Stirling Engines for Biomass Applications

Engine Model SD4-E

Heater designed for biomass fuels Alternator integrated in hermetical design Optimized Stirling cycle design with high efficiency regenerator

Low maintenance, pressurised, oil-free crankcase

The external combustion of the Stirling engine makes it very attractive for small-scale Combined Heat and Power (CHP) plants using biomass fuels. Stirling Danmark has developed engines specifically designed for power production from biomass. THE STIRLING PRINCIPLE Stirling engines are based on a closed cycle, where the working gas is alternately compressed in a cold cylinder volume and expanded in a hot cylinder volume. The heat input from the combustion of fuel is transferred to the working gas through a hot heat exchanger (the heater) at a high temperature typically between 950C and 1050C. The heat drives the pistons, which drive the crankshaft directly coupled to alternator shaft for power production. The remaining heat is transferred to the water cooling system. DESCRIPTION The engine is designed as a hermetically sealed unit with the alternator incorporated in a pressurised crankcase. Only static seals are necessary between the Helium working gas in the crank case and the surrounding air. All bearings are greased and the engine interior is oilfree. Piston rings and piston rod sealing rings have been made from PFTE-based materials for dry-running. The inter-nal design of the engine eliminates the need for high pres-sure piston rod seals, which is known to give problems for majority of other Stirling engine designs. The four cylinder Stirling engine, SD4E, has a nominal electric power output of 35 kW. The cylinders are arranged in a square, and Helium is used as the working gas at a mean pressure of approximately 4,5 MPa. The

four heater panels form a square combustion chamber. The asynchronous alternator, which is also used as a starter motor, has 6 poles corresponding to an engine speed of approximately 1000 rpm when coupled directly to the power grid. The heater is designed specifically for direct combustion of biomass: Wide flue gas passages in the heater section Careful design of flow paths through the heater Large surface area per unit heat transferred Easy cleaning access of heater panels either manually or by shock blasts.

APPLICATION The engine can by driven by almost any heat source which can deliver hot (flue) gas flow at approx. 1000C with low or no particles and ashes. Currently the engine has been optimised for gasification of low-quality wood chips. Depending on the system design this could be from solid, liquid or gaseous fuels. Examples: Direct combustion of wood chips Gasification (indirect combustion) of wood chips and other solid biomass Pyrolysis of difficult solid biomass fuels Combustion of biogas or bio-oil. Combustion of waste products such as glycerine Add-on to large boilers on natural gas or biomass

RELIABILITY The engine has been optimised for low maintenance and a long life-time. The design life of the engine is 100,000 hours, with 4,000-hour service intervals. RESEARCH & DEVELOPMENT The current design is based on 15 years of research and development at the Technical University of Denmark. More than 40,000 hours of operation have been accumulated on existing engines. Research and development is continuous, w.r.t. electrical efficiency, new features and simplified maintenance. ENGINE FEATURES Sturdy design and hermetical sealing for increased lifetime in dusty environments Oil-free mechanism with greased bearings. No risk of oil contamination of heat transfer surfaces Few movable parts Patented yoke mechanism Non-hazardous helium working gas High electrical efficiency Heater designed for biomass combustion Control system Interface for combustion chamber Proven design, thoroughly tested and verified for long term trouble less operation Competitive life-cycle cost
Close-up of heater

ENGINE SPECIFICATION Engine type SD4E

No. of cylinders Bore, mm Stroke, mm Phase angle Working gas Helium filling, Nm Mean pressure, MPa Min/max process pressure, MPa Alternator poles for 50 / 60 Hz Engine speed at 50 / 60 Hz, rpm Maximum Continuous Rating, KWe Heat output in water, kWt Heater temperature C Heat input to heater at MCR, kW Max cooling water inlet temperatureC Mass in kg 4 142 76 90 Helium 9 4.5 3.3 / 5.7 6/8 1014 / 914 35 / 32 88.5 70050 125 60 2500

35 kW 4-cylinder engine

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