DOE OSTI2015
The need for reliable and distributable energy sources is evident given the current forecasting of the world’s energy demand [1]. One prominent obstacle is the lack of an efficient direct heat-to-electricity conversion technology. The sodium thermo-electro-chemical converter (Na-TECC) is a highly efficient thermally regenerative electrochemical system (TRES) that can fill this void. The advantage of the Na-TECC over other direct conversion technologies is that it is a closed device (unlike fuel cells) requiring nothing more than a heat input (similar to thermoelectrics). It also has a high power density (> 1 W/cm2) and specific power up to 0.5 kW/kg , with the potential to achieve > 45% heat to electricity conversion efficiencies [2]. Furthermore, the converter rejects heat at a temperature hot enough to make it amenable for cogeneration, potentially under air-cooled operation. This electrochemical technology uses a special ion-selective solid-electrolyte called beta-alumina (Na2O•11Al2O3), that is highly conductive to sodium cations. A more conducting variation of this compound is beta”-alumina (Na2O•MgO•5Al2O3), where the magnesium acts as a stabilizer [3]. In the device, liquid sodium enters an evaporator where it is heated isobarically and vaporizes. The vapor is then oxidized at the interface between the anode and the solid-electrolyte. The Na-TECC generates electric power by allowing the high pressure oxidized sodium vapor ions to expand isothermally through the solid-electrolyte from the anode to the cathode. The liberated electrons are simultaneously conducted through an external load and recombine with the cations at the cathode. The low pressure sodium vapor is subsequently condensed and a wick pumps the liquid into the high pressure plenum to complete the cycle. Previous Na-TECCs have achieved efficiencies of 18% due to practical losses, whereas the potential efficiencies are above 45% [4]. Thermodynamic limitations and design constraints have limited previous devices from attaining these record efficiencies. Specifically, 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. Moreover, previous devices experienced a steady loss in performance throughout their lifetime. The drop in performance has been attributed to the electrolyte undergoing thermal and chemical breakdown due to crack propagation, loss of sodium oxide, and the formation of molten dendrites that create electrical shorts [5]. Finally, previous designs have also had a substantial problem with proper thermal management, with some showing thermal losses as great as 50% of the heat input. To improve the efficiency, a dual stage conversion process is being explored. 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, thus increasing the 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 is amenable for better thermal management and allows for less heat loss. This will also mitigate the thermal shock across the very thin (< 1 mm) solid electrolytes, reduce crack propagation and limit the percolation of the molten dendrites, and ultimately increase the lifetime of the device. As an additional benefit the dual stage can be designed using planer geometries, rather than tubular geometries used in previous single stage models, which can be manufactured less expensively. This modified geometry can be tailored to improve the thermal management by reducing the radiation losses, which has been the biggest source of thermal losses [2]. A dual stage concept for the Na-TECC has never been demonstrated in literature. In this presentation, the operation of a single stage device will be revisited and, by adopting concepts used for similar converters, the thermodynamic operation of the dual stage will be developed [6]. Using the dual stage approach, the efficiency and power equations have been redefined to include regeneration and reheat. Questions such as what current densities optimize the power output or which intermediate temperature maximizes the efficiency will also be answered. Initial calculations of the dual stage show that the thermal management is the most sensitive parameter. Although the ideal voltage produced by the dual stage can be higher, there are potential drawbacks. For example, by using a lower condenser temperature the dual stage device will have a higher open circuit voltage, but it will also have a larger overpotential due to the limited cathodic kinetics that occur at a lower temperature. In short, there are several trade-offs in this device that need to be balanced. 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.