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STIRLOCHARGER POWERED by EXHAUST HEAT for HIGH EFFICIENCY COMBUSTION and ELECTRIC GENERATION Adhiraj B

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STIRLOCHARGER POWERED BY EXHAUST HEAT FOR HIGH EFFICIENCY COMBUSTION AND ELECTRIC GENERTION

Adhiraj B. Mathur

Purdue University

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Mathur, Adhiraj B., "STIRLOCHARGER POWERED BY EXHAUST HEAT FOR HIGH EFFICIENCY COMBUSTION AND ELECTRIC GENERTION" (2015). Open Access eses. 1153.

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STIRLOCHARGER POWERED BY EXHAUST HEAT FOR HIGH EFFICIENCY COMBUSTION AND
ELECTRIC GENERATION

A Thesis
Submitted to the Faculty of
Purdue University by
Adhiraj B. Mathur

In Partial Fulfillment of the Requirements for the Degree of
Master of Science in Mechanical Engineering Technology

December 2015 Purdue University
West Lafayette, Indiana ii
ACKNOWLEDGEMENTS
I would like to thank my advisor Dr. Henry Zhang, the advisory committee, my family and friends for supporting me through this journey. iii
TABLE OF CONTENTS
Page
LIST OF TABLES....................................................................................................................vi LIST OF FIGURES.................................................................................................................vii LIST OF ABBREVIATIONS .....................................................................................................xi ABSTRACT..........................................................................................................................xiii CHAPTER 1 INTRODUCTION............................................................................................. 1
1.1 1.2
Scope............................................................................................................. 3
Significance ............................................................................................... 4

1.3 1.4 1.5 1.6 1.7 1.8
Research Question .................................................................................... 5 Assumptions.............................................................................................. 6 Limitations................................................................................................. 6 Delimitations............................................................................................. 7 Definition of Key Terms............................................................................. 7 Summary ................................................................................................... 8
CHAPTER 2 LITERATURE REVIEW..................................................................................... 9

Performance of Stirling Engines.............................................................. 13
Study of torque on a β-type Stirling engine..................................... 13 Study of torque and pressure of a Stirling engine ........................... 15 Variations of volume with crank angle ............................................ 18 Study of noise................................................................................... 22 Turbocharger performance in low exhaust environment ............... 24 Heat transfer from the turbine wall to compressor wall................. 26
2.2
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 iv
Page
Friction losses in Turbochargers ...................................................... 29 Super Stirling Engine ........................................................................ 32 Working fluids for Stirling engines................................................... 34 Stirling engine design parameters ................................................... 35 Stirling engine with a low temperature differential ........................ 36 β-Stirling engine with a rhombic drive............................................. 37 Summary .......................................................................................... 39
2.2.7 2.2.8 2.2.9 2.2.10 2.2.11 2.2.12 2.3
CHAPTER 3 RESEARCH METHODOLOGY ........................................................................ 41
3.1

3.2 3.3
Data Collection Methods ........................................................................ 41 Analysis.................................................................................................... 44 Threats To Validity .................................................................................. 45
CHAPTER 4 RESULTS....................................................................................................... 46

Engine to Stirlocharger Relationship....................................................... 46 Pressure of Working Gas In Stirlocharger............................................... 47 β-Stirlocharger Power ............................................................................. 49 α-Stirlocharger Power ............................................................................. 50 Compressor Speed of Stirlocharger ........................................................ 50 Compressor Boost Pressure.................................................................... 51 Stirlocharger Compressor Mass Flow Rate............................................. 52 Stirlocharger Thermal Efficiency............................................................. 53 Response Time of Stirlocharger .............................................................. 54 Gear Train Analysis.................................................................................. 55 Numerical Simulations ............................................................................ 56 β-Stirlocharger.................................................................................. 56 α-Stirlocharger.................................................................................. 60
4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12
4.12.1 4.12.2
CHAPTER 5 SUMMARY, CONCLUSIONS AND RECOMMENDATIONS............................. 64

v
Page
3D Model of the α-Stirlocharger...................................................... 66
MANUFACTURED PROTOTYPE ................................................................ 68 β-Stirlocharger Prototype ................................................................ 68 α-Stirlocharger Prototype ................................................................ 70
Baseline Tests.......................................................................................... 71
Torque Test on Compressor Impellor .............................................. 71
Turbine Backpressure Measurement Test.............................................. 72
Turbine without the compressor attached...................................... 74 Turbine with the compressor attached ........................................... 75 Backpressure Test Results................................................................ 75
Conclusions ............................................................................................. 77 Design...................................................................................................... 77
Performance..................................................................................... 80 Conclusion........................................................................................ 87
Recommendations .................................................................................. 89
5.1.2
5.2
5.2.1 5.2.2
5.3
5.3.1
5.4
5.4.1 5.4.2 5.4.3
5.5 5.5.1
5.5.2 5.5.3
5.6

LIST OF REFERENCES ................................................................................................... 91 APPENDIX ................................................................................................................... 94

vi
LIST OF TABLES

Table...............................................................................................................................Page

Table 2.2-1: Relative heat transfer characteristics for various gases (Thombare, 2006). 35

Table 5-1: β-Stirlocharger Specifications .......................................................................... 65 Table 5-2: α-Stirlocharger Specifications .......................................................................... 67 vii
LIST OF FIGURES

Figure .............................................................................................................................Page

Figure 2-1: The β-Stirling Engine Schematic(Foster, 2011) .............................................. 11 Figure 2-2: The Ideal Stirling cycle (Scollo, 2008) ............................................................. 12 Figure 2-3: Variation of cold Power and Torque as engine speed is increased for heater temperature 350°C of a β-Stirling(Sripakgorn et. al., 2010)............................................. 17 Figure 2-4: Variation of cold volume, hot volume, and total volume with crank angle (Karabulet et. al., 2010). ................................................................................................... 18 Figure 2-5: Variation of brake power with engine speed (Karabulet et. al., 2010).......... 21 Figure 2-6: Variation of brake power and engine torque with charge pressure (Karabulet et. al., 2010). ..................................................................................................................... 21 Figure 2-7: Direction of heat flux in a Turbocharger system (Aghaali, 2013)................... 28 Figure 2-8: Stirling cycle with single multi-phase working fluid (Gu, 2001) ..................... 36 Figure.2-9: Rhombic drive mechanism for a β-Stirling engine (Cheng, 2013).................. 38 Figure 3-1: Proposed sensor location and Stirlocharger Schematic................................. 42 Figure 4-1: Planetary Gear Train Schematic ..................................................................... 55 Figure 4-2: The variation in the hot and cold volumes of the β-Stirlocharger. ................ 56 viii

  • Figure
  • Page

Figure 4-3: The pressure of the β-Stirlocharger is shown with respect to the crank angle. The peak pressure is 147.98 kPa....................................................................................... 57 Figure 4-4: The simulated power of the β-Stirlocharger using the equations described in section 4.2......................................................................................................................... 57 Figure 4-5: Simulated Speed of the β-Stirlocharger using the equations in described in section 4.3......................................................................................................................... 58 Figure 4-6: Simulated output Boost Pressure of the β-Stirlocharger. .............................. 58 Figure 4-7: Simulated mass flow rate of air through the β-Stirlocharger compressor. ... 59 Figure 4-8: Simulated β-Stirlocharger thermal efficiency................................................. 59 Figure 4-9: The variation in the hot and cold volumes of the α-Stirlocharger. ................ 60 Figure 4-10: The pressure of the α-Stirlocharger is shown with respect to the crank angle. The peak pressure is 2550 kPa.......................................................................................... 60 Figure 4-11: The simulated power of the α-Stirlocharger using the equations described in section 4.2......................................................................................................................... 61 Figure 4-12: Simulated Speed of the α-Stirlocharger using the equations in described in section 4.3......................................................................................................................... 61 Figure 4-13: Simulated output Boost Pressure of the α-Stirlocharger............................. 62 Figure 4-14: Simulated mass flow rate of air through the α-Stirlocharger compressor... 62 Figure 4-15: Simulated β-Stirlocharger thermal efficiency............................................... 63 Figure 5-1: β-Stirlocharger 3D Model Schematic.............................................................. 64 ix

  • Figure
  • Page

Figure 5-2: α-Stirlocharger 3D Model Schematic.............................................................. 66 Figure 5-3: α-Stirlocharger Piston-Cylinder Rotational Schematic. (a) Normal position of the piston-cylinder, piston near pivot. (b) Piston-Cylinder rotates 15° CW as Piston approached TDC. (c) Piston-Cylinder rotates 15° CCW as Piston approached BDC......... 67 Figure 5-4: β-Stirlocharger................................................................................................ 68 Figure 5-5: Interior cylinder friction Zone......................................................................... 69 Figure 5-6: Force acting on the piston for (a) Stationary condition, (b) Pulling outward condition, (c) Pushing inward condition ........................................................................... 69 Figure 5-7: α-Stirlocharger................................................................................................ 70 Figure 5-8: α-Stirlocharger Flywheel Pivot........................................................................ 71 Figure 5-9: Impellor with Aluminum arm and thread loading.......................................... 72 Figure 5-10: Backpressure Test Bench.............................................................................. 73 Figure 5-11: Backpressure test schematic without compressor ...................................... 75 Figure 5-12: Air velocity measurements taken within the exhaust manifold of the test bench................................................................................................................................. 76 Figure 5-13: Pressure Differential measurements taken within the exhaust manifold of the test bench................................................................................................................... 77 Figure 6-1: A comparison of the β and α Stirlocharger output power .............................. 80 x

  • Figure
  • Page

Figure 6-2: Increase in the area within the P-V diagram for the Stirlocharger. (a) P-V diagram for β-Stirlocharger at engine speed 100 RPM, (b) P-V diagram for β- Stirlocharger at engine speed 6000 RPM, (c) P-V diagram for α-Stirlocharger at engine speed 100 RPM, (d) P-V diagram for α-Stirlocharger at engine speed 6000 RPM ........... 82 Figure 6-3: Comparison between the Speed of the Stirlocharger for α and β engines.... 82 Figure 6-4: Comparison of the boost pressure generated by the α and β engines.......... 83 Figure 6-5: IHI RHF4 Compressor Map showing the peak and average dP produced by the α-Stirlocharger............................................................................................................ 84 Figure 6-6: A comparison of the α and β Stirlocarger compressor mass flow rates. ....... 85 Figure 6-7: A comparison of the thermal efficiencies between the α and β Stirlochargers.................................................................................................................... 86 Figure 6-8: Comparison of the affect on engine performance between the α and β engine................................................................................................................................ 87 xi
LIST OF ABBREVIATIONS

  • IC
  • Internal Combustion

EGR Exhaust Gas Recirculation

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  • Glossary of Combustion

    Glossary of Combustion

    Glossary of Combustion Maximilian Lackner Download free books at Maximilian Lackner Glossary of Combustion 2 Download free eBooks at bookboon.com Glossary of Combustion 2nd edition © 2014 Maximilian Lackner & bookboon.com ISBN 978-87-403-0637-8 3 Download free eBooks at bookboon.com Glossary of Combustion Contents Contents Preface 5 1 Glossary of Combustion 6 2 Books 263 3 Papers 273 4 Standards, Patents and Weblinks 280 5 Further books by the author 288 4 Click on the ad to read more Download free eBooks at bookboon.com Glossary of Combustion Preface Preface Dear Reader, In this glossary, more than 2,500 terms from combustion and related fields are described. Many of them come with a reference so that the interested reader can go deeper. The terms are translated into the Hungarian, German, and Slovak language, as Central and Eastern Europe is a growing community very much engaged in combustion activities. Relevant expressions were selected, ranging from laboratory applications to large-scale boilers, from experimental research such as spectroscopy to computer simulations, and from fundamentals to novel developments such as CO2 sequestration and polygeneration. Thereby, students, scientists, technicians and engineers will benefit from this book, which can serve as a handy aid both for academic researchers and practitioners in the field. This book is the 2nd edition. The first edition was written by the author together with Harald Holzapfel, Tomás Suchý, Pál Szentannai and Franz Winter in 2009. The publisher was ProcessEng Engineering GmbH (ISBN: 978-3902655011). Their contribution is acknowledged. Recommended textbook on combustion: Maximilian Lackner, Árpád B.