Wa Water ter-ba base sed Ran d Rankin kine-Cyc Cycle Was le - - PowerPoint PPT Presentation

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Wa Water ter-ba base sed Ran d Rankin kine-Cyc Cycle Was le Waste te Hea Heat R t Rec ecov overy ery Sy Systems stems For En For Engine gines: s: - Challenges and Opportunities - Gunnar Latz 1 , Olof Erlandsson 2 , Thomas Skre

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SLIDE 1

Gunnar Latz1, Olof Erlandsson2, Thomas Skåre2, Arnaud Contet2, Sven Andersson1, Karin Munch1

Wa Water ter-ba base sed Ran d Rankin kine-Cyc Cycle Was le Waste te Hea Heat R t Rec ecov

  • very

ery Sy Systems stems For En For Engine gines: s:

  • Challenges and Opportunities -

1Chalmers University of Technology, Department of Applied Mechanics, Gothenburg, Sweden 2TitanX Engine Cooling AB, Sölvesborg, Sweden

ASME ORC 2015

  • 3rd International Seminar on ORC Power Systems -
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SLIDE 2

Gunnar Latz

Technology: Rankine cycle Motivation: Energy balance

Engine: Volvo D13, B75 Evaporator Condenser Expansion device Fluid pump

Rankine Cycle

Work

  • utput

Waste heat (e.g. EGR)

Introduction Introduction

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SLIDE 3

Gunnar Latz

Outline Outline

  • Motivation
  • Method
  • Results
  • Conclusion
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SLIDE 4

Gunnar Latz

Motivation Motivation

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SLIDE 5

Gunnar Latz

Motivation…

…for the project and the study

  • Build a research demonstrator (full-cycle+ engine)
  • Validation of components models
  • Identification of challenges on component level in

a full scale test rig …for water as a working fluid

  • Non flammable/poisonous
  • Thermal stability
  • Availability
  • Performance (?)

 Keep it simple!

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SLIDE 6

Gunnar Latz

Method Method

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SLIDE 7

Gunnar Latz

Method Method – Test Test rig rig layout layout

Condenser Fluid receiver Expansion tank EGR Boiler Pump Coolant in Coolant out Piston expander EGR in EGR out Filter Flow meter Oil separator Oil Tank Oil pump Oil cooler Coolant out Heater Pressure relief Bypass Pressure relief Flow meter

Working fluid Coolant Lubricant

Focus of this study

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SLIDE 8

Gunnar Latz

Piston expander (2 cyl., uniflow)

  • Bore/stroke: 90/60 mm (Ɛgeometric=21)
  • Inlet opening/closing: -17º/34º ATDC
  • Outlet opening/closing: 110º/250º ATDC
  • Modelling: GT-Suite (1D)

Method Method – Component simulation Component simulation

T

Inlet Outlet

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SLIDE 9

Gunnar Latz

Piston expander (2 cyl., uniflow)

  • Bore/stroke: 90/60 mm (Ɛgeometric=21)
  • Inlet opening/closing: -17º/34º ATDC
  • Outlet opening/closing: 110º/250º ATDC
  • Modelling: GT-Suite (1D)

Method Method – Component simulation Component simulation

T

Inlet Outlet

EGR boiler (plate type, counterflow)

  • Channels fluid/gas: 22/21 (vertical)
  • Fin geometry: Offset strip fin
  • Core length/height: 458/95 mm
  • Modelling: 0D lumped element, CFD (Ansys)

EGR Fluid in Vapor out

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SLIDE 10

Gunnar Latz

Method Method – Tests p Tests perf erformed

  • rmed

Rankine expander bypassed

 All ESC points

Rankine expander engaged

 Focus on A100/B100

*ESC = European Stationary Cycle, **Engine: Volvo D13 US10 25 50 75 100 1000 1200 1400 1600 1800 2000

Engine** load [%] Engine speed [rpm] ESC* operating points

A B C

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SLIDE 11

Gunnar Latz

Res Results ults – EGR EGR Boiler Boiler

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SLIDE 12

Gunnar Latz

EGR Water

1 bar 10 bar 30 bar ~7 ~70% % compared to st standard EG EGR R cooler ler

EGR aftercooler

Results Results – EGR EGR boiler boiler (t (test ri est rig) g)

ESC operating range

EGR

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SLIDE 13

Gunnar Latz

Results Results – EGR EGR boiler boiler

~B75

IR camera image, B75

400ºC 300ºC 200ºC 100ºC 30ºC Experiment HT (water) [kW] Simulation HT (water) [kW] x 0D model – – 1:1 Vapor phase volume fraction [-] Vapor out CFD (Ansys) Fluid in EGR EGR

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SLIDE 14

Gunnar Latz

Res Results ults – Pis Piston ton expan expander der

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SLIDE 15

Gunnar Latz

Results Results – Expander Expander (simu (simulated) lated)

Expander speed [rpm] Expander power [kW], (model) Steam flow rate [g/s], (model) Inlet pressure [bar] Inlet pressure [bar] ε = 21 ε = 21 ε = 13 ε = 13

Hypothesis: Maintaining power output and expander efficiency at 30% lower admission pressure when modifying expander compression ratio from 21 to 13

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SLIDE 16

Gunnar Latz

Results Results – Expander Expander (test, (test, B100) B100)

Compression ratio 21 (base) 13

𝜃𝑗𝑡𝑓𝑜𝑢𝑠𝑝𝑞𝑗𝑑 = 𝐹𝑦𝑞𝑏𝑜𝑒𝑓𝑠 𝑞𝑝𝑥𝑓𝑠 𝑁𝑏𝑡𝑡 𝑔𝑚𝑝𝑥 ∙ 𝐽𝑡𝑓𝑜𝑢𝑠𝑝𝑞𝑗𝑑 𝑓𝑜𝑢ℎ𝑏𝑚𝑞𝑧 𝑒𝑠𝑝𝑞 𝜃𝑢ℎ𝑓𝑠𝑛𝑏𝑚 = 𝐹𝑦𝑞𝑏𝑜𝑒𝑓𝑠 𝑞𝑝𝑥𝑓𝑠 𝐹𝐻𝑆 ℎ𝑓𝑏𝑢 𝑢𝑠𝑏𝑜𝑡𝑔𝑓𝑠

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SLIDE 17

Gunnar Latz

Results Results – System System test ( test (B100) B100)

EGR boiler Condenser Expander Fluid pump

ε = 13 P= 2.36 kW n = 780 rpm ƞis = 45 % 230ºC 18.5 bar 103ºC 1.16 bar 64ºC 1.05 bar 62ºC 18.6 bar 11 g/s 550ºC 260ºC

0,0 2,0 4,0 6,0 8,0 10,0 100 200 300 400 500 600

s [kJ/kg-K] T [°C]

2000 kPa 1000 kPa 101,3 kPa

0,2 0,4 0,6 0,8

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SLIDE 18

Gunnar Latz

Conclusion Conclusion

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SLIDE 19

Gunnar Latz

Conclusion Conclusion

EGR boiler

  • Internal flow circulation (steam “bubble”) reduced area for effective heat transfer
  • EGR aftercooler was required to maintain sufficient EGR cooling

Piston expander

  • High re-compression ratio of current expander design constrained power-output

at applied boundary conditions

  • Compression ratio 2113: Maintained power @ 30% lower inlet pressure

System tests with water

  • Large heat of evaporation and high boiling temperature:

→ Very low flow rates (< 15 g/s), challenging to control → Poor cooling of EGR

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SLIDE 20

Gunnar Latz

Volvo Car r Corpo rporati ration

Acknowledgements: Authors - Contact information:

Gunnar Latz (Chalmers) – latz@chalmers.se Olof Erlandsson (TitanX) – olof.erlandsson@titanx.com Thomas Skåre (TitanX) – thomas.skare@titanx.com Arnaud Contet (TitanX) – arnaud.contet@titanx.com Sven Andersson (Chalmers) – sven.b.andersson@chalmers.se Karin Munch (Chalmers) – karin.munch@chalmers.se