Theoretical exploration of a free-piston Stirling generator with a gas-compressing self-circulating heat exchanger

The free-piston Stirling generator (FPSG) holds great promise as a thermal-to-electrical conversion device for space applications. However, heat transfer remains a critical factor obstructing its scalability to high power levels. In this study, we propose a high-power FPSG with a gas-compressing self-circulating heat exchanger (GSHX) that utilizes high-pressure helium as the heat transfer fluid, enhancing the reliability of the heat exchanger. By incorporating a built-in gas-compressing device and check valves, the performance degradation caused by significant pressure fluctuations in the resonant self-circulating heat exchanger is effectively addressed. Through detailed simulations, we demonstrate the principle feasibility of the GSHX with a 4 m heat transfer loop, achieving an output electric power of 11 kW and a thermal-to-electric efficiency of 20.4%. Furthermore, the GSHX exhibits similar operating characteristics to traditional FPSGs, as we analyze the systems' stability under various operating conditions. Importantly, our findings reveal that the acoustic characteristics of the loop play a pivotal role in system performance, with operating parameters exhibiting periodic variations related to helium wavelength. By carefully optimizing system parameters, GSHX with a long loop length of 29 m can achieve comparable performance to systems with shorter loops. This study provides valuable insights into the operational characteristics and performance optimization of the GSHX, offering a comprehensive heat transfer solution for long-distance, high-efficiency, and highly reliable applications of high-power FPSGs in the space domain.