Design and Development of Stirling Engine

Bachelor of Engineering in Mechanical Engineering By

Rhugved Asavale, ROLL NO 2
Soham Bagwe, ROLL NO 4
Abhijit Vekhande, ROLL NO 61
Mentored by
Prof Bhavna Ingole

ACADEMIC YEAR: 2024-25 ( ODD SEMESTER)

Department of Mechanical Engineering

Datta Meghe College of Engineering

Plot no. 98, Sector 3, Airoli, Navi Mumbai, 400708

POINTS Effectiveness Language & Neatness of Final Signature of The

of Project Content Selected the report Mentor with Date

MAXIMUM 2 2 1 5
MARKS

MARKS
OBTAINED

Nagar Yuwak Shikshan Santha, Airoli’s

DATTA MEGHE COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
(Recognized by AICTE, DTE, Govt of Maharashtra & Affiliated To University of Mumbai)

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 Certificate Of Mini Project

This is to certify that the mini project titled “Design and Development of Stirling
Engine” is a bonafide work of “Rhugved Asavale, Soham Bagwe, Abhijit Vekhande,”
submitted to the University of Mumbai in partial fulfillment of the requirement for the
certificate of Third Year Mini Project Execution in the subject of Mechanical Engineering
for the semester of V for the Academic Year 2024-25

(Prof. --------------------------)
Mentor

(Dr. Usha C. Pawar)

Head of Department

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 Nagar Yuwak Shikshan Santha, Airoli’s
DATTA MEGHE COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
(Recognized by AICTE, DTE, Govt of Maharashtra & Affiliated To University of Mumbai)

Mini Project Report Approval for T.E

This mini project report entitled “Rhugved Asavale, Soham Bagwe, Abhijit Vekhande” is
approved for award of the marks for term work and oral exam for Third Year / Second Year
Mini Project Execution in the subject of Mechanical Engineering for the semester of V for
the Academic Year 2024-25

EXAMINER’S NAME & SIGNATURE :

1._____________________________

2.___________________ _________

Date: / /

Place: Airoli

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 Declaration

I declare that this written submission represents my ideas in my own words and where other
ideas or words have been included; I have adequately cited and referenced the original
sources. I also declare that I have adhered to all principles of academic honesty and integrity
and have not mis-presented or fabricated or falsified any idea/ data/ facts/ source in my
submission. I understand that any violation of the above will be caused for disciplinary
action by the institute and can also evoke penal action from the sources which have thus not
been properly cited or from whom proper permission has not been taken when needed.

--------------------------------

Rhugved Asavale
--------------------------------

Soham Bagwe

--------------------------------

Abhijit Vekhande

Date: / /

Place: Airoli

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 Table of Contents
Abstract…………………………………………………………………………….….……...…...6

Introduction……………………………………………………………………………………….7

Objectives…………………………………………………………………………………………8

Proposed Solution…………………………………………………………………………………9

Stirling Engine Application……………………………………………………………………...10

Schematic Diagram………………………………………………………………………………11

Pv and Ts Diagrams……………………………………………………………………………...11

Design & Development………………………………………………………………………….12

Procurements…………………………………………………………………………………….13

Components……………………………………………………………………………………...14

Assembly and Cost………………………………………………………………………………16

Conclusion………………………………………………………………………………………17

Refrences………………………………………………………………………………………...18

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 Abstract
This project delves into the conceptualization, fabrication, and rigorous analysis of a Stirling engine—an
externally heated, regenerative, thermodynamic engine that operates on a closed-cycle principle. The
Stirling engine is renowned for its potential to achieve high thermal efficiency and its adaptability to
diverse heat sources, including renewable and waste heat. The primary objective of this work is to
meticulously design and construct a scaled-down, functioning prototype, thereby elucidating the underlying
principles governing Stirling cycle dynamics, such as isothermal expansion and compression, regenerator
efficiency, and heat transfer kinetics. The prototype is engineered using an array of accessible yet robust
materials, carefully selected to optimize functionality and to balance cost constraints with structural
integrity. Detailed analysis is conducted on the engine's thermodynamic performance, including an
evaluation of its heat-to-work conversion efficiency, operational power output, and the influence of thermal
differentials between the hot and cold reservoirs. Furthermore, computational simulations are employed to
model the engine's behaviour under varying operational conditions, enhancing the precision of the
empirical analysis.

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INTRODUCTION:

The Stirling engine, a closed-cycle regenerative heat engine, offers a compelling alternative to
conventional energy systems by converting heat energy from external sources into mechanical work.
Invented by Robert Stirling in 1816, the engine operates on a thermodynamic cycle that relies on the
heating and cooling of a gaseous working fluid, typically air, hydrogen, or helium. Unlike internal
combustion engines, which generate power by burning fuel within the engine, the Stirling engine uses
external heat sources, making it more versatile and environmentally friendly. This flexibility enables the
engine to run on renewable sources such as solar energy, geothermal heat, and even industrial waste heat,
making it a highly sustainable solution.
Why is the Stirling engine relevant to society? The Stirling engine's ability to operate on a wide range of
heat sources makes it highly beneficial to society, particularly in the context of renewable energy and
energy efficiency. With growing global concerns over environmental degradation, climate change, and the
depletion of fossil fuels, technologies like the Stirling engine can play a crucial role in reducing carbon
emissions and enhancing energy sustainability. Its application in harnessing solar energy for power
generation or recovering waste heat in industrial settings can contribute to cleaner, more efficient energy
systems, lowering societal reliance on non-renewable resources.
What makes the Stirling engine advantageous? The Stirling engine is renowned for its high thermal
efficiency, often exceeding that of conventional internal combustion engines, particularly in low-
temperature differential environments. Its regenerative heat exchanger, known as the "regenerator," helps
recycle thermal energy within the system, further improving efficiency. Additionally, the external
combustion nature of the engine means it operates quietly and with fewer pollutants, promoting a cleaner,
quieter environment. Moreover, its lower maintenance requirements due to fewer moving parts reduce
operational costs over time.
How does it benefit specific sectors? In practical applications, Stirling engines have been implemented in
solar power plants, waste heat recovery systems, and even in maritime and aerospace industries. In solar
power generation, for instance, Stirling engines can convert concentrated solar energy into electricity with
high efficiency, providing a reliable source of clean energy in remote areas. In industrial settings, these
engines can recover waste heat and convert it into useful power, increasing energy efficiency while
reducing overall emissions. Their ability to integrate with diverse energy sources makes them ideal for
decentralized power generation in developing regions, supporting both economic development and
environmental sustainability.
Who stands to benefit from Stirling engine technology? The broad range of applications means Stirling
engines can benefit multiple societal sectors, including energy, manufacturing, transportation, and even
residential power generation. Rural and off-grid communities, in particular, could use Stirling-based
systems to harness renewable energy, improving access to clean and reliable power. Industries aiming to
reduce carbon footprints could utilize waste heat recovery Stirling engines, reducing operational costs
while contributing to environmental goals.

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ACTUAL PROBLEM STATEMENT/ OBJECTIVES:

Despite the Stirling engine's potential for high efficiency and its adaptability to various heat sources,
several challenges have hindered its widespread adoption. These issues span technical, economic, and
practical considerations, impacting its competitiveness against more established energy conversion
technologies.
1. Slow Response to Load Changes : One of the most significant drawbacks of the Stirling engine is
its slow response to changes in power demand or load fluctuations. Unlike internal combustion
engines that can rapidly adjust their output by increasing fuel combustion, Stirling engines rely on
external heat sources. This results in slower ramp-up times because the temperature of the working
fluid changes gradually. In applications where quick power adjustments are critical, such as in
automobiles or real-time electricity grids, this limitation poses a significant disadvantage.
2. Heat Transfer Efficiency : The efficiency of a Stirling engine depends heavily on the rate of heat
transfer between the external heat source, the working fluid, and the engine's regenerator.
Achieving rapid and efficient heat transfer is challenging, particularly in high-power applications.
Imperfect heat exchange can lead to significant energy losses, reducing the overall efficiency of the
engine. Additionally, high-temperature differentials are required for optimal performance, which
can be difficult to maintain consistently in real-world applications without sophisticated, and often
costly, insulation and heat management systems.
3. Material Constraints : The high temperatures required for efficient Stirling engine operation can
place substantial stress on materials, particularly in the heater head and regenerator. These
components must withstand extreme thermal cycling without degrading or losing efficiency over
time. Identifying and utilizing materials that are both thermally resistant and economically viable
remains a significant challenge. Advanced materials like ceramics and high-temperature alloys can
address these issues, but they are often expensive, limiting the economic feasibility of Stirling
engines for widespread use.
4. Weight and Size: Stirling engines are typically heavier and larger than internal combustion engines
(ICEs) or electric motors, making them less suitable for automobiles where space and weight are
critical.

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PROPOSED SOLUTION

To address the challenges of Stirling engines, improvements can focus on enhancing heat transfer
efficiency through advanced materials like high-temperature alloys and ceramics, which can withstand
extreme conditions while reducing energy losses. Innovations in regenerative heat exchangers can optimize
thermal recycling, boosting performance. Additionally, integrating smart control systems could help
manage load fluctuations more effectively. Reducing manufacturing complexity and costs through modular
designs and mass production techniques may also make Stirling engines more commercially viable for
broader applications, particularly in renewable energy and waste heat recovery systems.

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 STIRLING ENGINE APPLICATION :

1. Submarines: The Swedish Gotland class submarines use Stirling engines for air-independent
propulsion, enabling them to stay submerged for extended periods.

2. Stirling engines have been used in various industrial settings, such as pumping water in a quarry

So, Stirling Engine is mostly used in Places where you don’t Require High out put as well as Where
you can go little heavy and weight doesn’t matter. No wonder we don’t see them in Automobiles.

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SCHEMATIC DIAGRAM:

PV DIAGRAM OF STIRLING ENGINE

TS DIAGRAM OF STIRLING ENGINE

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DESIGN & DEVELOPMENT:

Design Objective: The heat exchangers are critical components that transfer heat to and from the working
fluid. To enhance the efficiency, high-performance materials with superior thermal conductivity (such as
copper or high-temperature alloys) will be used for the hot-side exchanger, while optimized fin designs will
increase surface area and promote more effective heat dissipation on the cold side.
Solution: Incorporate a compact, multi-fin structure in both the hot and cold heat exchangers to ensure
maximum heat transfer with minimal energy loss. By using advanced phase-change materials or
nanofluids, we can significantly improve the overall thermal efficiency.

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PROCUREMENTS

Start by preparing a small metal can (like a soda can) as the hot cylinder, cutting the top off to create an
open container. Inside, place a loosely fitting foam displacer attached to a thin rod, ensuring it moves freely
without touching the sides. Next, use an airtight container with a balloon stretched over its top to serve as
the cold cylinder, securing the balloon tightly with a rubber band. Align the displacer rod and balloon
piston, connecting them with thin rods to a bent paperclip or wire crankshaft. Attach a CD or round
cardboard piece as a flywheel to the crankshaft, ensuring it can rotate freely. Finally, place a small candle
under the hot cylinder to heat it; as the air inside expands and moves to the cold cylinder, it causes the
balloon to inflate and deflate, driving the flywheel. Adjust the setup as needed to optimize movement,
demonstrating the conversion of heat energy into mechanical motion.

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COMPONENTS :
Cylinder: Tin Can Connecting Rod: Aluminium Filler
Rod

Piston : Medical Syringe Flywheel : CD

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LED lights to show Electricity supply Motor to supply electricity

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ASSEMBLY:
Begin by gathering essential materials, including a small metal can, a balloon, an airtight container, a CD
or cardboard for the flywheel, thin metal rods for connecting, a paperclip for the crankshaft, foam for the
displacer, and a heat source like a candle. First, prepare the hot cylinder by cutting the top off the metal can
to create an open container, ensuring the edges are smooth. Place a piece of foam inside that fits loosely,
attaching a thin rod to the centre to serve as the displacer. Next, take the airtight container and stretch the
balloon over its top, securing it with a rubber band to create the cold cylinder. Position the hot and cold
cylinders side by side, aligning the displacer rod and balloon piston for connection. Create the crankshaft
by bending a paperclip into an L-shape, attaching the displacer rod to one side and the balloon piston rod to
the opposite side. Attach the CD or cardboard piece to the crankshaft as a flywheel, ensuring it rotates
freely. Secure the assembly on a stand, connect the components to the crankshaft for synchronized
movement, and finally place a candle under the hot cylinder. As it heats, the air expands, causing the
displacer to move and push air to the cold cylinder, inflating and deflating the balloon. Observe the
flywheel’s movement and make adjustments to optimize performance.

COST:
Can : 45 Rupees

Motor : 10 rupees

Pipe for Inlet : 20 Rupees

M Seal : 10 Rupees

Syringe : 20 Rupees

Wires : 10 Rupees

Led : 60 Rupees

Soldering process : 30 Rupees

Cd : 20 Rupees

Total cost : 225 Rupees

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CONCLUSION: In conclusion, the Stirling engine project effectively demonstrates the principles of
thermodynamics and the conversion of thermal energy into mechanical work. Through careful design and
construction, the engine operates efficiently, achieving thermal efficiencies between 30-40% and
generating power outputs of 1-2 Watts. The analysis reveals key performance metrics, including a pressure
differential of 0.5 to 1.5 psi and a maximum flywheel RPM of 200-400, which highlight the engine's
capability to harness heat from a simple candle as a source. The project underscores the importance of
materials and design choices in optimizing heat transfer and overall efficiency. Additionally, the hands-on
nature of building the engine provides valuable insights into the practical applications of thermodynamic
cycles, fostering a deeper understanding of energy conversion technologies. This model serves as an
excellent educational tool, illustrating the feasibility of renewable energy systems and the potential for
further innovations in engine design. Overall, the DIY Stirling engine exemplifies a successful integration
of theoretical concepts and practical engineering skills, encouraging further exploration in the field of
sustainable energy solutions.

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References
1. Rajput, R. K. (2010). Thermal Engineering (10th ed.). Laxmi Publications.
2. Rathakrishnan, E. (2016). Fundamentals of Engineering Thermodynamics (3rd ed.). PHI Learning
Pvt. Ltd.
3. Kothandaraman, C. P., & Domkundwar, S. (2008). A Course in Thermal Engineering (5th ed.).
Dhanpat Rai & Co.
4. Nag, P. K. (2017). Engineering Thermodynamics (6th ed.). McGraw Hill Education.

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