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Advanced Lean Burn Micro-CHP Genset

MAHLE Powertrain
Advanced Lean Burn Micro-CHP Genset
GENSETS Mahle
Program: 
ARPA-E Award: 
$3,572,223
Location: 
Farmington Hills, MI
Project Term: 
11/01/2015 to 12/31/2019
Project Status: 
ACTIVE
Technical Categories: 
Critical Need: 
In 2013, centralized U.S. power plants had an average electricity generation efficiency of only 33%, wasting 67% of primary energy as heat and emitting 2 billion tons of CO2, about 38% of U.S. total emissions. Further, 6% of electricity is generally lost during transmission and distribution from the power plant to the customer. An alternative to centrally produced power is distributed generation, in which electricity is generated at the point of use. Residential combined heat and power (CHP) systems can burn natural gas to produce electricity for a home while also using the waste heat for space and water heating. The potential energy efficiency for CHP systems is more than 80% and significant adoption of such systems would enable dramatic reductions in primary energy use and concurrent CO2 emissions. However, usage of small CHP systems is not widespread because systems currently on the market are limited by high price, low efficiency, and short lifetime. The GENSETS program seeks to develop 1 kW (electric) CHP generators that have high fuel-to-electricity generation efficiency, long life, low cost, and low emissions.
Project Innovation + Advantages: 
MAHLE Powertrain with partners at Oak Ridge National Laboratory, Louthan Engineering, Kohler Company, and Intellichoice Energy will design and develop a CHP generator that uses an internal combustion engine with a turbulent jet ignition (TJI) combustion system. Similar to an automotive internal combustion engine, the proposed system follows the same process: the combustion of natural gas fuel creates a force that moves a piston, transferring chemical energy to mechanical energy used in conjunction with a generator to create electricity. The TJI combustion system incorporates a pre-chamber combustor, enabling the engine to operate in ultra-lean conditions (i.e. high air to fuel mixture), which results in significant improvement in engine thermal efficiency. The team will further increase the system's efficiency by using low friction engine components, while a low-temperature after-treatment system will reduce exhaust emissions.
Potential Impact: 
If successful, MAHLE's project will facilitate development and commercialization of economical, efficient, and durable CHP systems for residential use. These advancements support progress toward ARPA-E's overall goals as follows:
Security: 
Innovations developed in this project could help households and businesses become more energy self-reliant and less susceptible to energy-related outages through distributed, local generation of power and heat.
Environment: 
Widespread adoption of high-efficiency residential CHP systems could decrease overall primary energy consumption and therefore reduce CO2 emissions associated with electricity generation by up to 10%.
Economy: 
Cost-effective natural gas-fueled residential CHP systems could offer consumers lower electricity and heating bills.
Contacts
ARPA-E Program Director: 
Dr. David Tew
Project Contact: 
Mr. Michael Bunce
Partners
Oak Ridge National Laboratory
Release Date: 
6/18/2015