Extract energy heat engine

Lead Proponent

Smarter Alloys

Project Background

The Extract Energy Heat Engine project aimed to convert low-grade waste heat (LGWH) into usable electricity by developing an innovative engine based on shape memory alloy (SMA), which coul operate under conditions below 90°C and with a temperature differential as small as 15°C. The LGWH engine is enabled by a core made of bundles of SMA springs, processed using our Multiple Memory Material (MMM) technology. This core has the ability to absorb heat at discrete temperatures, programmed using the MMM technology. By cycling a hot and cold water source, the SMA core undergoes a phase transformation, causing the springs to either extend or contract. This linear motion is converted to rotary motion to drive a generator and produce clean electricity.

Results

This project successfully demonstrated commercial viability of the Extract Energy SMA heat engine through the development of a 500 W prototype. Impressively, the prototype generated far beyond the target energy amount, with peak power exceeding 2 kW. Subsequent efforts focused on scaling the system to a capacity of over 10 kW.

To achieve this, Smarter Alloys built a fully instrumented thermal simulation facility, designed to simulate industrial processes for bench testing heat engines. This setup facilitated the development and testing of innovative alloys to enhance energy recovery and durability. With an improved heat transfer and fluid flow design, the material demonstrated enhanced work output performance.

Smarter Alloys constructed a 500W system and field-tested it at a combined heat and power facility used for district heating. The system used excess heat to power the Extract Energy heat engine, which generated in excess of 2 kW power. This field operation validated their energy model and provided crucial data for scaling the system to 10 kW and beyond.

In progressing from a 500W prototype to the design of a 10 kW model, the project paves the way for future scaling towards megawatt-sized power production.

Benefits to Canada

The project demonstrated this promising technology with substantial potential for reducing greenhouse gas emissions and seamlessly integrating into existing industrial processes. By doing so, it marks significant advancements in energy efficiency and environmental sustainability.

Initial roll-out will target waste heat in the oil and gas industry, power generation, and manufacturing sectors, converting it into useful electricity. Embracing the Extract Energy heat engine within these sectors has the potential to yield emission reductions solely from use of waste heat.

Over the course of the project, Smarter Alloys more than doubled its personnel while accelerating this trajectory as scaling commences. As the development of the technology continues, more jobs will be created in skilled fields, such as engineering, fabrication, quality management, technology, and administration. All these positions are well paying, sustainable, and value-added roles that will contribute to a clean economy.

Next steps

The successful completion of the project has laid the groundwork for scaling up the heat engine to a 10kW prototype, and eventually, towards their aim of a modular 100kW unit targeting megawatt scale power production.

The Extract Energy technology promises significant GHG reduction job creation, improved air quality, and seamless integration into existing processes. With further testing and development, this technology could revolutionize commercial energy efficiency.

Technology in Action

In Their Words

"BESC was the crucial catalyst that sparked our venture into waste heat recovery. Their support substantially aided in transforming our benchtop prototype into a commercially viable solution. Collaborating with valuable partners expedites our progress towards deploying a scaled system, making a significant impact on reducing greenhouse gas emissions. Successfully demonstrating power production on a multi-kilowatt scale improves our prospects for success, paving the way for potential partners and funding essential to drive our clean technology towards commercialization. With over half of the energy produced lost as waste heat, our solution stands to significantly improve efficiency in power production, manufacturing, and mining, making a substantial contribution to reducing greenhouse gas emissions."

Ibraheem Khan, CEO