Analisi sperimentale delle prestazioni di un sistema micro-ORC

Con l’aumento del consumo mondiale di risorse energetiche del pianeta, è diventato sempre più necessario utilizzare sistemi energetici che sfruttino al meglio la fonte di energia che li alimenta. Una delle soluzioni in questo ambito è quella proposta dagli Organic Rankine Cycle (ORC). Questi sistemi recuperano energia termica altrimenti non utilizzabile per le temperature troppo basse e sfruttano sorgenti termiche con ampi range di temperatura. L’elaborato volge all’analisi sperimentale delle prestazioni di un sistema Micro-ORC di piccola taglia, con rendimento termodinamico massimo dichiarato dal costruttore del 10 %. Inizialmente vengono descritti i fluidi organici e i sistemi che ne fanno uso, descrivendo anche esempi bibliografici di banchi prova per interpretare al meglio i risultati ottenuti con quello disponibile, che viene poi descritto, comprendendo i circuiti di asservimento dell’acqua calda e fredda, i punti di misura e il programma di acquisizione dati. Ci si concentra poi sulla descrizione e l’utilizzo dei codici implementati per l’elaborazione dei dati acquisiti. Questi hanno permesso di osservare gli andamenti temporali delle grandezze fondamentali per il sistema e valutarne la ripetibilità del comportamento nel corso di differenti prove. Vengono proposte infine le mappe di funzionamento per l’intero impianto e per i vari sotto-sistemi, offrendone un’interpretazione e inquadrandone i punti di lavoro ottimali. Attraverso la loro osservazione si sono dedotte le condizioni necessarie per avere un funzionamento ritenuto stabile del sistema ed è stato possibile ottimizzare le procedure svolte durante le fasi di test e di acquisizione dati. Sarà oggetto di studi futuri l’ottimizzazione dell’impianto, prolungando i tempi di esercizio a parità di carico elettrico e frequenza imposta alla pompa, con il fine di ottenere delle curve di prestazioni confrontabili con quelle presenti in bibliografia per altri sistemi ORC.

GROUND COOLING SYSTEM FOR IMPROVING THE EFFICIENCY OF LOW TEMPERATURE POWER GENERATION

This paper presents an analysis of an organic Rankine cycle (ORC) with dry cooling system aided by an earth-coupled passive cooling system. Several organic fluids were considered as working fluids in the ORC in the temperature range of 125-200 degrees C. An earth-air-heat-exchanger (EMU) is studied for a location in the United States (Las Vegas) and another in India (New Delhi), to pre cool the ambient air before entering an air-cooled condenser (ACC). It was observed that the efficiency of the system improved by 1-3% for the system located in Las Vegas and fluctuations associated with temperature variations of the ambient air were also reduced when the EAHE system was used. A ground-coupled heat pump (GCHP) is also studied for these locations where cooling water is pre cooled in an underground buried pipe before entering a condenser heat exchanger in a closed loop. The area of the buried pipe and the condenser size are calculated per kW of power generation for various working fluids.

Mathematical Modelling of a Reciprocating Piston Expander

Modern internal combustion (IC) engines reject around two thirds of the energy provided by the fuel as low-grade waste heat. Capturing a portion of this waste heat energy and transforming it into a more useful form of energy could result in a significant reduction in fuel consumption. By using the low-grade heat, an organic Rankine cycle (ORC) can produce mechanical work from a pressurised organic fluid with the use of an expander.
Ideal gas assumptions are shown to produce significant errors in expander performance predictions when using an organic fluid. This paper details the mathematical modelling technique used to accurately model the thermodynamic processes for both ideal and non-ideal fluids within the reciprocating expander. A comparison between the two methods illustrates the extent of the errors when modelling a reciprocating piston expander. Use of the ideal gas assumptions are shown to produce an error of 55% in the prediction of power produced by the expander when operating on refrigerant R134a.

Automotive waste heat recovery: Working fluid selection and related boundary conditions

This paper presents the rational for the selection of fluids for use in a model based study of sub and supercritical Waste Heat Recovery (WHR) Organic Rankine Cycle (ORC). The study focuses on multiple vehicle heat sources and the potential of WHR ORC’s for its conversion into useful work. The work presented on fluid selection is generally applicable to any waste heat recovery system, either stationary or mobile and, with careful consideration, is also applicable to single heat sources. The fluid selection process presented reduces the number of potential fluids from over one hundred to a group of under twenty fluids for further refinement in a model based WHR ORC performance study. The selection process uses engineering judgement, legislation and, where applicable, health and safety as fluid selection or de-selection criteria. This paper also investigates and discusses the properties of specific ORC fluids with regard to their impact on the theoretical potential for delivering efficient WHR ORC work output. The paper concludes by looking at potential temperature and pressure WHR ORC limits with regard to fluid properties thereby assisting with the generation of WHR ORC simulation boundary conditions.

Modelling of Evaporator in Waste Heat Recovery System using Finite Volume Method and Fuzzy Technique

The evaporator is an important component in the Organic Rankine Cycle (ORC)-based Waste Heat Recovery (WHR) system since the effective heat transfer of this device reflects on the efficiency of the system. When the WHR system operates under supercritical conditions, the heat transfer mechanism in the evaporator is unpredictable due to the change of thermo-physical properties of the fluid with temperature. Although the conventional finite volume model can successfully capture those changes in the evaporator of the WHR process, the computation time for this method is high. To reduce the computation time, this paper develops a new fuzzy based evaporator model and compares its performance with the finite volume method. The results show that the fuzzy technique can be applied to predict the output of the supercritical evaporator in the waste heat recovery system and can significantly reduce the required computation time. The proposed model, therefore, has the potential to be used in real time control applications.

Development of Shape-Optimization Tools for the Aerodynamic Design of Turbomachinery Blades

The aim of this work is to develop an automated tool for the optimization of turbomachinery blades founded on an evolutionary strategy. This optimization scheme will serve to deal with supersonic blades cascades for application to Organic Rankine Cycle (ORC) turbines. The blade geometry is defined using parameterization techniques based on B-Splines curves, that allow to have a local control of the shape. The location in space of the control points of the B-Spline curve define the design variables of the optimization problem. In the present work, the performance of the blade shape is assessed by means of fully-turbulent flow simulations performed with a CFD package, in which a look-up table method is applied to ensure an accurate thermodynamic treatment. The solver is set along with the optimization tool to determine the optimal shape of the blade. As only blade-to-blade effects are of interest in this study, quasi-3D calculations are performed, and a single-objective evolutionary strategy is applied to the optimization. As a result, a non-intrusive tool, with no need for gradients definition, is developed. The computational cost is reduced by the use of surrogate models. A Gaussian interpolation scheme (Kriging model) is applied for the estimated n-dimensional function, and a surrogate-based local optimization strategy is proved to yield an accurate way for optimization. In particular, the present optimization scheme has been applied to the re-design of a supersonic stator cascade of an axial-flow turbine. In this design exercise very strong shock waves are generated in the rear blade suction side and shock-boundary layer interaction mechanisms occur. A significant efficiency improvement as a consequence of a more uniform flow at the blade outlet section of the stator is achieved. This is also expected to provide beneficial effects on the design of a subsequent downstream rotor. The method provides an improvement to gradient-based methods and an optimized blade geometry is easily achieved using the genetic algorithm.

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.

The use of solar colletor for heating and electricity for a single family house

The presented work is related to the use of solar energy for the needs of heating and electricity for a single house located in Poland. Electricity will provided by energy conversion in the turbine by means of Organic Rankine Cycle (ORC), in which the operating medium (water heated in solar collector) is heating refrigerator in the heating exchanger. The solar installation is integrated with heat accumulator and wood boiler, which is used in the situation that collector is not enough to fill requirements of thermal comfort. There are chosen also all the necessary components of the system. In the work is also performed the economic assessment, by F chart method, to evaluate the profitability of the project, taking into total costs and savings.

Evaluation of isopentane, R-245fa and their mixtures as working fluids for organic Rankine cycles

Low grade thermal energy from sources such as solar, geothermal and industrial waste heat in the temperature range of 380-425 K can be converted to electrical energy with reasonable efficiency using isopentane and R-245fa. While the former is flammable and the latter has considerable global warming potential, their mixture in 0.7/0.3 mole fraction is shown to obviate these disadvantages and yet retain dominant merits of each fluid. A realistic thermodynamic analysis is carried out wherein the possible sources of irreversibilities such as isentropic efficiencies of the expander and the pump and entropy generation in the regenerator, boiler and condenser are accounted for. The performance of the system in the chosen range of heat source temperatures is evaluated. A technique of identifying the required source temperature for a given output of the plant and the maximum operating temperature of the working fluid is developed. This is based on the pinch point occurrence in the boiler and entropy generation in the boiling and superheating regions of the boiler. It is shown that cycle efficiencies of 10-13% can be obtained in the range investigated at an optimal expansion ratio of 7-10. (C) 2012 Elsevier Ltd. All rights reserved.

Aplicação de um ciclo orgânico de Rankine à indústria Naval

Trabalho Final de Mestrado para obtenção de grau de Mestre em Engenharia Mecânica

Microchannel heat exchangers: An attractive option for the regenerator of a mobile orc waste heat recovery system

The performance of microchannel heat exchangers was assessed in gas-to-liquid applications in the order of several tens of kWth . The technology is suitable for exhaust heat recovery systems based on organic Rankine cycle. In order to design a light and compact microchannel heat exchanger, an optimization process is developed. The model employed in the procedure is validated through computational fluid-dynamics analysis with commercial software. It is shown that conjugate effects have a significant impact on the heat transfer performance of the device.

Progettazione di un impianto orc per il recupero energetico da fumi

Il crescente fabbisogno energetico mondiale, dovuto essenzialmente al rapido incremento di popolazione originatosi nel secolo scorso, unitamente alla necessità di ridurre le emissioni di anidride carbonica, porta a ricercare continuamente nuove fonti primarie di energia nonché metodi innovativi per il recupero di quest’ultima da materiali di scarto. I Cicli Rankine a fluido Organico (Organic Rankine Cycle) rappresentano in questo senso una tecnologia emergente capace di rivoluzionare il concetto di risparmio energetico. In questa tesi viene effettuato uno studio dettagliato della tecnologia ORC, che mira ad identificarne i principali vantaggi e le maggiori problematiche, con particolare riferimento ad un caso di studio concreto, riguardante l’installazione di un impianto di recupero energetico da fumi di combustione all’interno di uno stabilimento di produzione di nero di carbonio. Il cuore della tesi è rappresentato dall’individuazione e dall’analisi dettagliata delle alternative impiantistiche con cui il recupero energetico può essere realizzato. Per ognuna di esse, dopo una breve spiegazione, viene effettuato il calcolo dell’energia elettrica prodotta annualmente con l’ausilio un simulatore di processo. Successivamente vengono esposte le proposte ricevute dai fornitori interpellati per la fase di progettazione di base dell’impianto di recupero energetico. Nell’ultima parte della tesi viene presentata la simulazione fluidodinamica del camino di una delle linee di produzione dell’impianto di Ravenna, effettuata utilizzando un codice CFD e mirata alla verifica dell’effettiva quantità di calore recuperato dai fumi e dell’eventuale presenza di condense lungo la ciminiera. I risultati ottenuti mostrano che la tecnologia ORC, utilizzata per il recupero energetico in ambito industriale, possiede delle grosse potenzialità. La massimizzazione dei vantaggi derivanti dall’utilizzo di questi sistemi è tuttavia fortemente condizionata dalla capacità di gestire al meglio l’integrazione degli impianti di recupero all’interno dei processi produttivi esistenti.

Analisi del rendimento di sistemi micro ORC di tipo sperimentale

In questo lavoro si analizza il rendimento isoentropico di diversi espansori adottati all’interno di sistemi micro-ORC (Organic Rankine Cycle). Si parte da una descrizione generale dei sistemi ORC, mettendone in evidenza le principali caratteristiche, il layout tipico, le differenze rispetto ad un ciclo Rankine tradizionale, e gli ambiti di utilizzo. Si procede ad una trattazione teorica del rendimento isoentropico del compressore e dell’espansore, specificando le ipotesi adottate nei calcoli e mettendo in luce la relazione tra rendimento isoentropico e politropico nell’uno e nell’altro apparato. Si passa poi alla descrizione delle quattro principali tipologie di espansori presenti in letteratura: scroll, screw, vane e piston, e si prosegue con l'analisi nel dettaglio della letteratura relativa alla valutazione dell’efficienza di questi quando utilizzati all’interno di un sistema micro-ORC. Infine, dopo aver descritto il sistema ORC del laboratorio di via Terracini del DIN, illustrandone layout, componenti principali, potenza scambiata all’interno dei componenti e modalità di calcolo adottata per la valutazione del rendimento isoentropico dell’espansore e del sistema complessivo, si confrontano i dati di efficienza di questo con quelli reperiti in letteratura. Il confronto del rendimento, dell'espansore e complessivo, del sistema del DIN, 33.8% e 1,818% rispettivamente, con quelli degli altri sistemi, è risultato di difficilmente valutazione a causa delle condizioni di forte off-design del sistema stesso. Dalla ricerca è inoltre emerso che i fluidi più utilizzati nella sperimentazione, e dunque capaci di migliori prestazioni, sono R245fa, R134a e R123. Per quel che riguarda infine gli espansori, nel range di potenza di 1-10 kW, lo scroll risulta essere il migliore.

Candidate radial-inflow turbines and high-density working fluids for geothermal power systems

Optimisation of Organic Rankine Cycle (ORCs) for binary-cycle geothermal applications could play a major role in determining the competitiveness of low to moderate temperature geothermal resources. Part of this optimisation process is matching cycles to a given resource such that power output can be maximised. Two major and largely interrelated components of the cycle are the working fluid and the turbine. Both components need careful consideration: the selection of working fluid and appropriate operating conditions as well as optimisation of the turbine design for those conditions will determine the amount of power that can be extracted from a resource. In this paper, we present the rationale for the use of radial-inflow turbines for ORC applications and the preliminary design of several radial-inflow machines based on a number of promising ORC systems that use five different working fluids: R134a, R143a, R236fa, R245fa and n-Pentane. Preliminary meanline analysis lead to the generation of turbine designs for the various cycles with similar efficiencies (77%) but large differences in dimensions (139–289 mm rotor diameter). The highest performing cycle, based on R134a, was found to produce 33% more net power from a 150 °C resource flowing at 10 kg/s than the lowest performing cycle, based on n-Pentane.