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Thesis Technoecomonic Optimization and Working THESIS TECHNOECOMONIC OPTIMIZATION AND WORKING FLUID SELECTION FOR AN ENGINE COOLANT DRIVEN TURBO-COMPRESSION COOLING SYSTEM Submitted by Derek Nicholas Young Department of Mechanical Engineering In partial fulfillment of the requirements For the Degree of Master of Science Colorado State University Fort Collins, Colorado Summer 2018 Master’s Committee: Advisor: Todd M. Bandhauer Jason C. Quinn Jesse Burkhardt Copyright Derek Nicholas Young 2018 All Rights Reserved ABSTRACT TECHNOECOMONIC OPTIMIZATION AND WORKING FLUID SELECTION FOR AN ENGINE COOLANT DRIVEN TURBO-COMPRESSION COOLING SYSTEM The abundance of low grade waste heat presents an opportunity to recover typically unused heat energy and improve system efficiencies in a number of different applications. This work examines the technoeconomic performance of a turbo-compression cooling system designed to recover ultra-low grade (≤ 100°C) waste heat from engine coolant in large marine diesel engine- generator sets. In addition, five different working fluids (R134a, R152a, R245fa, R1234ze(E), and R600a) were studied for this application to better understand the effects of fluid properties on technical and economic system performance. A coupled thermodynamic, heat exchanger, and economic model was developed to calculate the payback period of the turbo-compression cooling system. Then, the payback period was minimized by optimizing the surface area of the heat exchangers by varying the effectiveness of the heat exchangers. The sensitivity of the payback period to the heat exchanger effectiveness values was quantified to inform future design considerations. The turbo-compression cooling system with R152a had the lowest payback period of 1.67 years and an initial investment of $181,846. The R1234ze(E) system had the highest cooling capacity of 837 kW and the highest overall COP of 0.415. The R152a system provided cooling for $0.0060 per kWh which was nearly 10 times cheaper than the cost of cooling provided by a traditional electrically driven vapor compression system onboard a marine vessel. ii ACKNOWLEDGEMENTS I would like to first thank Dr. Todd Bandhauer for providing guidance and his expert opinions throughout my graduate career. Every day is interesting while working for Dr. Bandhauer because of his unending excitement for thermal sciences. He truly took a chance on me when I came to CSU because I didn’t know a thing about engineering. I appreciate his patience as I was coming up to speed the first two semesters (and beyond). I’m truly lucky to have him as a mentor! This short paragraph cannot do justice to how much he has influenced me. I’d also like to thank the other graduate students in the ITS Lab, specifically Shane Garland, David Hobby, John Simon, Alex Grauberger, Spencer Gibson, and Torben Grumstrup. If I could put second authors on this thesis, I would. The hours upon hours we’ve spent bouncing ideas off each other (some really, really dumb ideas that led us to great ones) has been so important and helpful to me. Understanding different perspectives in solving the same problem has helped me grow as an individual and an engineer. In addition, I’d like to give a shout out to some individuals at the Powerhouse Energy Campus: the Control Room Crew, Colin Gould, John Mizia, Andrew Zdanowicz, Chris van Roekel, Betsy Farris, Adam Friss, Max Flagge, and many more that I haven’t listed here (sorry, I have to send this thesis to Dr. B in ~30 minutes). When you work surrounded by great friends, it makes the work a lot more enjoyable. Further, the grassroots movement known as the Energy Institute Sports League (EISL) has been a great stress reliever and community builder for the last year or so. I’d also like to thank my family and friends. Without your unending love and support, I wouldn’t be half the person I am today. Mom, Dad, G, L-Dog: thank you all so much. I love you iii guys with everything I have! I’d also like to thank Kendyl ‘Kenny G’ Kelly: you are the best I could ask for! I appreciate your sense of adventure, compassion, and calming presence. I love ya a whole ton. iv TABLE OF CONTENTS ABSTRACT .................................................................................................................................. ii ACKNOWLEDGEMENTS .......................................................................................................... iii LIST OF TABLES ........................................................................................................................ vii LIST OF FIGURES ..................................................................................................................... viii NOMENCLATURE ....................................................................................................................... x CHAPTER 1. Introduction ....................................................................................................... 1 1.1. Motivation for Waste Heat Recovery ............................................................................. 1 1.2. Waste Heat Availability .................................................................................................. 3 1.3. Waste Heat Recovery Systems and Applications ........................................................... 6 1.4. Research Objectives ........................................................................................................ 9 1.5. Thesis Organization ...................................................................................................... 10 CHAPTER 2. Literature Review ............................................................................................ 11 2.1. Absorption Refrigeration Technology .......................................................................... 12 2.1.1. Review of technology research ............................................................................. 16 2.1.2. Review of technoeconomic research .................................................................... 23 2.2. Organic Rankine-Vapor Compression Refrigeration.................................................... 30 2.2.1. Review of technology research ............................................................................. 31 2.2.2. Review of technoeconomic research .................................................................... 42 2.3. Research Needs for Thermally Activated Cooling Systems ......................................... 48 2.4. Specific Aims of this Study .......................................................................................... 51 CHAPTER 3. Modeling Approach ......................................................................................... 53 3.1. Turbo-Compression Cooling System ............................................................................ 53 3.2. Overview of Modeling Approach ................................................................................. 56 3.3. Thermodynamic Modeling............................................................................................ 57 3.3.1. Full System Model ................................................................................................ 59 3.3.2. Working Fluid Selection ....................................................................................... 61 3.3.3. Turbo-compression Cooling Thermodynamic Model .......................................... 62 3.3.4. Cordier Analysis ................................................................................................... 64 3.4. Plate and Frame Heat Exchanger Modeling ................................................................. 67 3.4.1. Epsilon-NTU Heat Exchanger Method ................................................................. 69 3.4.2. Correlations for Heat Transfer Coefficients in Plate and Frame Heat Exchangers 73 3.4.3. Pressure Drop in Plate and Frame Heat Exchangers ............................................ 77 3.5. Economic Modeling ...................................................................................................... 83 3.5.1. Component Cost Models....................................................................................... 83 3.5.2. System Refrigerant Charge ................................................................................... 85 3.5.3. Simple Payback Period ......................................................................................... 87 3.5.4. Discounted Cash Flow Rate of Return.................................................................. 89 3.6. Technoeconomic Optimization ..................................................................................... 93 CHAPTER 4. Results of Technoeconomic Optimization and Working Fluid Selection ....... 97 4.1. Thermodynamic Performance ....................................................................................... 97 4.2. Heat Exchanger Design............................................................................................... 101 v 4.3. Economic Performance ............................................................................................... 108 4.4. Sensitivity Analysis .................................................................................................... 117 4.5. Model Validation ........................................................................................................ 121 CHAPTER 5. Conclusions and Recommendation for Further Work ................................... 124 5.1. Recommendations for Future Work...........................................................................
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