West Virginia University Research Corporation (WVURC)

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.

West Virginia University Research Corporation (WVURC), along with its partners at ANSYS, Inc., Sustainable Engineering, Wilson Works, and Stryke Industries, will develop a CHP generator for residential use based on a two-stroke, spark-ignited free-piston internal combustion engine (ICE). Traditional internal combustion engines use the force generated by the combustion of a fuel (natural gas in this case) to move a piston, transferring chemical energy to mechanical energy, which when used in conjunction with a generator produces electricity. This free-piston design differs from traditional slider-crank ICE models by eliminating the crankshaft and using a spring to increase frequency and stabilize operation. The resulting design is compact with few moving parts and has reduced frictional losses. In place of a traditional alternator, this engine drives a permanent magnet linear electric generator.

If successful, West Virginia’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: