to and from the salt. The unique innovation in this project is an integrated TES/pool boiler heat transfer system that is the simplest approach identified to date and arguably has the best potential for minimizing the levelized cost of energy (LCOE). The Phase 1 objectives are to design, build and test a 1-hour TES proof-of-concept lab demonstrator integrated with an Infinia 3 kW Stirling engine, and to conduct a preliminary design of a 12-hour TES on-sun prototype

Free-Piston Stirling Engine Generators

Free-Piston Stirling Engines (FPSEs) have recently attracted attention as a promising energy conversion technology because of their desirable characteristics such as high efficiency, high reliability, and easy and quiet operation. FPSE are truly a closed cycle system that works using variations in the internal pressure to drive the power piston that is connected to the reciprocating magnets in a linear alternator for energy conversion. The lack of manual linages and the use of clearance seals in a FPSE increase both the system’s reliability and lifespan, as there is no contact or wear on the seals. These desirable attributes coupled with the fuel independence of FPSE makes them ideal candidates for use in remote power generation applications, particularly where maintenance is a high concern such as in NASA deep space missions, solar power generator, and combined heat and power systems. This chapter presents an introduction to FPSE along with a brief review of the underlying thermodynamics and Stirling cycle analysis. The general engineering analysis and numerical modeling approaches of Stirling engines will be discussed, followed by a section of engine design and efficiency calculations

Active vibration and balance system for closed cycle thermodynamic machines

An active balance system is provided for counterbalancing vibrations of an axially reciprocating machine. The balance system includes a support member, a flexure assembly, a counterbalance mass, and a linear motor or an actuator. The support member is configured for attachment to the machine. The flexure assembly includes at least one flat spring having connections along a central portion and an outer peripheral portion. One of the central portion and the outer peripheral portion is fixedly mounted to the support member. The counterbalance mass is fixedly carried by the flexure assembly along another of the central portion and the outer peripheral portion. The linear motor has one of a stator and a mover fixedly mounted to the support member and another of the stator and the mover fixedly mounted to the counterbalance mass. The linear motor is operative to axially reciprocate the counterbalance mass. A method is also provided

Active balance system and vibration balanced machine

An active balance system is provided for counterbalancing vibrations of an axially reciprocating machine. The balance system includes a support member, a flexure assembly, a counterbalance mass, and a linear motor or an actuator. The support member is configured for attachment to the machine. The flexure assembly includes at least one flat spring having connections along a central portion and an outer peripheral portion. One of the central portion and the outer peripheral portion is fixedly mounted to the support member. The counterbalance mass is fixedly carried by the flexure assembly along another of the central portion and the outer peripheral portion. The linear motor has one of a stator and a mover fixedly mounted to the support member and another of the stator and the mover fixedly mounted to the counterbalance mass. The linear motor is operative to axially reciprocate the counterbalance mass

Hybrid phase-change Lattice Boltzmann simulation of vapor condensation on vertical subcooled walls

Saturated vapor condensation on homogenous and heterogeneous subcooled walls is presented in this study by adopting a hybrid phase-change multiple-relaxation-time Lattice Boltzmann model. The effects of wall wettability on the condensation process, including droplets’ growth, coalescence and falling, and the influence of vapor flow to condensation are investigated. The results demonstrate that the heat fluxes around the triple-phase contact lines are higher than that in other cold areas in homogeneous subcooled walls, which actually indicates the fact that filmwise condensation is preventing the continuous condensation process. Furthermore, the dropwise condensation can be formed more easily on the heterogeneous surface with a mixed surface wettability. At last, the dynamic process of condensation of continuous vapor flow is also investigated by considering the homogenous and heterogeneous subcooled surfaces. The results show that the heterogeneous surface with mixed wettability doesn’t contribute to the formation, growth of droplets, when compared to the homogeneous surface. It is expected that this study can bring more attentions to simulate condensation using multiphase LBM for complex geometries in heat transfer community

A Microfabricated Segmented-Involute-Foil Regenerator for Enhancing Reliability and Performance of Stirling Engines

An actual-size microfabricated regenerator comprised of a stack of 42 disks, 19 mm diameter and 0.25 mm thick, with layers of microscopic, segmented, involute-shaped flow channels was fabricated and tested. The geometry resembles layers of uniformly-spaced segmented-parallel-plates, except the plates are curved. Each disk was made from electro-plated nickel using the LiGA process. This regenerator had feature sizes close to those required for an actual Stirling engine but the overall regenerator dimensions were sized for the NASA/Sunpower oscillating-flow regenerator test rig. Testing in the oscillating-flow test rig showed the regenerator performed extremely well, significantly better than currently used random-fiber material, producing the highest figures of merit ever recorded for any regenerator tested in that rig over its approximately 20 years of use

A Microfabricated Segmented-Involute-Foil Regenerator for Enhancing Reliability and Performance of Stirling Engines: Phase II Final Report for the Radioisotope Power Conversion Technology NRA Contract NAS3-03124

An actual-size microfabricated regenerator comprised of a stack of 42 disks, 19 mm diameter and 0.25 mm thick, with layers of microscopic, segmented, involute-shaped flow channels was fabricated and tested. The geometry resembles layers of uniformly-spaced segmented-parallel-plates, except the plates are curved. Each disk was made from electro-plated nickel using the LiGA process. This regenerator had feature sizes close to those required for an actual Stirling engine but the overall regenerator dimensions were sized for the NASA/Sunpower oscillating-flow regenerator test rig. Testing in the oscillating-flow test rig showed the regenerator performed extremely well, significantly better than currently used random-fiber material, producing the highest figures of merit ever recorded for any regenerator tested in that rig over its ~20 years of use

Microfabricated Segmented-Involute-Foil Regenerator for Stirling Engines

An involute-foil regenerator was designed, microfabricated, and tested in an oscillating-flow test rig. The concept consists of stacked involute-foil nickel disks (see figure) microfabricated via a lithographic process. Test results yielded a performance of about twice that of the 90-percent random-fiber currently used in small Stirling converters. The segmented nature of the involute- foil in both the axial and radial directions increases the strength of the structure relative to wrapped foils. In addition, relative to random-fiber regenerators, the involute-foil has a reduced pressure drop, and is expected to be less susceptible to the release of metal fragments into the working space, thus increasing reliability. The prototype nickel involute-foil regenerator was adequate for testing in an engine with a 650 C hot-end temperature. This is lower than that required by larger engines, and high-temperature alloys are not suited for the lithographic microfabrication approach

A Microfabricated Involute-Foil Regenerator for Stirling Engines

A segmented involute-foil regenerator has been designed, microfabricated and tested in an oscillating-flow rig with excellent results. During the Phase I effort, several approximations of parallel-plate regenerator geometry were chosen as potential candidates for a new microfabrication concept. Potential manufacturers and processes were surveyed. The selected concept consisted of stacked segmented-involute-foil disks (or annular portions of disks), originally to be microfabricated from stainless-steel via the LiGA (lithography, electroplating, and molding) process and EDM (electric discharge machining). During Phase II, re-planning of the effort led to test plans based on nickel disks, microfabricated via the LiGA process, only. A stack of nickel segmented-involute-foil disks was tested in an oscillating-flow test rig. These test results yielded a performance figure of merit (roughly the ratio of heat transfer to pressure drop) of about twice that of the 90% random fiber currently used in small ~ 100 W Stirling space-power convertors in the Reynolds Number range of interest (50-100). A Phase III effort is now underway to fabricate and test a segmented-involute-foil regenerator in a Stirling convertor. Though funding limitations prevent optimization of the Stirling engine geometry for use with this regenerator, the Sage computer code will be used to help evaluate the engine test results. Previous Sage Stirling model projections have indicated that a segmented-involute-foil regenerator is capable of improving the performance of an optimized involute-foil engine by 6-9%; it is also anticipated that such involute-foil geometries will be more reliable and easier to manufacture with tight-tolerance characteristics, than random-fiber or wire-screen regenerators. Beyond the near-term Phase III regenerator fabrication and engine testing, other goals are (1) fabrication from a material suitable for high temperature Stirling operation (up to 850 C for current engines; up to 1200 C for a potential engine-cooler for a Venus mission), and (2) reduction of the cost of the fabrication process to make it more suitable for terrestrial applications of segmented involute foils. Past attempts have been made to use wrapped foils to approximate the large theoretical figures of merit projected for parallel plates. Such metal wrapped foils have never proved very successful, apparently due to the difficulties of fabricating wrapped-foils with uniform gaps and maintaining the gaps under the stress of time-varying temperature gradients during start-up and shut-down, and relatively-steady temperature gradients during normal operation. In contrast, stacks of involute-foil disks, with each disk consisting of multiple involute-foil segments held between concentric circular ribs, have relatively robust structures. The oscillating-flow rig tests of the segmented-involute-foil regenerator have demonstrated a shift in regenerator performance strongly in the direction of the theoretical performance of ideal parallel-plate regenerators

Innovative Phase Change Thermal Energy Storage Solution for Baseload Power Phase 1 Final Report

The primary purpose of this project is to develop and validate an innovative, scalable phase change salt thermal energy storage (TES) system that can interface with Infinia’s family of free-piston Stirling engines (FPSE). This TES technology is also appropriate for Rankine and Brayton power converters. Solar TES systems based on latent heat of fusion rather than molten salt temperature differences, have many advantages that include up to an order of magnitude higher energy storage density, much higher temperature operation, and elimination of pumped loops for most of Infinia’s design options. DOE has funded four different concepts for solar phase change TES, including one other Infinia awarded project using heat pipes to transfer heat to and from the salt. The unique innovation in this project is an integrated TES/pool boiler heat transfer system that is the simplest approach identified to date and arguably has the best potential for minimizing the levelized cost of energy (LCOE). The Phase 1 objectives are to design, build and test a 1-hour TES proof-of-concept lab demonstrator integrated with an Infinia 3 kW Stirling engine, and to conduct a preliminary design of a 12-hour TES on-sun prototype