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Modelling and Optimization of an Adsorption Cooling System for Automotive Applications (Doctoral Program of Energy Technology)

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Modelling and Optimization of an Adsorption Cooling System for Automotive Applications (Doctoral Program of Energy Technology) UNIVERSIDAD POLITÉCNICA DE VALENCIA DEPARTAMENTO DE TERMODINÁMICA APLICADA Modelling and optimization of an adsorption cooling system for automotive applications (Doctoral Program of Energy Technology) Author Maria Verde Trindade Supervisor Dr. Eng. José Miguel Corberán Salvador Valencia, July 2015 i ii Tesis doctoral Modelling and optimization of an adsorption cooling system for automotive applications Realizada por: Maria Verde Trindade Dirigida por: Dr. D. José Miguel Corberán Salvador Tribunal Calificador: Presidente: Dr. D. Joan Carles Bruno Argilaguet Secretario: Dr. D. José Gonzálvez Maciá Vocales: Dr. D. José Ramón Garcia Cascales Valencia, Julio 2015 iii iv “It's only those who do nothing that make no mistakes, I suppose.” Joseph Conrad, An Outcast of the Islands “I don't like work - no man does - but I like what is in the work - the chance to find yourself. Your own reality - for yourself not for others - what no other man can ever know. They can only see the mere show, and never can tell what it really means.” Joseph Conrad, Heart of Darkness v vi ACKNOWLEDGEMENTS I would like to express my deep appreciation and thanks to my thesis supervisor, Prof. José Miguel Corberán, for giving me the opportunity and motivation to undertake this work. His continuous encouragement, suggestions, advice and guidance throughout this entire course have been a beneficial contribution to this study. Sincere gratitude is also due to Robert de Boer and Simon Smeding of the Energy Research Centre of the Netherlands (ECN), and also Angelo Freni and Alessio Sapienza of the Institute for Advanced Energy Technologies "Nicola Giordano" (CNR-ITAE) for their constant helpfulness and productive collaboration throughout this study. I also would like to thank the members of the examination committee, for their attention and time. In addition, I would like to acknowledge the support I have received from the Fundação para a Ciência e a Tecnologia (FCT) while pursuing this degree. Special thanks to Isabel, Carolina and Ainoa for their friendship and cooperation. Finally, I would like to thank my partner, Apollo. Without his love, patience and understanding, I certainly would have never succeeded in seeing this study to its end. It is to him, and my love for him, that I dedicate this work. vii viii SUMMARY This PhD study deals with the modelling of an adsorption system designed to provide air conditioning for vehicles, and is driven by the waste heat available from the water/glycol cooling circuit of the engine. The system is based on the sequential heating/cooling of two sorption beds containing a solid sorption material which desorbs or adsorbs water vapour. The condensation of the vapour is carried out by a cooling circuit while the subsequent evaporation of the condensed liquid is employed to produce the cooling effect, generating chilled water, which is then employed to cool down the air of the cabin. The developed model is fully dynamic and is based on zero-dimensional lumped parameter models for all the necessary components of the overall system including the engine, the beds, the heating circuit, the cooling circuit, the chilled water circuit and the vehicle cabin. The sorption bed model takes into account the non-equilibrium of the adsorption and desorption processes and is able to work with any kind of adsorbent materials, but the study has been restricted to silica gel and zeolite which are among the most appropriate materials for this application. The model is employed to simulate a standard driving cycle of a vehicle, evaluating the instantaneous available heat from the engine cooling system and the dynamic behaviour of the described sorption A/C system, resulting in the estimation of the evolution of the cabin temperature along the cycle. The model of the overall system has been developed under the MATLAB® Simulink® programming environment. The model of the adsorption system has been first validated against experimental results, showing its excellent capabilities to predict the dynamic behaviour of the system. The model was then used to analyse the influence of the main design parameters of the bed and the main operation parameters on the system's performance: cooling capacity and coefficient of performance (COP). This was done in order to provide rules for the optimal design and operation of this kind of systems. ix Finally, the model has been employed to analyse the overall system (engine, adsorption system, heating and cooling circuits, chilled water circuit and cabin) performance along a standard driving cycle, under various operation strategies with regards to the initial state of the adsorbent material in the beds, and operation conditions both for a car and a truck. The results show the difficulties of activating the system at the initial periods of the cycle, when the engine is warming up, and the difficulties to synchronise the operation of the system with the availability of waste energy. They also highlight the limitation in capacity of the designed system, showing that it would not able to fulfil the comfort requirements inside the cabin in hot days or after soaking conditions. Part of this PhD study was carried out in the frame of an R&D project called “Thermally Operated Mobile Air Conditioning Systems – TOPMACS”, financially supported by the EU under the FP6 program, which was devoted to the evaluation of the feasibility and performance of potential sorption system solutions for the air conditioning of vehicles. x RESUMEN Esta tesis doctoral se centra en el modelado de un sistema de adsorción diseñado para proporcionar aire acondicionado de vehículos a partir del calor residual disponible en el circuito de refrigeración de agua/glicol del motor. El sistema se basa en el calentamiento/enfriamiento secuencial de dos reactores que contienen un material adsorbente sólido que desorbe o absorbe vapor de agua. La condensación del vapor se lleva a cabo mediante un circuito de refrigeración, mientras que la posterior evaporación del agua condensada se emplea para producir agua fría, que se emplea finalmente en enfriar el aire de la cabina. El modelo desarrollado es completamente dinámico y se basa en modelos cero dimensionales de parámetros concentrados, para todos y cada uno de los componentes del sistema global incluyendo el motor, los reactores, el circuito de calentamiento, el circuito de enfriamiento, el circuito de agua fría y la cabina del vehículo. El modelo del reactor contempla el no equilibrio de los procesos de adsorción o desorción y es capaz de trabajar con cualquier par de materiales adsorbentes. No obstante el estudio se ha restringido a gel de sílice y zeolita que se encuentran entre los materiales más adecuados para esta aplicación. El modelo se emplea para simular un ciclo de conducción estándar del vehículo, evaluando el calor disponible instantáneamente en el sistema de refrigeración del motor, y el comportamiento dinámico del sistema descrito adsorción-Aire Acondicionado, permitiendo como resultado principal la estimación de la evolución de la temperatura de la cabina a lo largo el ciclo. El modelo del sistema global se ha desarrollado en el marco del entorno de programación MATLAB® Simulink®. El modelo del sistema de adsorción se ha validado primero contra resultados experimentales demostrando las excelentes capacidades del modelo para predecir el comportamiento dinámico del sistema. A continuación, el modelo se ha aplicado para analizar la influencia de los principales parámetros de diseño del reactor, y de los principales parámetros de operación, sobre el rendimiento del sistema: la capacidad y coeficiente de xi operación (COP), con el fin de proporcionar directrices para el diseño y operación óptima de este tipo de sistemas. Por último, el modelo ha sido empleado para analizar el funcionamiento y prestaciones del sistema en su conjunto (motor, sistema de absorción, los circuitos de calefacción y refrigeración, circuito de agua fría, y la cabina) a lo largo de un ciclo de conducción estándar, bajo diferentes estrategias de operación en lo que se refiere al estado inicial del material adsorbente en los reactores, y las condiciones de operación, para el caso de un coche, y para el de un camión. Los resultados muestran las dificultades de la activación del sistema en los periodos iniciales del ciclo, cuando el motor se está calentando, y las dificultades para sincronizar el funcionamiento del sistema con la disponibilidad de energía térmica excedente del motor, así como la limitación en la capacidad de enfriamiento del sistema diseñado, que no resulta capaz de satisfacer los requerimientos mínimos de confort dentro de la cabina en los días calurosos o de enfriarlo con suficiente rapidez cuando el vehículo ha estado estacionado bajo el sol durante varias horas. Parte de este estudio de doctorado se ha llevado a cabo en el marco de un proyecto de I + D denominado " Thermally Operated Mobile Air Conditioning Systems – TOPMACS", financiado parcialmente por la UE en el marco del programa FP6, y que perseguía la evaluación de la viabilidad y el potencial de aplicación de soluciones de sistemas de adsorción activadas por el calor residual del motor para el aire acondicionado de vehículos. xii RESUM Aquesta tesi doctoral es centra en el model d'un sistema d'adsorció dissenyat per a proporcionar aire acondicionat a vehicles a partir de la calor residual disponible al circuit de refrigeració d'aigua / glicol del motor. El sistema es basa en l'escalfament / refredament seqüencial de dos reactors que contenen un material adsorbent sòlid que desorbeix o absorbeix vapor d'aigua. La condensació del vapor es porta a terme mitjançant un circuit de refrigeració, mentre que la posterior evaporació de l'aigua condensada s'utilitza per a produir aigua freda, que s'empra finalment en refredar l'aire de la cabina. El model desenvolupat és completament dinàmic i es basa en models zero dimensionals de paràmetres concentrats, per a tots i cada un dels components del sistema global incloent el motor, els reactors, el circuit d'escalfament, el circuit de refredament, el circuit d'aigua freda i la cabina del vehicle.
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