Methods of increasing net work output of organic Rankine cycles for low-grade waste heat recovery with a detailed analysis using a zeotropic working fluid mixture and scroll expander
Abstract
An organic Rankine cycle (ORC) is a thermodynamic cycle that is well-suited for waste heat recovery. It is generally employed for waste heat with temperatures in the range of 80 °C – 300 °C. When the application is strictly to convert waste heat into work, thermal efficiency is not recommended as a key performance metric. In such an application, maximization of the net power output should be the objective rather than maximization of the thermal efficiency. Two alternative cycle configurations that can increase the net power produced from a heat source with a given temperature and flow rate are proposed and analyzed. These cycle configurations are 1) an ORC with two-phase flash expansion and 2) an ORC with a zeotropic working fluid mixture (ZRC). A design-stage ORC model is presented for consistent comparison of multiple ORC configurations. The finite capacity of the heat source and heat sink fluids is a key consideration in this model. Of all working fluids studied for the baseline ORC, R134a and R245fa yield the highest net power output from a given heat source. Results of the design-stage model indicate that the ORC with two-phase flash expansion offers the most improvement over the baseline ORC. However, the level of improvement that could be achieved in practice is highly uncertain due to the requirement of highly efficient two-phase expansion. The ZRC shows improvement over the baseline as long as the condenser fan power requirement is not negligible. At the highest estimated condenser fan power, the ZRC shows the most improvement, while the ORC with flash expansion is no longer beneficial. The ZRC was selected for detailed study because it does not require two-phase expansion. An experimental test rig was used to evaluate baseline ORC performance with R134a and with R245fa. The ZRC was tested on the same rig with a mixture of 62.5% R134a and 37.5% R245fa. The tested expander is a minimally-modified, of-the-shelf automotive scroll compressor. The high performance to cost ratio of this machine lends significant credence to the economic viability of small-scale, low-temperature ORCs. The experimental campaign covered two heat source temperatures, the full range of pump and expander speeds, a full range of heat source and heat sink fluid flow rates, and various charge levels for the three working fluids. This resulted in 366 steady-state measurements. The steady state measurements are used to develop a detailed ORC model. The model is based on multi-fluid performance maps for the pump and expander and a robust moving-boundary heat exchanger model. It is validated against the measured data and predicts the net power output of the tested ORC with a mean absolute percent error of 7.16%. Comparisons made with the detailed model confirm the predictions of the design-stage model. Using a conservative estimate of the condenser fan power, 19.1% improvement of the ZRC over the baseline ORC is indicated for a source temperature of 80 °C. For a 100 °C source temperature, 13.8% improvement is indicated. A key feature of the detailed ORC model is that it calculates the charge inventory of the working fluid in each heat exchanger and line set. Total system charge can also be specified as a model input. The model can represent the total charge well for R134a at low measured charge levels. As the measured charge level increases, the model becomes less accurate. Reasons for the deviation of the model at higher charge are investigated. It is expected that a charge tuning scheme could be employed to improve the accuracy of model-predicted charge.
Degree
Ph.D.
Advisors
Groll, Purdue University.
Subject Area
Alternative Energy|Mechanical engineering|Energy
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