Stirling engine

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Cut away diagram of a Rhombic Drive Beta Stirling Engine Design
Pink - Hot cylinder wall, Dark grey - Cold cylinder wall (with coolant inlet and outlet pipes in Yellow), Dark Green - Thermal insulation separating the two cylinder ends, Light Green - Displacer piston, Dark Blue - Power piston, Light Blue - Flywheels.

The Stirling engine is a closed-cycle piston heat engine. The term "closed-cycle" means that the working gas is permanently contained within the cylinder, unlike the "open-cycle" internal combustion engine and the steam engine which refesh their working gas (either air/fuel mixture , or high pressure steam respectively) every cycle. The Stirling engine is traditionally classified as an external combustion engine, despite the fact that heat can be supplied by non-combusting sources such as solar and nuclear energy. A Stirling engine operates through the use of an external heat source and an external heat sink, each maintained within a limited temperature range, and a having sufficiently large temperature difference between them.

Background

In the conversion of heat into mechanical work, Stirling engines can achieve the highest efficiency of any real heat engine, up to 80% of the Carnot efficiency, limited only by non-ideal properties of the working gas and engine materials, such as friction, thermal conductivity, tensile strength, creep, melting point, etc. The engines can theoretically run on any heat source of sufficient quality, including solar, chemical and nuclear.

In contrast to internal combustion engines, Stirling engines are usually more energy efficient, quieter, and more reliable with lower-maintenance requirements. They are preferred for certain niche applications that value these unique advantages, particularly in cases where the primary objective is not to minimize the capital cost per unit power ($/kW), but rather to minimize the cost per unit energy generated by the engine ($/kWh). Compared to an internal combustion engine of a given power rating, Stirling engines currently have a higher capital cost and are usually larger and heavier, thus the engine technology is rarely competitive on this basis alone. For some applications however, a proper Cost-benefit analysis can favor a Stirling engine over an internal combustion engine.

In recent years, the advantages of Stirling engines have become increasingly significant, given the general rise in energy costs, energy shortages and environmental concerns such as climate change. These growing interests in Stirling technology have fostered the ongoing research and development of Stirling devices. The applications include water pumping, space based Astronautics, and electrical generation from plentiful energy sources that are incompatible with the internal combustion engine, such as solar energy, agricultural waste and domestic refuse.

History

See the History and development section below.

The Stirling Engine was invented and developed by Reverend Dr Robert Stirling and his brother James, an engineer, over several years starting in 1816. The original patent by Rev. Stirling was called the "economizer", for its enhancement of fuel-economy. The patent also mentioned the possibility of using the device in an engine. Several patents were later awarded to the two brothers for different configurations including pressurized versions of the engine. This component is now commonly known as the "regenerator", and is essential in all high-power Stirling devices.

Functional Description

The engine cycle

A desktop alpha stirling engine. The working fluid in this engine is air. The hot heat exchange is the glass cylinder on the right, and the cold heat exchanger is the finned cylinder on the top. This engine uses a small alcohol burner (bottom right) as a heat source.

Since the Stirling engine is a closed cycle, it contains a fixed quantity of gas called a "working fluid", most commonly air, hydrogen or helium. In normal operation, the engine is sealed and no gas enters or leaves the engine. No valves are required, unlike other types of piston engines. The Stirling engine, like most heat-engines, cycles through four main processes: cooling, compression, heating and expansion. This is accomplished by moving the gas back and forth between hot and cold heat exchangers. The hot heat exchanger is in thermal contact with an external heat source, e.g. a fuel burner, and the cold heat exchanger being in thermal contact with an external heat sink, e.g. air fins. A change in gas temperature will cause a corresponding change in gas pressure, while the motion of the piston causes the gas to be alternately expanded and compressed.

The gas follows the behavior described by the gas laws which describe how a gas's pressure, temperature and volume are related. When the gas is heated, because it is in a sealed chamber, the pressure rises and this then acts on the power piston to produce a power stroke. When the gas is cooled the pressure drops and this means that less work needs to be done by the piston to compress the gas on the return stroke, thus yielding a net power output.

A Stirling engine and generator set with 55 kW electrical output, for combined heat and power applications. Click image for detailed description.

When one side of the piston is open to the atmosphere, the operation of the cold cycle is slightly different. As the sealed volume of working gas comes in contact with the hot side, it expands, doing work on both the piston and on the atmosphere. When the working gas contacts the cold side, the atmosphere does work on the gas and "compresses" it. Atmospheric pressure, which is greater than the cooled working gas, pushes on the piston.

To summarize, the Stirling engine uses the potential energy difference between its hot end and cold end to establish a cycle of a fixed amount of gas expanding and contracting within the engine, thus converting a temperature difference across the machine into mechanical power.

The greater the temperature difference between the hot and cold sources, the greater the power produced, and thus, the lower the efficiency required for the engine to run.

Small demonstration engines have been built which will run on a temperature difference of as little as 15 °C, e.g. between the palm of a hand and the surrounding air, or between room temperature and melting water ice. (Ref) , (Ref -pdf)

The Regenerator

In true Stirling engines a regenerator, typically a mass of metal wire, is located in the path of the gas between the hot and cold heat exchangers. As the gas cycles between the hot and sides, its heat is temporarily transferred to and from the regenerator.

In beta and gamma some designs (see below), there is a displacer piston which also acts as a regenerator. The displacer piston does not have a seal, and with a loose fit tolerances a small air gap between the piston and the cylinder allows the gas to flow around the displacer as it is displaced to the other end of the cylinder. In these designs, the surfaces of the displacer and cylinder alone provide some regeneration.

The regeneration contributes greatly to the overall efficiency and power produced by a Stirling engine. The regenerator was the key feature invented by Robert Stirling in 1816 which greatly improved his machine and distinguished it from other "hot air engines".

The regenerator is a reverse flow heat exchanger, which tends to improve thermal efficiency wherever it is found in technology or in nature.

Engine configurations

Engineers classify Stirling engines into three distinct types. The Alpha type engine relies on interconnecting the power pistons of multiple cylinders to move the working gas, with the cylinders held at different temperatures. The Beta and Gamma type Stirling engines use a displacer piston to move the working gas back and forth between hot and cold heat exchangers in the same cylinder.

Alpha Stirling

  • An alpha Stirling contains two separate power pistons in separate cylinders, one "hot" piston and one "cold" piston. The hot piston cylinder is situated inside the higher temperature heat exchanger and the cold piston cylinder is situated inside the low temperature heat exchanger. This type of engine has a very high power-to-volume ratio but has technical problems due to the usually high temperature of the "hot" piston and the durability of its seals. (See animation here [1])

Beta Stirling

  • A beta Stirling has a single power piston arranged within the same cylinder on the same shaft as a displacer piston. The displacer piston is a loose fit and does not extract any power from the expanding gas but only serves to shuttle the working gas from the hot heat exchanger to the cold heat exchanger. When the working gas is pushed to the hot end of the cylinder it expands and pushes the power piston. When it is pushed to the cold end of the cylinder it contracts and the momentum of the machine, usually enhanced by a flywheel, pushes the power piston the other way to compress the gas. Unlike the alpha type, the beta type avoids the technical problems of hot moving seals. (See animation here [2])

Action of a Beta type Stirling engine

1 Power piston (hatched) has compressed the gas, the displacer piston (grey) has moved so that most of the gas is adjacent to the hot heat exchanger.
2 The heated gas increases its pressure and pushes the power piston along the cylinder. This is the power stroke.



3 The displacer piston now moves to shunt the gas to the cold end of the cylinder.



4 The cooled gas is now compressed by the flywheel momentum. This takes less energy since when it cooled its pressure also dropped.

Gamma Stirling

  • A gamma Stirling is simply a beta Stirling in which the power piston is mounted in a separate cylinder alongside the displacer piston cylinder, but is still connected to the same flywheel. The gas in the two cylinders can flow freely between them but remains a single body. This configuration produces a lower compression ratio but is mechanically simpler and often used in multi-cylinder Stirling engines. (See animation here [3])

Other types

Changes to the configuration of mechanical Stirling engines continue to interest engineers and inventors. Notably, some are in pursuit of the rotary Stirling engine; the goal here is to convert power from the Stirling cycle directly into torque, a similar goal to that which led to the design of the rotary combustion engine. No practical engine has yet been built but a number of concepts, models and patents have been produced. [1]

There is also a field of "free piston" Stirling cycles engines, including those with liquid pistons and those with diaphragms as pistons.

An alternative to the mechanical Stirling engine is the fluidyne pump, which uses the Stirling cycle via a hydraulic piston. In its most basic form it contains a working gas, a liquid and two non-return valves. The work produced by the fluidyne goes into pumping the liquid.

Heat sources

Point focus parabolic dish with Stirling engine and its solar tracker at Plataforma Solar de Almería (PSA) in Spain.

Any temperature difference will power a Stirling engine and the term "external combustion engine" often applied to it is misleading. A heat source may be the result of combustion but can also be solar, geothermal, or nuclear or even biological. Likewise a "cold source" below the ambient temperature can be used as the temperature difference. (see liquid nitrogen economy). A cold source may be the result of a cryogenic fluid or iced water. Since small differential temperatures require large mass flows, parasitic losses in pumping the heating or cooling fluids rise and tend to reduce the efficiency of the cycle.

Because a heat exchanger separates the working gas from the heat source, a wide range of combustion fuels can be used, or the engine can be adapted to run on waste heat from some other process. Since the combustion products do not contact the internal moving parts of the engine, a Stirling engine can run on landfill gas containing siloxanes without the accumulation of silica that damages internal combustion engines running on this fuel. The life of lubricating oil is longer than for internal-combustion engines.

The U.S. Department of Energy in Washington, NASA Glenn Research Center in Cleveland, and Stirling Technology Co. of Kennewick, Wash., are developing a free-piston Stirling converter for a Stirling Radioisotope Generator. This device would use a plutonium source to supply heat.

History and development

Invention of the Stirling engine is credited to the Scottish clergyman Rev. Robert Stirling who, in 1816, made significant improvements to earlier designs and took out the first patent. He was later assisted in its development by his engineer brother James Stirling.

The inventors sought to create a safer alternative to the steam engines of the time, whose boilers often exploded due to the high pressure of the steam and the inadequate materials. Stirling engines will convert any temperature difference directly into movement.

Devices called air engines have been recorded from as early as 1699 around the time when the laws of gases were first set out. The English inventor Sir George Cayley is known to have devised air engines c. 1807. Robert Stirling's innovative contribution of 1816 was what he called the 'Economiser'. Now known as the regenerator, it stored heat from the hot portion of the engine as the air passed to the cold side, and released heat to the cooled air as it returned to the hot side. This innovation improved the efficiency of Stirling's engine enough to make it commercially successful in particular applications, and has since been a component of every air engine that is called a Stirling engine.

During the nineteenth century the Stirling engine found applications anywhere a source of low to medium power was required, a role that was eventually usurped by the electric motor at the century's end.

It was also employed in reverse as a heat pump to produce early refrigeration.

In the late 1940s, the Philips Electronics company in The Netherlands was searching for a versatile electricity generator to enable worldwide expansion of sales of its electronic devices in areas with no reliable electricity infrastructure. The company put a huge R&D research effort into Stirling engines building on research it had started in the 1930s and which lasted until the 1970s. The only lasting commercial product for Philips was its reversed Stirling engine: the Stirling cryocooler (see below).

Los Alamos National Laboratory has developed an "Acoustic Stirling Heat Engine" [4] with no moving parts. It converts heat into intense acoustic power which (quoted from given source) "can be used directly in acoustic refrigerators or pulse-tube refrigerators to provide heat-driven refrigeration with no moving parts, or ... to generate electricity via a linear alternator or other electroacoustic power transducer".

The Stirling Cycle

The ideal stirling cycle consists of four thermodynamic processes acting on the working fluid:

This ideal stirling cycle is commonly known as a "squared-cycle", because the transitions between the processes are discontinuous; so when the cycle is graphed on a Pressure-Volume plot, the shape of the cycle contains corners. A real stirling cycle in a stirling engine, requires relatively smooth motion which is commonly sinusoidal or quasi-sinusoidal. In this case the shape of the PV-plot is elliptical. Also in a real engine cycle, the heat transfer performance of the heat exchangers ranges from 100% effectiveness in an isothermal process, to 0% effectiveness in an adiabatic process (no heat transfer). The compression and expansion processes can be modeled as a polytropic processes [5]

,

where k is constant, and n is bounded by:

.

where is the specific heat capacity at constant volume (J/kgK) and is the specific heat capacity at constant pressure (J/kgK)

Compared to the ideal cycle, the efficiency of a real engine is reduced by irreversibilities, friction, and the loss of short-circuit conducted heat, so that the overall efficiency is often only about half of the ideal (Carnot) efficiency. [6]

Advantages of Stirling engines

  • The heat is external and the burning of a fuel-air mixture can be more accurately controlled.
  • They can run directly on any available heat source, not just one produced by combustion, so they can be employed to run on heat from solar, geothermal, biological or nuclear sources.
  • A continuous combustion process can be used to supply heat, so emission of unburned fuel can be greatly reduced.
  • Most types of Stirling engines have the bearing and seals on the cool side; consequently, they require less lubricant and last significantly longer between overhauls than other reciprocating engine types.
  • The engine as a whole is much less complex than other reciprocating engine types. No valves are needed. Fuel and intake systems are very simple.
  • They operate at relatively low pressure and thus are much safer than typical steam engines.
  • Low operating pressure allows the usage of less robust cylinders and of less weight.
  • They can be built to run very quietly and without air, for use in submarines or in space.
  • They start easily and run more efficiently in cold weather, features lacking in their internal combustion cousins.
  • A Stirling engine which is pumping water can be configured so that the pumped water cools the cool side. This is, of course, most effective when pumping cold water.
  • They are extremely flexible. They can be used as CHP (Combined Heat and Power) in winters and as coolers in summers (cryocooling).

Disadvantages of Stirling engines

  • Stirling engine designs require both input and output heat exchangers, which must contain the pressure of the working fluid at high temperature and resist corrosive effects of the heat source and of the atmosphere. These material requirements increase the cost of the engine, especially when they are designed to the high level of "effectiveness" (heat exchanger efficiency) needed for optimizing energy costs. However in some cases these costs are justified through the use of low-cost renewable fuel sources.
  • Stirling engines that run on small temperature differentials are quite large for the amount of power that they produce, due to the heat exchangers. Increasing the temperature differential and/or pressure allows smaller Stirling engines to produce more power.
  • Dissipation of waste heat is especially complicated because the coolant temperature is kept as low as possible to maximize thermal efficiency. This increases the size of the radiators, which can make packaging difficult. Along with materials cost, this has been one of the factors limiting the adoption of Stirling engines as automotive prime movers. However, for other applications high power density is not required, such as [propulsion], and stationary microgeneration systems using combined heat and power (CHP). ref)
  • A Stirling engine cannot start instantly; it literally needs to "warm up". This is true of all external combustion engines, but the warm up time may be shorter for Stirlings than for others of this type such as steam engines. Stirling engines are best used as constant speed engines.
  • Power output of a Stirling tends to be constant and to adjust can sometimes requires careful design and additional mechanisms. Typically, changes in output are achieved by varying the displacement of the engine (often through use of a swashplate crankshaft arrangement) or by changing the mass of working fluid. This property is less of a drawback in hybrid electric propulsion or "base load" utility generation where a constant power output is actually desirable.
  • Hydrogen's low viscosity, high thermal conductivity and specific heat makes it the most efficient working gas, in terms of thermodynamics and fluid dynamics, to use in a Stirling engine. However, given the high diffusion rate associated with this low molecular weight gas, hydrogen will leak through solid metal, thus it is very difficult to maintain pressure inside the engine for any length of time without replacement. Typically, auxiliary systems need to be added to maintain the proper quantity of working fluid. These systems can be a gas storage bottle or a gas generator. Hydrogen can be generated either by electrolysis of water, or by the reaction of acid on metal. Hydrogen can also cause the embrittlement of metals. Helium must be supplied by bottled gas. Some engines use air as the working fluid which is less thermodynamically efficient but minimizes the problems of gas containment and supply. Most technically advanced Stirling engines like those developed for United States government labs use helium as the working gas, because it functions close to the efficiency and power density of hydrogen with fewer of the material containment issues. Hydrogen is also a very flammable gas, while helium is inert. Compressed air can also be explosive because it contains a high partial pressure of oxygen. Oxygen can be removed from air through an oxidation reaction, or equivalently, bottled nitrogen can be used.

Applications

Combined heat and power applications

CHP is an economical source of mechanical or electrical power, which utilises a heat source in conjunction with a secondary heating application, usually a pre-existing energy use, such as an industrial process. Usually the primary heat source will enter the Stirling engine heater, since that will usually be at a higher temperature than the heating application, and the "waste" heat from the engine's heater will supply the secondary heating application. The power produced by the engine is often used to run an industrial or agricultural process, which in turn creates biomass waste refuse that can be used as free fuel for the engine, thus reducing waste removal costs. The overall process is very resourceful, thus making it efficient and cost-effective overall.

WhisperGen, a New Zealand firm with offices in Christchurch, has developed an "AC Micro Combined Heat and Power" stirling cycle engine. These microCHP units are gas-fired central heating boilers which sell power back into the electricity grid. WhisperGen announced in 2004 that they were producing 80,000 units for the residential market in the United Kingdom. A 20 unit trial in Germany started in 2006.

Solar power generation

Placed at the focus of a parabolic mirror a Stirling engine can convert solar energy to electricity with an efficiency better than photovoltaic cells. On August 11 2005, Southern California Edison announced an agreement to purchase solar powered Stirling engines from Stirling Energy Systems[7] over a twenty year period and in quantity (20,000 units) sufficient to generate 500 megawatts of electricity. These systems, on a 4,500 acre (19 km²) solar farm, will use mirrors to direct and concentrate sunlight onto the engines which will in turn drive generators.

Stirling cryocoolers

Any Stirling engine will also work in reverse as a heat pump: i.e. when a motion is applied to the shaft, a temperature difference appears between the reservoirs. One of their modern uses is in refrigeration and cryogenics.

The essential mechanical components of a Stirling cryocooler are identical to a Stirling engine. The turning of the shaft will compress the working gas causing its temperature to rise. This heat will then be dissipated by pushing the gas against a heat exchanger. Heat would then flow from the gas into this heat exchanger which would probably be cooled by passing a flow of air or other fluid over its exterior. The further turning of the shaft will then expand the working gas. Since it had just been cooled the expansion will reduce its temperature even further. The now very cold gas will be pushed against the other heat exchanger and heat would flow from it into the gas. The external side of this heat exchanger would be inside a thermally insulated compartment such as a refrigerator. This cycle would be repeated once for each turn of the shaft. Heat is in effect pumped out of this compartment, through the working gas of the cryocooler and dumped into the environment. The temperature inside the compartment will drop because its insulation prevents ambient heat from coming in to replace that pumped out.

As with the Stirling engine, efficiency is improved by passing the gas through a “Regenerator” which buffers the flow of heat between the hot and cold ends of the gas chamber.

The first Stirling-cycle cryocooler was developed at Philips in the 1950s and commercialized in such places as liquid nitrogen production plants. The Philips Cryogenics business evolved until it was split off in 1990 to form the Stirling Cryogenics & Refrigeration BV, Stirling The Netherlands. This company is still active in the development and manufacturing Stirling cryocoolers and cryogenic cooling systems.

A wide variety of smaller size Stirling cryocoolers are commercially available for tasks such as the cooling of sensors.

Thermoacoustic refrigeration uses a Stirling cycle in a working gas which is created by high amplitude sound waves.

Heat pump

A Stirling heat pump is very similar to a Stirling cryocooler, the main difference being that it usually operates at room-temperature and its principal application to date is to pump heat from the outside of a building to the inside, thus cheaply heating it.

As with any other Stirling device, heat flows from the expansion space to the compression space; however, in contrast to the Stirling engine, the expansion space is at a lower temperature than the compression space, so instead of producing work, an input of mechanical work is required by the system (in order to satisfy the second law of thermodynamics). When the mechanical work for the heat-pump is provided by a second Stirling engine, then the overall system is called a "heat-driven, heat-pump".

The expansion-side of the heat-pump is thermally coupled to the heat-source, which is often the external environment. The compression side of the Stirling device is placed in the environment to be heated, for example a building, and heat is "pumped" into it. Typically there will be thermal insulation between the two sides so there will be a temperature rise inside the insulated space.

Heat-pumps are by far the most energy-efficient types of heating systems. Stirling heat-pumps also often have a higher coefficient of performance than conventional heat-pumps. To date, these systems have seen limited commercial use; however, use is expected to increase along with market demand for energy conservation, and adoption will likely be accelerated by technological refinements.

Marine engines

Kockums[8], the Swedish shipbuilder, had built at least 10 commercially successful Stirling powered submarines during the 1980s. As of 2005 they have started to carry compressed oxygen with them. (No endurance stated.)

Nuclear power

There is a potential for nuclear-powered Stirling engines in electric power generation plants. Replacing the steam turbines of nuclear power plants with Stirling engines might simplify the plant, yield greater efficiency, and reduce the radioactive by-products. A number of breeder reactor designs use liquid sodium as coolant. If the heat is to be employed in a steam plant, a water/sodium heat exchanger is required, which raises some concern as sodium reacts violently with water. A Stirling engine obviates the need for water anywhere in the cycle.

United States government labs have developed a modern Stirling engine design known as the Stirling Radioisotope Generator for use in space exploration. It is designed to generate electricity for deep space probes on missions lasting decades. The engine uses a single displacer to reduce moving parts and uses high energy acoustics to transfer energy. The heat source is a dry solid nuclear fuel slug and the cold source is space itself.

Aircraft engines

They hold theoretical promise as aircraft engines. They are quieter, less polluting, gain efficiency with altitude (internal combustion piston engines lose efficiency), are more reliable due to fewer parts and the absence of an ignition system, produce much less vibration (airframes last longer) and safer, less explosive fuels may be used. (see below "Argument on why the Stirling engine can be applied in aviation" or "Why Aviation Needs the Stirling Engine" by Darryl Phillips, a 4-part series in the March 1993 to March 1994 issues of Stirling Machine World)

Geothermal energy

Some believe that the ability of the Stirling engine to convert geothermal energy to electricity and then to hydrogen may well hold the key to replacement of fossil fuels in a future hydrogen economy. [2]

Low temperature difference engines

A low temperature difference (Low Delta T) Stirling engine will run on any low temperature differential, for example the difference between the palm of a hand and room-temperature. Usually they are designed in a gamma configuration, for simplicity, and without a regenerator. They are typically unpressurized, running at near-atmospheric pressure. The power produced is less than one watt, and they are intended for demonstration purposes only. They are sold as toys and educational models.

References

  1. ^ Rotary Stirling Engines This site is intended to assist and support all enthusiasts who work to advance the cause of the Stirling Cycle engine. Accessed October 2006
  2. ^ The American Stirling Company Opinion on Geothermal Energy and the Stirling engine. Accessed December 2006.
  • Van Wylan, Gordon J. and Sontag, Richard F. (1976). Fundamentals of Classical Thermodynamics SI Version 2nd Ed. New York: John Wiley and Sons. ISBN 0-471-04188-2.{{cite book}}: CS1 maint: multiple names: authors list (link)
  • Walker, G. (1985). Free Piston Stirling Cycle Engines. Springer-Verlag. ISBN 0-387-15495-7.
  • Hargreaves, C. M. (1991). The Philips Stirling Engine. Elsevier Publishers. ISBN 0-444-88463-7.

Further reading

  • P. H. Ceperley (1979). "A pistonless Stirling engine — The traveling wave heat engine". J. Acoust. Soc. Am. 66: 1508–1513.
  • Beale Number, estimating the power output of a Stirling Engine

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