This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Parametric Optimization of a Rankine Cycle Based Waste Heat Recovery System for a 1.1 MW Diesel-Gen-Set
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on April 14, 2020 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
In this study, a 1.1 MW diesel-gen-set is used to design a Waste Heat Recovery (WHR) system to generate additional power using Rankine cycle (RC). A computer code is written in commercial Engineering Equation Solver (EES) software to solve equations of overall energy and mass balance, heat transfer, evaporation, condensation, frictional and heat losses for heat exchangers, turbine, pumps, cooling tower and connecting pipes connecting different components. After initial design of the WHR system, manufacturers are contacted to find out the availability of parts, and then, accordingly the design is changed. There are several heat exchangers required to heat the water from liquid to superheated steam and then, it is passed to the turbine. Then, after the expansion in the turbine, it is passed to the condenser to condense the steam to water. Optimization is done on the heat exchangers, focusing on the tube length and diameter. The tube length is changed in accordance to the availability on the market, where it comes in 2 m length. At the rated power of the gen-set, with a pressure ratio of 100 (inlet and outlet pressures to the turbine are 30 bar and 0.3 bar, respectively), an overall improvement of 12.2% is achieved. Results from this study can be applied to large diesel engines used for large trucks which fall in the USA commercial truck category of Class 7 and 8 of heavy trucks, large diesel-gen-set and mobile applications such as ships, heavy construction equipment, ultra-heavy mining movers, excavators and locomotives. It found that the WHR system could be as heavy as the gen-set and they are bulky. Therefore, not only the overall efficiency improvement is important, the size and weight of the WHR system is also very important.
CitationBari, S. and Loh, W., "Parametric Optimization of a Rankine Cycle Based Waste Heat Recovery System for a 1.1 MW Diesel-Gen-Set," SAE Technical Paper 2020-01-0890, 2020.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
- Bari, S. , “An Experimental Study of a Waste Heat Recovery System Connected to a Diesel-Gen-Set,” SAE Technical Paper 2017-01-0123, 2017, https://doi.org/10.4271/2017-01-0123.
- Pulkrabek, W.W. , Engineering Fundamental of the Internal Combustion Engine (Essex, UK: Pearson Prentice Hall, 2004).
- Eastop, T. and McConkey, A. , Applied Thermodynamics for Engineering Technologists (Singapore: Prentice Hall, 1997).
- Heywood, J. , Internal Combustion Engine Fundamentals (McGraw-Hill Education, 1988).
- Caton, J.A. , “Operating Characteristics of a Spark-Ignition Engine Using the Second Law of Thermodynamics: Effects of Speed and Load,” SAE Technical Paper 2000-01-0952, 2000, https://doi.org/10.4271/2000-01-0952.
- Briggs, T.E., Wagner, R., Edwards, K.D., Curran, S. et al. , “A Waste Heat Recovery System for Light Duty Diesel Engines,” SAE Technical Paper 2010-01-2205, 2010, https://doi.org/10.4271/2010-01-2205.
- Saidur, R., Rahim, N.A., Ping, H.W., Jahirul, M.I. et al. , “Energy and Emission Analysis for Industrial Motors in Malaysia,” Energy Policy 37:8, 2009.
- Hasanuzzaman, M., Rahim, N.A., Saidur, R., and Kazi, S.N. , “Energy Savings and Emissions Reductions for Rewinding and Replacement of Industrial Motor,” Energy 36:40, 2011.
- Yang, C., Xie, H., and Zhou, S.K. , “Overall Optimization of Rankine Cycle System for Waste Heat Recovery of Heavy-Duty Vehicle Diesel Engines Considering the Cooling Power Consumption,” Science China Technological Sciences 59:309-321, 2016.
- Hossain, S.N. and Bari, S. , “Additional Power Generation from the Exhaust Gas of Diesel Engine by Bottoming Rankine Cycle,” SAE Technical Paper 2013-01-1639, 2013, https://doi.org/10.4271/2013-01-1639.
- Bari, S. and Hossain, S.N. , “Design and Optimization of Compact Heat Exchangers to be Retrofitted into a Vehicle for Heat Recovery from a Diesel Engine,” Procedia Engineering 105:472-479, 2015.
- Heywood, J.B. , “Automotive Engines and Fuels: A Review of Future Options,” Progress in Energy and Combustion Science 7:155-184, 1981.
- Teng, H., Cowland, C., and Regner, G. , “Achieving High Engine Efficiency for Heavy-Duty Diesel Engines by Waste Heat Recovery using Supercritical Organic Rankine Cycle,” SAE Technical Paper 2006-01-3522, 2006, https://doi.org/10.4271/2006-01-3522.
- Dolz, V., Novella, R., Antonio, G., and Sanchez, J. , “HD Diesel Engine Equipped with a Bottoming Rankine Cycle as a Waste Heat Recovery System. Part 1: Study and Analysis of the Waste Heat Energy,” Aplied Thermal Engineering 36:269-278, 2012.
- Hossain, S.N. and Bari, S. , “Effect of Different Working Fluids on Shell and Tube Heat Exchanger to Recover Heat from Exhaust of an Automotive Diesel Engine,” in World Renewable Energy Congress, Linköping, Sweden, May 8-13, 2011, 764-771.
- Hung, T.C., Shai, T.Y., and Wang, S.K. , “A Review of Organic Rankine Cycles (ORCs) for the Recovery of Lowgrade Waste Heat,” Energy 22:661-667, 1997.
- Wang, E.H., Zhang, H.G., Fan, B.Y., Ouyang, M.G. et al. , “Study of Working Fluid Selection of Organic Rankine Cycle (ORC) for Engine Waste Heat Recovery,” Energy 36:3406-3418, 2011.
- Hossain, S.N. and Bari, S. , “Waste Heat Recovery from Exhaust of a Diesel Generator Set Using Organic Fluids,” Procedia Engineering 90:439-444, 2014.
- Wei, D., Lu, X., Lu, Z., and Gu, J. , “Performance Analysis and Optimization of Organic Rankine Cycle (ORC) for Waste Heat Recovery,” Energy Conversion and Management 48:1113-1119, 2007.
- Wei, M.S., Fang, J.L., and Ma, C.C. , “Waste Heat Recovery from Heavy-Duty Diesel Engine Exhaust Gases by Medium Temperature ORC System,” Sci China Tech Sci 54:2746-2753, 2011.
- Badr, O., Naik, S., O’Callaghan, P.W., and Probert, S.D. , “Expansion Machine for a Low Power-Output Steam Rankine Cycle Engine,” Applied Energy 39:93-116, 1991.
- Quoilin, S., Lemort, V., and Lebrun, J. , “Experimental Study and Modeling of an Organic Rankine Cycle Using Scroll Expander,” Applied Energy 87:1260-1268, 2010.
- Rubaiyat, S.N.H. and Bari, S. , “Waste Heat Recovery Using Shell and Tube Heat Exchanger from the Exhaust of an Automotive Engine,” in 13th Asian Congress of Fluid Mechanics, Dhaka, Bangladesh, 2010, 864-867.
- Tchanche, B., Quoilin, S., Declaye, S., Papadakis, G. et al. , “Economic Optimization of Small Scale Organic Rankine Cycles,” Lausanne, Switzerland, June 14-17, 2010.
- Wali, E. , “Optimum Working Fluids for Solar Powered Rankine Cycle Cooling of Buildings,” Solar Energy 25:235-241, 1980.
- Kanchibhotla, S.A., Joshi, S., and Bari, S. , “Design and Optimization of Exhaust Gas Heat Recovery System Based on Rankine Cycle and Organic Cycles,” SAE Technical Paper 2018-01-1369, 2018, https://doi.org/10.4271/2018-01-13698.
- Kanchibhotla, S.A. and Bari, S. , “Optimum Design Point to Recover Maximum Possible Exhaust Heat Over the Operating Range of a Small Diesel Truck Using Bottoming Rankine Cycle,” SAE Technical Paper 2018-01-1377, 2018, https://doi.org/10.4271/2018-01-1377.
- Joshi, S., Kanchibhotla, S.A., and Bari, S. , “Waste Heat Recovery System for a Turbocharged Diesel Generator at Full and Part Load Operating Conditions Using Rankine and Organic Rankine Cycles,” SAE Technical Paper 2018-01-1370, 2018, https://doi.org/10.4271/2018-01-1370.
- N. Expo , “Diesel Ship Engines,” https://www.nauticexpo.com/boat-manufacturer/diesel-ship-engine-45112.html, accessed Dec. 17, 2020.
- F. H. A. (FHWA) , “Vehicle Weight Classes & Categories,” https://afdc.energy.gov/data/10380, accessed Dec. 17, 2020.
- Wikipedia , “Truck Classification,” accessed Jan. 17, 2020.