DOE OSTI2016
The need for reliable and distributable energy is evident, but one prominent obstacle is the lack of an efficient direct heat-to-electricity converter. The sodium thermo-electro-chemical converter (Na-TECC) is a highly efficient thermally regenerative electrochemical system (TRES) that can fill this void. This electrochemical technology uses an ion-selective solid-electrolyte called beta-alumina that is highly conductive to sodium cations. The Na-TECC generates electric power by allowing high pressure sodium cations to expand isothermally through the solid-electrolyte. Theoretically, a device interacting with thermal reservoirs at 1150 K and 550 K should operate above 45% efficiency, but actual devices have not surpassed efficiencies of 20%. The maximum potential voltage in these previous devices was substantially reduced by the kinetic limitations of the charge transfer in the cathode (referred to as the overpotential) and by Joule heating losses due to the solid-electrolyte resistance, electrode resistance, and current collector resistance. To overcome this discrepancy, a dual stage conversion process is being proposed. Rather than using one isothermal expansion step, the dual cycle will employ two separate electrolytes to allow two separate expansion steps: one at the high temperature, and another at an intermediate temperature. This new cycle is thermodynamically favorable as it allows for regeneration from the isobaric cooling of the first expansion step, and reheat to complete the expansion in the second step. This allows the engine to reach a lower condenser temperature than its single stage counterpart for a given heat input, resulting in an increased overall efficiency. The temperature drop across each electrolyte in the dual stage device (e.g., ~ 400 K) is smaller than the temperature drop across a comparable single stage device (e.g., ~ 800 K). This makes the device amenable to better thermal management and allows for less heat loss. Also, the intermediate stage will mitigate the thermal shock across the very thin (< 1 mm) solid electrolyte, reduce crack propagation, limit the percolation of the molten dendrites, and ultimately increase the lifetime of the device. A dual stage concept for the Na-TECC has never been demonstrated in literature, so it is necessary to properly re-define the thermodynamic parameters such as heat loss, maximum power, and optimal current density. Certain drawbacks from a dual stage concept will also be addressed, such as the need for larger electrochemical area and the increased pressure losses. It will be demonstrated that the dual stage device must have lower thermal losses than a single stage device if it is to have a higher efficiency. The improved operation of the Na-TECC can have a transformational effect on small combined heat and power (CHP) systems at the 1-5 kW range.