Low-temperature organic Rankine cycle engine with isothermal expansion for use in desalination

Groundwater salinity is a widespread problem that contributes to the freshwater deficit of humanity. Consequently, where conventional energy supply is also lacking, organic Rankine cycle (ORC) engines are being considered as a feasible option to harness readily available low-grade heat (<180°C) to drive the desalination of the saline water via reverse osmosis (RO). However, this application is still not very well developed, and has significantly high specific energy consumption (SEC). Hence, this study explores the isothermal expansion of the ORC working fluid to achieve improved efficiency for driving a batch-RO desalination process, "DesaLink". Here, the working fluid is directly vaporized in the expansion cylinder which is heated externally by heat transfer fluid, thus obviating the need for a separate external boiler and high-pressure piping. Experimental investigations with R245fa have shown cycle efficiency of 8.8%. And it is predicted that the engine could drive DesaLink to produce 256 L of freshwater per 8 h per day, from 4000 ppm saline water, with a thermal and mechanical SEC of 2.5 and 0.36 kWh/m3, respectively, representing a significant improvement on previously reported or predicted SEC values. © 2014 © 2014 Balaban Desalination Publications. All rights reserved.

Low-temperature isothermal Rankine cycle for desalination

In brackish groundwater desalination, high recovery ratio (of fresh water from saline feed) is desired to minimise concentrate reject. To this effect, previous studies have developed a batch reverse osmosis (RO) desalination system, DesaLink, which proposed to expand steam in a reciprocating piston cylinder and transmit the driving force through a linkage crank mechanism to pressurise batches of saline water (recirculating) in a water piston cylinder unto RO membranes. However, steam is largely disadvantaged at operation from low temperature (< 150oC) thermal sources; and organic working fluids are more viable, though, the obtainable thermal cycle efficiencies are generally low with low temperatures. Consequently, this thesis proposed to investigate the use of organic working fluid Rankine cycle (ORC) with isothermal expansion, to drive the DesaLink machine, at improved thermal efficiency from low temperature thermal sources. Following a review of the methods of achieving isothermal expansion, ‘liquid flooded expansion’ and ‘expansion chamber surface heating’ were identified as potential alternative methods. Preliminary experimental comparative analysis of variants of the heated expansion chamber technique of effecting isothermal expansion favoured a heated plain wall technique, and as such was adopted for further optimisation and development. Further, an optimised isothermal ORC engine was built and tested at < 95oC heat source temperature, with R245fa working fluid – which was selected from 16 working fluids that were analysed for isothermal operation. Upon satisfactory performance of the test engine, a larger (10 times) version was built and coupled to drive the DesaLink system. Operating the integrated ORC-RO DesaLink system, gave freshwater (approximately 500 ppm) production of about 12 litres per hour (from 4000 ppm feed water) at a recovery ratio of about 0.7 and specific energy consumption of 0.34 kWh/m3; and at a thermal efficiency of 7.7%. Theoretical models characterising the operation and performance of the integrated system was developed and utilised to access the potential field performance of the system, when powered by two different thermal energy sources – solar and industrial bakery waste heat – as case studies.

Self-powered desalination of geothermal saline groundwater:technical feasibility

This theoretical study shows the technical feasibility of self-powered geothermal desalination of groundwater sources at <100 °C. A general method and framework are developed and then applied to specific case studies. First, the analysis considers an ideal limit to performance based on exergy analysis using generalised idealised assumptions. This thermodynamic limit applies to any type of process technology. Then, the analysis focuses specifically on the Organic Rankine Cycle (ORC) driving Reverse Osmosis (RO), as these are among the most mature and efficient applicable technologies. Important dimensionless parameters are calculated for the ideal case of the self-powered arrangement and semi-ideal case where only essential losses dependent on the RO system configuration are considered. These parameters are used to compare the performance of desalination systems using ORC-RO under ideal, semi-ideal and real assumptions for four case studies relating to geothermal sources located in India, Saudi Arabia, Tunisia and Turkey. The overall system recovery ratio (the key performance measure for the self-powered process) depends strongly on the geothermal source temperature. It can be as high as 91.5% for a hot spring emerging at 96 °C with a salinity of 1830 mg/kg.

Uniform design for the optimization of Al2O3 nanofilms produced by electrophoretic deposition

Surface modification by means of nanostructures is of interest to enhance boiling heat transfer in various applications including the organic Rankine cycle (ORC). With the goal of obtaining rough and dense aluminum oxide (Al2O3) nanofilms, the optimal combination of process parameters for electrophoretic deposition (EPD) based on the uniform design (UD) method is explored in this paper. The detailed procedures for the EPD process and UD method are presented. Four main influencing conditions controlling the EPD process were identified as nanofluid concentration, deposition time, applied voltage and suspension pH. A series of tests were carried out based on the UD experimental design. A regression model and statistical analysis were applied to the results. Sensitivity analyses of the effect of the four main parameters on the roughness and deposited mass of Al2O3 films were also carried out. The results showed that Al2O3 nanofilms were deposited compactly and uniformly on the substrate. Within the range of the experiments, the preferred combination of process parameters was determined to be nanofluid concentration of 2 wt.%, deposition time of 15 min, applied voltage of 23 V and suspension pH of 3, yielding roughness and deposited mass of 520.9 nm and 161.6 × 10− 4 g/cm2, respectively. A verification experiment was carried out at these conditions and gave values of roughness and deposited mass within 8% error of the expected ones as determined from the UD approach. It is concluded that uniform design is useful for the optimization of electrophoretic deposition requiring only 7 tests compared to 49 using the orthogonal design method.

Review of low-temperature vapour power cycle engines with quasi-isothermal expansion

External combustion heat cycle engines convert thermal energy into useful work. Thermal energy resources include solar, geothermal, bioenergy, and waste heat. To harness these and maximize work output, there has been a renaissance of interest in the investigation of vapour power cycles for quasi-isothermal (near constant temperature) instead of adiabatic expansion. Quasi-isothermal expansion has the advantage of bringing the cycle efficiency closer to the ideal Carnot efficiency, but it requires heat to be transferred to the working fluid as it expands. This paper reviews various low-temperature vapour power cycle heat engines with quasi-isothermal expansion, including the methods employed to realize the heat transfer. The heat engines take the form of the Rankine cycle with continuous heat addition during the expansion process, or the Stirling cycle with a condensable vapour as working fluid. Compared to more standard Stirling engines using gas, the specific work output is higher. Cryogenic heat engines based on the Rankine cycle have also been enhanced with quasi-isothermal expansion. Liquid flooded expansion and expander surface heating are the two main heat transfer methods employed. Liquid flooded expansion has been applied mainly in rotary expanders, including scroll turbines; whereas surface heating has been applied mainly in reciprocating expanders. © 2014 Elsevier Ltd.

A high-efficiency solar rankine engine with isothermal expansion

Though the principle of the solar Rankine cycle is well known, with several examples reported in the literature, there is yet a scarcity of engines that could be efficiently applied in small-scale (<100 KW) applications. Hence, this paper presents a variant of the engine that uses an isothermal expansion to achieve a theoretical efficiency close to the Carnot limit. Generation of steam inside the power cylinder obviates the need for an external boiler. The device is suitable for slow-moving applications and is of particular interest for driving a batch-desalination process. Preliminary experiments have shown cycle efficiency of 16%, and a high work ratio of 0.997. ©The Author 2013. Published by Oxford University Press. All rights reserved.

Mathematical modelling and optimisation of a water heat pump

The purpose of the work described here has been to seek methods of narrowing the present gap between currently realised heat pump performance and the theoretical limit. The single most important pre-requisite to this objective is the identification and quantitative assessment of the various non-idealities and degradative phenomena responsible for the present shortfall. The use of availability analysis has been introduced as a diagnostic tool, and applied to a few very simple, highly idealised Rankine cycle optimisation problems. From this work, it has been demonstrated that the scope for improvement through optimisation is small in comparison with the extensive potential for improvement by reducing the compressor's losses. A fully instrumented heat pump was assembled and extensively tested. This furnished performance data, and led to an improved understanding of the systems behaviour. From a very simple analysis of the resulting compressor performance data, confirmation of the compressor's low efficiency was obtained. In addition, in order to obtain experimental data concerning specific details of the heat pump's operation, several novel experiments were performed. The experimental work was concluded with a set of tests which attempted to obtain definitive performance data for a small set of discrete operating conditions. These tests included an investigation of the effect of two compressor modifications. The resulting performance data was analysed by a sophisticated calculation which used that measurements to quantify each dagradative phenomenon occurring in that compressor, and so indicate where the greatest potential for improvement lies. Finally, in the light of everything that was learnt, specific technical suggestions have been made, to reduce the losses associated with both the refrigerant circuit and the compressor.

Cost and performance analysis of new wood-fuelled power plant concepts

The objective of the thesis was to analyse several process configurations for the production of electricity from biomass. Process simulation models using AspenPlus aimed at calculating the industrial performance of power plant concepts were built, tested, and used for analysis. The criteria used in analysis were performance and cost. All of the advanced systems appear to have higher efficiencies than the commercial reference, the Rankine cycle. However, advanced systems typically have a higher cost of electricity (COE) than the Rankine power plant. High efficiencies do not reduce fuel costs enough to compensate for the high capital costs of advanced concepts. The successful reduction of capital costs would appear to be the key to the introduction of the new systems. Capital costs account for a considerable, often dominant, part of the cost of electricity in these concepts. All of the systems have higher specific investment costs than the conventional industrial alternative, i.e. the Rankine power plant; Combined beat and power production (CUP) is currently the only industrial area of application in which bio-power costs can be considerably reduced to make them competitive. Based on the results of this work, AsperiPlus is an appropriate simulation platform. How-ever, the usefulness of the models could be improved if a number of unit operations were modelled in greater detail. The dryer, gasifier, fast pyrolysis, gas engine and gas turbine models could be improved.

A solar-powered reverse osmosis system for high recovery of freshwater from saline groundwater

Desalination of groundwater is essential in arid regions that are remote from both seawater and freshwater resources. Desirable features of a groundwater desalination system include a high recovery ratio, operation from a sustainable energy source such as solar, and high water output per unit of energy and land. Here we propose a new system that uses a solar-Rankine cycle to drive reverse osmosis (RO). The working fluid such as steam is expanded against a power piston that actuates a pump piston which in turn pressurises the saline water thus passing it through RO membranes. A reciprocating crank mechanism is used to equalise the forces between the two pistons. The choice of batch mode in preference to continuous flow permits maximum energy recovery and minimal concentration polarisation in the vicinity of the RO membrane. This study analyses the sizing and efficiency of the crank mechanism, quantifies energy losses in the RO separation and predicts the overall performance. For example, a system using a field of linear Fresnel collectors occupying 1000 m2 of land and raising steam at 200 °C and 15.5 bar could desalinate 350 m3/day from saline water containing 5000 ppm of sodium chloride with a recovery ratio of 0.7.

DesaLink:solar powered desalination of brackish groundwater giving high output and high recovery

Desalination of groundwater is essential in many arid areas that are far from both seawater and fresh water resources. The ideal groundwater desalination system should operate using a sustainable energy source and provide high water output per land area and cost. To avoid discharging voluminous brine, it should also provide high recovery. To achieve these aims, we have designed DesaLink, a novel approach to linking the solar Rankine cycle to reverse osmosis (RO). To achieve high recovery without the need for multiple RO stages, DesaLink adopts a batch mode of operation. It is suited to use with a variety of solar thermal collectors including linear Fresnel reflectors (LFR). For example, using a LFR occupying 1,000m of land and providing steam at 200°C and 15.5 bar, DesaLink is predicted to provide 350m of fresh water per day at a recovery ratio of 0.7, when fed with brackish groundwater containing 5,000ppm of sodium chloride. Here, we report preliminary experiments to assess the feasibility of the concept. We study the effects of longitudinal dispersion, concentration polarisation and describe a pilot experiment to demonstrate the batch process using a materials testing machine. In addition, we demonstrate a prototype of DesaLink running from compressed air to simulate steam.

Desalination of brackish water by a batch reverse osmosis desalink system for use with solar thermal energy

For remote, semi-arid areas, brackish groundwater (BW) desalination powered by solar energy may serve as the most technically and economically viable means to alleviate the water stresses. For such systems, high recovery ratio is desired because of the technical and economical difficulties of concentrate management. It has been demonstrated that the current, conventional solar reverse osmosis (RO) desalination can be improved by 40–200 times by eliminating unnecessary energy losses. In this work, a batch-RO system that can be powered by a thermal Rankine cycle has been developed. By directly recycling high pressure concentrates and by using a linkage connection to provide increasing feed pressures, the batch-RO has been shown to achieve a 70% saving in energy consumption compared to a continuous single-stage RO system. Theoretical investigations on the mass transfer phenomena, including dispersion and concentration polarization, have been carried out to complement and to guide experimental efforts. The performance evaluation of the batch-RO system, named DesaLink, has been based on extensive experimental tests performed upon it. Operating DesaLink using compressed air as power supply under laboratory conditions, a freshwater production of approximately 300 litres per day was recorded with a concentration of around 350 ppm, whilst the feed water had a concentration range of 2500–4500 ppm; the corresponding linkage efficiency was around 40%. In the computational aspect, simulation models have been developed and validated for each of the subsystems of DesaLink, upon which an integrated model has been realised for the whole system. The models, both the subsystem ones and the integrated one, have been demonstrated to predict accurately the system performance under specific operational conditions. A simulation case study has been performed using the developed model. Simulation results indicate that the system can be expected to achieve a water production of 200 m3 per year by using a widely available evacuated tube solar collector having an area of only 2 m2. This freshwater production would satisfy the drinking water needs of 163 habitants in the Rajasthan region, the area for which the case study was performed.

A cost-effective steam-driven RO plant for brackish groundwater

Desalination is a costly means of providing freshwater. Most desalination plants use either reverse osmosis (RO) or thermal distillation. Both processes have drawbacks: RO is efficient but uses expensive electrical energy; thermal distillation is inefficient but uses less expensive thermal energy. This work aims to provide an efficient RO plant that uses thermal energy. A steam-Rankine cycle has been designed to drive mechanically a batch-RO system that achieves high recovery, without the high energy penalty typically incurred in a continuous-RO system. The steam may be generated by solar panels, biomass boilers, or as an industrial by-product. A novel mechanical arrangement has been designed for low cost, and a steam-jacketed arrangement has been designed for isothermal expansion and improved thermodynamic efficiency. Based on detailed heat transfer and cost calculations, a gain output ratio of 69-162 is predicted, enabling water to be treated at a cost of 71 Indian Rupees/m3 at small scale. Costs will reduce with scale-up. Plants may be designed for a wide range of outputs, from 5 m3/day, up to commercial versions producing 300 m3/day of clean water from brackish groundwater.