The Design, Construction, and Experimental Evaluation of a Compact Thermoacoustic-Stirling Engine Generator for Use in a micro-CHP Applianc

Micro combined heat and power or micro-CHP is the simultaneous generation of useful heat and electricity on a residential scale. The heat and electricity are produced at the point of use, avoiding the distribution losses associated with a centralized power plant. These appliances combine a conventional gas-fired condensing boiler with an electric power module capable of generating electricity from the heat of combustion. Currently, the leading power modules for micro-CHP appliances are free-piston Stirling engines (FPSEs) which can generate 1050 watts of electricity at a thermal-to-electric efficiency of 26%.[1] These external combustion engines have been under development for the last 25 years, with FPSE micro-CHP appliances only recently being introduced to the commercial market. Publications by developers assert unlimited service life and high efficiency, with low noise and emissions; but despite these claims, the actual reliability and cost of manufacturing has prevented their successful mass-market adoption. A Thermoacoustic-Stirling Engine Generator or TaSEG is one possible alternative to FPSE's. A TaSEG uses a thermoacoustic engine, or acoustic heat engine, which can efficiently convert high temperature heat into acoustic power while maintaining a simple design with fewer moving parts than traditional FPSE's. This simpler engine is coupled to an electrodynamic alternator capable of converting acoustic power into electricity. This thesis outlines the design, construction, and experimental evaluation of a TaSEG which is appropriate for integration with a gas burner inside of a residential micro- CHP appliance. The design methodology is discussed, focusing on how changes in the geometry affected the predicted performance. Details of its construction are given and the performance of the TaSEG is then outlined. The TaSEG can deliver 132 watts of electrical output power to an electric load with an overall measured thermal-to-electric (first law) efficiency of eta T--E=8.32%, corresponding to 14% of Carnot etac. The volumetric power density of this TaSEG is 8.9 kW/m3. While the demonstrated overall efficiency is modest (for reasons that are largely understood), this TaSEG has moved the technology away from laboratory prototypes toward a commercially viable power module having a design configuration suitable for implementation in a micro-CHP appliance. Based on the TaSEG's measured experimental performance results, recommendations for future work that might improve the overall efficiency of the TaSEG are also presented.