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Masters Thesis: Efficient Design of Maritime Chiller Configurations

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Masters Thesis: Efficient Design of Maritime Chiller Configurations Efficient Design of Maritime Chiller Configurations The integration of absorption chillers with a diesel engine’s cooling water circuit LTZ3 (TD) A.J. van Fulpen Master of Science Thesis Efficient Design of Maritime Chiller Configurations The integration of absorption chillers with a diesel engine’s cooling water circuit Master of Science Thesis For the degree of Master of Science in Marine Engineering at Delft University of Technology LTZ3 (TD) A.J. van Fulpen June 13, 2016 Report nr: SDPO.016.014.m Graduation Committee Prof. Ir. J.J. Hopman Chairman Ir. K. Visser Daily Supervisor TU Delft Ir. T. van Beek Daily Supervisor Wärsilä Dr. Ir. C.A. Infante Ferreira Third Reader Ir. J. den Haan Fourth Reader Faculty of Mechanical, Maritime and Materials Engineering (3mE) · Delft University of Technology The work in this thesis was supported by Wärtsilä Netherlands B.V. Their cooperation is hereby gratefully acknowledged. Copyright c Marine Technology All rights reserved. Abstract Reducing emissions in the shipping industry has been a hot topic for more then a decade due to different reasons. High oil prices used to motivate shipbuilders to increase a vessel’s total fuel efficiency. Nowadays, these developments are driven by CO2-taxes and emission controlled areas so that in the end, the environmental impact by the burning of fossil fuels will be reduced. An effective way in improving a vessel’s efficiency is by the recovery of waste heat. Lots of researches and implementations of recovering heat from exhaust gases exist, but recovering heat from an engine’s cooling water circuit isn’t implemented on global scale yet, while the heat in this circuit for some engines might be as high as 20 % of the total incoming energy. This thesis explores the available technology in recovering heat from medium-grade energy streams (water with a temperature around 90 ◦C) and focusses mainly on the integration of a single-stage absorption chiller on a frigate. A frigate was initially expected to be suitable because of its balance between available heat and required cooling capacity. Although this balance is indeed present, a developed dynamic model showed the complexity of coupling the absorption chiller to an engine with a highly variable operating range. In order to integrate an absorption chiller with a diesel engine, the most important design consideration is the temperature of the engine’s cooling water after the absorption chiller. This temperature should remain constant over time, but this temperature is very dependent on the mass flow and seawater temperature, which calls for a control system. By creating a hot water by-pass, this temperature can be kept constant, which is easier to maintain when the operating range is small. For a frigate with a hybrid propulsion, 4 % of fuel could be saved with a return on investment of 12 years. When using a direct configuration, the RoI would be 20 years for the same reduction in fuel consumption. Better potential have ships with a constant operating profile (a cargo ship) or ships with multiple generator sets (a hybrid cruise ship). For the latter, a fuel reduction of 210 tons per month could be realized, which results in a return on investment of 7 years. Master of Science Thesis LTZ3 (TD) A.J. van Fulpen ii LTZ3 (TD) A.J. van Fulpen Master of Science Thesis Table of Contents Abbreviations vii List of Acronyms................................... vii List of Symbols ix Preface xi 1 Introduction1 1-1 Background..................................... 1 1-2 Research objective.................................. 2 1-3 Structure of the thesis................................ 2 2 Waste Heat Driven Refrigeration Configurations5 2-1 The Vapour Compression Cooling Machine..................... 5 2-2 Organic Rankine-Vapour Compression Cycle.................... 8 2-3 Vapour Absorption Cooling Machine........................ 8 2-3-1 Fluid Pairs.................................. 11 2-3-2 Crystallization................................ 12 2-3-3 State of the Art VACM........................... 13 2-4 Two-Stage Absorption Chiller............................ 17 2-4-1 Serial Two-Stage Absorption Chiller.................... 17 2-4-2 Parallel Two-Stage Absorption Chiller................... 18 2-4-3 State of the Art Two-Stage VACM..................... 19 2-5 Combined Vapour Compression-Absorption Machine................ 20 2-5-1 State of the Art Combined Chillers..................... 21 2-6 Cascaded Vapour Compression-Absorption System................. 22 2-6-1 State of the Art CVCAS.......................... 23 2-7 Configuration Overview............................... 24 Master of Science Thesis LTZ3 (TD) A.J. van Fulpen iv Table of Contents 3 Case Study: Air Defence and Command Frigate 27 3-1 Available Heat.................................... 27 3-1-1 Propulsion.................................. 27 3-1-2 Power Generation.............................. 32 3-2 Cooling Capacity.................................. 33 3-2-1 Chilled Water Plant............................. 33 3-2-2 Chilled Water Distribution System..................... 34 3-2-3 Temperature Levels............................. 36 3-2-4 Actual Usage of Cooling System...................... 37 3-3 Proposed System Design.............................. 39 4 Steady-state model for design condition 41 4-1 Steady State Model................................. 41 4-1-1 Fluid Properties............................... 43 4-1-2 Steady-state equations........................... 43 4-1-3 Initial Design Conditions.......................... 45 4-2 Sensitivity Analysis................................. 46 4-2-1 Effect of LiBr Concentration........................ 46 4-2-2 Effect of generator temperatures...................... 49 4-2-3 Pressure drop................................ 50 4-3 Design Point..................................... 50 4-3-1 Coupling Fluids............................... 51 5 Dynamic Model of an Absorption Chiller 53 5-1 Modelling Paradigms................................ 53 5-1-1 Control Volumes............................... 53 5-1-2 Dynamic description of system....................... 56 5-1-3 Time Scale.................................. 57 5-1-4 Causality Principle.............................. 58 5-1-5 Fluid Pairs.................................. 60 5-2 Condenser...................................... 60 5-2-1 Condenser - Storage Equations Two-Phase Side.............. 61 5-2-2 Condenser - Storage Equation Wall..................... 64 5-2-3 Condenser - Storage Equation Cooling Water............... 64 5-2-4 Condenser - Resistive Equations...................... 66 5-3 Evaporator...................................... 67 5-4 Absorber....................................... 67 5-5 Generator...................................... 69 5-6 Solution Heat Exchanger.............................. 70 5-6-1 Heat Transfer................................ 71 5-7 Valve......................................... 71 5-8 Pump........................................ 74 5-9 Design Process and parametrization........................ 76 LTZ3 (TD) A.J. van Fulpen Master of Science Thesis Table of Contents v 6 Model Validation and Verification 83 6-1 Dynamic Validation Small-Scale Absorption Chiller................ 83 6-1-1 System behaviour after hot water temperature increase.......... 84 6-1-2 Validation with Evola’s work........................ 88 6-2 System Characteristics................................ 90 6-2-1 Temperature Profiles Heat Exchangers................... 91 6-2-2 Sensitivity - Hot Water Inlet Temperature................. 92 6-2-3 Sensitivity - Chilled water inlet temperature................ 94 6-2-4 Sensitivity - Cooling water inlet temperature................ 95 6-2-5 Sensitivity - Hot water mass flow...................... 97 7 Integration on Frigate 99 7-1 Configuration 1; No control............................. 102 7-2 Configuration 2; Internal control.......................... 103 7-2-1 Control by variable heat exchange area................... 104 7-2-2 Controlling by decreasing cooling water mass flow............. 107 7-3 Configuration 3; Hot water by-pass......................... 109 7-3-1 Configuration 3b; Combining by-pass and area............... 111 7-4 Configuration 4; Shared HT-CW circuit...................... 113 7-5 Configuration 5; 2 ACM per engine......................... 114 7-6 Integration with generator sets........................... 116 7-7 Total Cooling Capacity and Fuel Reduction.................... 118 7-7-1 Actual fuel reduction............................ 120 7-7-2 Return on Investment............................ 120 7-8 Dynamic Response.................................. 121 7-8-1 Time constant................................ 121 7-8-2 Crystallization................................ 123 7-9 Future Integration.................................. 124 7-10 Practical considerations............................... 127 7-10-1 Need for compressor coolers........................ 128 7-10-2 Cold water buffers.............................. 128 7-10-3 Separated water distribution system.................... 128 7-10-4 Recommendation.............................. 128 8 Integration on Other Platforms 131 8-1 Suitable Platforms.................................. 131 8-2 Return on Investment................................ 132 9 Conclusions and Recommendations 135 9-1 Conclusions..................................... 135 9-1-1 Main Conclusion............................... 135 9-1-2 Other Relevant Conclusions......................... 136 9-2 Recommendations.................................. 138 Master
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