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PERFORMANCES OF AN ORC POWER
UNIT FOR WASTE HEAT RECOVERY
ON HEAVY DUTY ENGINE
Roberto Cipollone, Davide Di Battista
Department of Industrial and Information Engineering and
Economics – University of L’Aquila - Italy
Federica Bettoja
FIAT Research Center – Turin, Italy
SAE INTERNATIONAL
• Waste Heat Recovery opportunity for emission savings
• Experimental test bench development
• Fluid choice
• Hot thermal source characterization (Heavy Duty ICE)
• Heat recovery vapor generator
• Turbine characterization
• Pump
• Condenser
• Overall plant performances
• Energetic and exergetic analyses
• Conclusions
Summary
ORC Conference 2017 2 D. Di Battista
SAE INTERNATIONAL
Heat Recovery Vapor Generator characterization
ORC Conference 2017 7
- Effectiveness close to 0.8
- Low gas side pressure drop
Steel finned coil heat exchanger
min , ,( )h i c i
Q
C T T
D. Di Battista
SAE INTERNATIONAL
Condenser characterization
ORC Conference 2017 8
- Cooling water is at 50°C
- R245fa at 5 bar and 90°C inlet temperature
Plate heat exchanger
D. Di Battista
mwater
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Turbine characterization
ORC Conference 2017 9
Axial turbine
- Oil circuit for gear
lubrication
- Syncronous electric
generator
- 24 V DC current rectifier
D. Di Battista
SAE INTERNATIONAL
Pump characterization
ORC Conference 2017 10
Internal gear pump
- Oil free
- DC brushless motor
- Magnetic clutch
D. Di Battista
-High volumetric effficiency
-Low electric absorption
- 100 – 300 g/s mass flow rate
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Test bench description
ORC Conference 2017 12 D. Di Battista
1100 mm
700 mm
700 mm
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Selected tests – Entropy diagrams
ORC Conference 2017 13
A B
C D
D. Di Battista
- High distance from
hot source
- High condenser
undercooling
- Low superheating
value in lower loads
conditions
- Higher
desuperheating
Regeneration
opportunity
PICE=53 kW
PICE=110 kW
PICE=72 kW
PICE=93 kW
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Selected tests – Entropy diagrams
ORC Conference 2017 14
A B
D. Di Battista
PICE=53 kW PICE=72 kW
SAE INTERNATIONAL
Selected tests – Entropy diagrams
ORC Conference 2017 15
C D
D. Di Battista
PICE=110 kW PICE=93 kW
SAE INTERNATIONAL
Plant energy balance
ORC Conference 2017 16
- Thermal power recovered up
to 55 kW
- Max turbine thermodynamical
power = 6 kW @ full engine
load (110 kW)
- Negiglible pump power
D. Di Battista
SAE INTERNATIONAL
Efficiencies analysis
ORC Conference 2017 17
, ,
3 2
, . , .
1( )
el turb el pump
plant
hs
T pump
th
HRVG turb cond pump
ex
hs hs in hs out ref hs in hs out
P P
Q
h h
h h
I I I I
m h h T s s
D. Di Battista
- Thermodynamic efficiency around 10 %
- Overall plant efficiency only 3%
- Exergetic efficiency is 30 % in lower loads and under 20% in higher load cases
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Exergy analysis
ORC Conference 2017 18
3 2 , ,
2 1 2 1
3 4 3 4
4 1 4 1
( ) ( )
( ) ( )
[( ) ( )]
( ) ( )
HRVG WF hs hs in hs outref
pump pump WF ref
turb WF ref turb
cond WF ref
I T m s s m s s
I P m h h T s s
I m h h T s s P
I m h h T s s
D. Di Battista
- Higher irreversibilities related to HRVG temperatures distance
(in particular in higher load cases)
- Neglibile irreversibilities on turbine and pump
- Condenser ones also high
- Exergetic efficiency from 30 % to 20 %
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Conclusions
ORC Conference 2017 19
• ORC based plant for Waste Heat Recovery from Internal
Combustion Engine
• R245fa as actual fluid choice road to R1233zd
• Heat recovery vapor generator finned coil heat exchanger
• Axial turbine (smaller and lightweight, high efficiency)
• Internal gear pump
• Overall plant performances
• Compactness
• Maximum heat recovered about 55 kW
• Up to 10 % thermodynamic efficiency (maximum ICE load)
• 3 % of global efficiency (24 V electrical power)
D. Di Battista
SAE INTERNATIONAL
Conclusions
ORC Conference 2017 20
• Axial turbine conversion efficiency
• 80% of isentropic efficiency 6 kW thermodynamical power
• 2,5 kW as maximum rated electrical power
• Very low 24 V DC electrical conversion efficiency (40-50%)
• Lubrication oil management
• Turbine start-up difficulties due to the fluid thermal regimation
(need of a turbine bypass branch)
D. Di Battista
SAE INTERNATIONAL
Regeneration stage study
ORC Conference 2017 21 D. Di Battista
Reduction of condenser heat rejected
Smaller condenser
•Up to 16-18 % of thermodynamic efficiency improvement
•Heat recovery reduction of the same amplitude
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