Hyliion to Design MW-Scale KARNO Generator System for U.S. Navy

The U.S. Navy granted Hyliion an SBIR government contract: Award Phase 1, N241-060, enables Hyliion to create a preliminary, MW-scale modular generator system design. The design incorporates Navy specifications with Hyliion’s KARNO generator technology. The KARNO generator can operate on multiple fuels, including NATO F-76, and features hermetically sealed architecture with a single moving part per shaft.

The system will be scalable to various power needs and adaptable to available platform space, meeting the U.S. government’s USV cross-platform requirements. Hyliion will combine multiple 200-kW KARNO gensets to achieve specified power output.

“We are honored to receive this SBIR contract from the United States Navy,” said Thomas Healy, Founder and CEO of Hyliion. “This award is a testament to the KARNO generator’s expected ability to offer efficient, flexible, and low-maintenance power generation. We are excited to contribute to the Navy’s mission and explore higher power solutions for their USV initiative.”

KARNO generator; Image Credits: Hyliion

SBIR supports scientific and technological advancements by investing federal research funds in projects that bolster the national economy and defense infrastructure. The modular generator concept, outlined in N241-060, will configure smaller kW-scale building block power units in a high-density package to reach 4,000-hour no-touch maintenance periodicity. Longer maintenance intervals allow for continuous operation in naval environments.

KARNO Generator News

In late July 2024, Hyliion signed a non-binding letter of intent (LOI) to supply a 200-kW KARNO generator to power U.S. Energy’s RNG fueling station, boosting its energy efficiency and enabling further natural gas integration in the commercial transportation sector.

The KARNO generator is a fuel-adaptive solution, operating with hydrogen, natural gas, biogas, or propane, and uses a linear architecture to economically and efficiently produce electricity. It offers lower maintenance costs and a reduced emissions profile compared to traditional generator units.

In May, Hyliion Holdings and Victory Clean Energy executed a non-binding LOI to deploy generators for Victory’s subsidiary, H2 Energy Group (H2EG). Under the LOI, Victory Clean Energy will purchase up to 10 KARNO generators from Hyliion for deployment at H2EG’s hydrogen-production facilities. H2EG will rely on the KARNO generators to produce electricity using hydrogen-rich syngas obtained from biomass to power its operations.

The initial five KARNO units will be delivered to H2EG in the second half of 2025, each capable of generating an approximate power output of 200 kW and a collective capacity of 1 MW. The company will also leverage the KARNO generators’ combined heat-and-power features, using excess heat to improve the efficiency of its manufacturing process. Upon the successful deployment of these KARNO units, the LOI includes an option for H2EG to purchase five additional generators.