Analysis of a novel waste heat recovery mechanism for an I.C. engine

Typical internal combustion engines lose about 75% of the fuel energy through the engine coolant, exhaust and surface radiation. Most of the heat generated comes from converting the chemical energy in the fuel to mechanical energy and in turn thermal energy is produced. In general, the thermal energy is unutilized and thus wasted. This report describes the analysis of a novel waste heat recovery (WHR) system that operates on a Rankine cycle. This novel WHR system consists of a second piston within the existing piston to reduce losses associated with compression and exhaust strokes in a four-cycle engine. The wasted thermal energy recovered from the coolant and exhaust systems generate a high temperature and high pressure working fluid which is used to power the modified piston assembly. Cycle simulation shows that a large, stationary natural gas spark ignition engine produces enough waste heat to operate the novel WHR system. With the use of this system, the stationary gas compression ignition engine running at 900 RPM and full load had a net increase of 177.03 kW (240.7 HP). This increase in power improved the brake fuel conversion efficiency by 4.53%.

Application of a dynamic event tree methodolgy to steam generator tube rupture sequences

The Integrated Safety Assessment (ISA) methodology, developed by the Spanish Nuclear Safety Council (CSN), has been applied to a thermo-hydraulical analysis of a Westinghouse 3-loop PWR plant by means of the dynamic event trees (DET) for Steam Generator Tube Rupture (SGTR) sequences. The ISA methodology allows obtaining the SGTR Dynamic Event Tree taking into account the operator actuation times. Simulations are performed with SCAIS (Simulation Code system for Integrated Safety Assessment), which includes a dynamic coupling with MAAP thermal hydraulic code. The results show the capability of the ISA methodology and SCAIS platform to obtain the DET of complex sequences.

Small modular incinerator systems with heat recovery : a technical, environmental, and economic evaluation /

November 1979.

Small modular incinerator systems with heat recovery : a technical, environmental, and economic evaluation : executive summary /

Mode of access: Internet.

Heat engines; steam, gas, steam turbines and their auxiliaries,

Mode of access: Internet.

Manual on heat recovery for schools and hospitals /

"June 1983."

The development of heat recovery equipment from conception to commercialisation

A comprehensive survey of industrial sites and heat recovery products revealed gaps between equipment that was required and that which was available. Two heat recovery products were developed to fill those gaps: a gas-to-gas modular heat recovery unit; a gas-to-liquid exhaust gas heat exchanger. The former provided an entire heat recovery system in one unit. It was specifically designed to overcome the problems associated with existing component system of large design commitment, extensive installation and incompatibility between parts. The unit was intended to recover heat from multiple waste gas sources and, in particular, from baking ovens. A survey of the baking industry defined typical waste gas temperatures and flow rates, around which the unit was designed. The second unit was designed to recover heat from the exhaust gases of small diesel engines. The developed unit differed from existing designs by having a negligible effect on engine performance. In marketing terms these products are conceptual opposites. The first, a 'product-push' product generated from site and product surveys, required marketing following design. The second, a 'market-pull' product, resulted from a specific user need; this had a captive market and did not require marketing. Here marketing was replaced by commercial aspects including the protection of ideas, contracting, tendering and insurance requirements. These two product development routes are compared and contrasted. As a general conclusion this work suggests that it can be beneficial for small companies (as was the sponsor of this project) to undertake projects of the market-pull type. Generally they have a higher probability of success and are less capital intensive than their product-push counterparts. Development revealed shortcomings in three other fields: British Standards governing heat exchangers; financial assessment of energy saving schemes; degree day procedure of calculating energy savings. Methods are proposed to overcome these shortcomings.

Numerical Analysis on a Dual-Loop Waste Heat Recovery System Coupled with an ORC for Vehicle Applications

The internal combustion (IC) engines exploits only about 30% of the chemical energy ejected through combustion, whereas the remaining part is rejected by means of cooling system and exhausted gas. Nowadays, a major global concern is finding sustainable solutions for better fuel economy which in turn results in a decrease of carbon dioxide (CO2) emissions. The Waste Heat Recovery (WHR) is one of the most promising techniques to increase the overall efficiency of a vehicle system, allowing the recovery of the heat rejected by the exhaust and cooling systems. In this context, Organic Rankine Cycles (ORCs) are widely recognized as a potential technology to exploit the heat rejected by engines to produce electricity. The aim of the present paper is to investigate a WHR system, designed to collect both coolant and exhausted gas heats, coupled with an ORC cycle for vehicle applications. In particular, a coolant heat exchanger (CLT) allows the heat exchange between the water coolant and the ORC working fluid, whereas the exhausted gas heat is recovered by using a secondary circuit with diathermic oil. By using an in-house numerical model, a wide range of working conditions and ORC design parameters are investigated. In particular, the analyses are focused on the regenerator location inside the ORC circuits. Five organic fluids, working in both subcritical and supercritical conditions, have been selected in order to detect the most suitable configuration in terms of energy and exergy efficiencies.

Waste Heat Recovery Systems: Numerical and Experimental Analysis of organic Rankine Cycle Solutions

This thesis aims to present the ORC technology, its advantages and related problems. In particular, it provides an analysis of ORC waste heat recovery system in different and innovative scenarios, focusing on cases from the biggest to the lowest scale. Both industrial and residential ORC applications are considered. In both applications, the installation of a subcritical and recuperated ORC system is examined. Moreover, heat recovery is considered in absence of an intermediate heat transfer circuit. This solution allow to improve the recovery efficiency, but requiring safety precautions. Possible integrations of ORC systems with renewable sources are also presented and investigated to improve the non-programmable source exploitation. In particular, the offshore oil and gas sector has been selected as a promising industrial large-scale ORC application. From the design of ORC systems coupled with Gas Turbines (GTs) as topper systems, the dynamic behavior of the GT+ORC innovative combined cycles has been analyzed by developing a dynamic model of all the considered components. The dynamic behavior is caused by integration with a wind farm. The electric and thermal aspects have been examined to identify the advantages related to the waste heat recovery system installation. Moreover, an experimental test rig has been realized to test the performance of a micro-scale ORC prototype. The prototype recovers heat from a low temperature water stream, available for instance in industrial or residential waste heat. In the test bench, various sensors have been installed, an acquisitions system developed in Labview environment to completely analyze the ORC behavior. Data collected in real time and corresponding to the system dynamic behavior have been used to evaluate the system performance based on selected indexes. Moreover, various operational steady-state conditions are identified and operation maps are realized for a completely characterization of the system and to detect the optimal operating conditions.

Modelling of ORC components and systems for low-medium temperature heat recovery applications with reduced environmental impact

Although its great potential as low to medium temperature waste heat recovery (WHR) solution, the ORC technology presents open challenges that still prevent its diffusion in the market, which are different depending on the application and the size at stake. Focusing on the micro range power size and low temperature heat sources, the ORC technology is still not mature due to the lack of appropriate machines and working fluids. Considering instead the medium to large size, the technology is already available but the investment is still risky. The intention of this thesis is to address some of the topical themes in the ORC field, paying special attention in the development of reliable models based on realistic data and accounting for the off-design performance of the ORC system and of each of its components. Concerning the “Micro-generation” application, this work: i) explores the modelling methodology, the performance and the optimal parameters of reciprocating piston expanders; ii) investigates the performance of such expander and of the whole micro-ORC system when using Hydrofluorocarbons as working fluid or their new low GWP alternatives and mixtures; iii) analyzes the innovative ORC reversible architecture (conceived for the energy storage), its optimal regulation strategy and its potential when inserted in typical small industrial frameworks. Regarding the “Industrial WHR” sector, this thesis examines the WHR opportunity of ORCs, with a focus on the natural gas compressor stations application. This work provides information about all the possible parameters that can influence the optimal sizing, the performance and thus the feasibility of installing an ORC system. New WHR configurations are explored: i) a first one, relying on the replacement of a compressor prime mover with an ORC; ii) a second one, which consists in the use of a supercritical CO2 cycle as heat recovery system.

Analise técnica e econômica para seleção de sistemas de cogeração em ciclo combinado

Pós-graduação em Engenharia Mecânica - FEG

Desarrollo de un modelo para la caracterización termoeconómica de ciclos combinados de turbinas de gas y de vapor en condiciones de carga variable

En la actualidad, el interés por las plantas de potencia de ciclo combinado de gas y vapor ha experimentado un notable aumento debido a su alto rendimiento, bajo coste de generación y rápida construcción. El objetivo fundamental de la tesis es profundizar en el conocimiento de esta tecnología, insuficientemente conocida hasta el momento debido al gran número de grados de libertad que existen en el diseño de este tipo de instalaciones. El estudio se realizó en varias fases. La primera consistió en analizar y estudiar las distintas tecnologías que se pueden emplear en este tipo de centrales, algunas muy recientes o en fase de investigación, como las turbinas de gas de geometría variable, las turbinas de gas refrigeradas con agua o vapor del ciclo de vapor o las calderas de paso único que trabajan con agua en condiciones supercríticas. Posteriormente se elaboraron los modelos matemáticos que permiten la simulación termodinámica de cada uno de los componentes que integran las plantas, tanto en el punto de diseño como a cargas parciales. Al mismo tiempo, se desarrolló una metodología novedosa que permite resolver el sistema de ecuaciones que resulta de la simulación de cualquier configuración posible de ciclo combinado. De esa forma se puede conocer el comportamiento de cualquier planta en cualquier punto de funcionamiento. Por último se desarrolló un modelo de atribución de costes para este tipo de centrales. Con dicho modelo, los estudios se pueden realizar no sólo desde un punto de vista termodinámico sino también termoeconómico, con lo que se pueden encontrar soluciones de compromiso entre rendimiento y coste, asignar costes de producción, determinar curvas de oferta, beneficios económicos de la planta y delimitar el rango de potencias donde la planta es rentable. El programa informático, desarrollado en paralelo con los modelos de simulación, se ha empleado para obtener resultados de forma intensiva. El estudio de los resultados permite profundizar ampliamente en el conocimiento de la tecnología y, así, desarrollar una metodología de diseño de este tipo de plantas bajo un criterio termoeconómico. ABSTRACT The growing energy demand and the need of shrinking costs have led to the design of high efficiency and quick installation power plants. The success of combined cycle gas turbine power plants lies on their high efficiency, low cost and short construction lead time. The main objective of the work is to study in detail this technology, which is not thoroughly known owing to the great number of degrees of freedom that exist in the design of this kind of power plants. The study is divided into three parts. Firstly, the different technologies and components that could be used in any configuration of a combined cycle gas turbine power plant are studied. Some of them could be of recent technology, such as the variable inlet guide vane compressors, the H-technology for gas turbine cooling or the once-through heat recovery steam generators, used with water at supercritical conditions. Secondly, a mathematical model has been developed to simulate at full and part load the components of the power plant. At the same time, a new methodology is proposed in order to solve the equation system resulting for any possible power plant configuration. Therefore, any combined cycle gas turbine could be simulated at any part load condition. Finally a themoeconomic model is proposed. This model allows studying the power plant not only from a thermodynamic point of view but also from a thermoeconomic one. Likewise, it allows determining the generating costs or the cash flow, thus achieving a trade off between efficiency and cost. Likewise, the model calculates the part load range where the power plant is profitable. Once the thermodynamic and thermoeconomic models are developed, they are intensively used in order to gain knowledge in the combined cycle gas turbine technology and, in this way, to propose a methodology aimed at the design of this kind of power plants from a thermoeconomic point of view.

Gasification technology assessment of sterile coal to clean electrical power generation.

Sterile coal is a low-value residue associated to the coal extraction and mining activity. According to the type and origin of the coal bed configuration, sterile coal production can mainly vary on quantity, calorific value and presence of sulphur compounds. In addition, the potential availability of sterile coal within Spain is apparently high and its contribution to the local power generation would be of interest playing a significant role. The proposed study evaluates the availability and deployment of gasification technologies to drive clean electricity generation from waste coal and sterile rock coal, incorporating greenhouse gas emission mitigation systems, like CO2, H2S and NOx removal systems. It establishes the target facility and its conceptual basic design proposal. The syngas obtained after the gasification of sterile coal is processed through specific conditioning units before entering into the combustion chamber of a gas turbine. Flue gas leaving the gas turbine is ducted to a heat recovery steam generation boiler; the steam produced within the boilerdrives a steam turbine. The target facility resembles a singular Integrated Gasification in Combined Cycle (IGCC) power station. The evaluation of the conceptual basic design according to the power output set for a maximum sterile contribution, established that rates over 95% H2S and 90% CO2 removal can be achieved. Noticeable decrease of NOx compounds can be also achieved by the use of commercial technology. A techno-economic approach of the conceptual basic design is made evaluating the integration of potential unitsand their implementation within the target facility aiming toachieve clean power generation. The criterion to be compliant with the most restrictive regulation regarding environmental emissions is setting to carry out this analysis.

Offdesign operation of kraft recovery boiler

A model to solve heat and mass balances during the offdesign load calculations was created. These equations are complex and nonlinear. The main new ideas used in the created offdesign model of a kraft recovery boiler are the use of heat flows as torn iteration variables instead of the current practice of using the mass flows, vectorizing equation solving, thus speeding up the process, using non dimensional variables for solving the multiple heat transfer surface problem and using a new procedure for calculating pressure losses. Recovery boiler heat and mass balances are reduced to vector form. It is shown that these vectorized equations can be solved virtually without iteration. The iteration speed is enhanced by the use of the derived method of calculating multiple heat transfer surfaces simultaneously. To achieve this quick convergence the heat flows were used as the torn iteration parameters. A new method to handle pressure loss calculations with linearization was presented. This method enabled less time to be spent calculating pressure losses. The derived vector representation of the steam generator was used to calculate offdesign operation parameters for a 3000 tds/d example recovery boiler. The model was used to study recovery boiler part load operation and the effect of the black liquor dry solids increase on recovery boiler dimensioning. Heat flows to surface elements for part load calculations can be closely approximated with a previously defined exponent function. The exponential method can be used for the prediction of fouling in kraft recovery boilers. For similar furnaces the firing of 80 % dry solids liquor produces lower hearth heat release rate than the 65 % dry solids liquor if we fire at constant steam flow. The furnace outlet temperatures show that capacity increase with firing rate increase produces higher loadings than capacity increase with dry solids increase. The economizers, boiler banks and furnaces can be dimensioned smaller if we increase the black liquor dry solids content. The main problem with increased black liquor dry solids content is the decrease in the heat available to superheat. Whenever possible the furnace exit temperature should be increased by decreasing the furnace height. The increase in the furnace exit temperature is usually opposed because of fear of increased corrosion.