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Designing the Dynamic Response of Organic Rankine Cycle Evaporators in Waste Heat Recovery Applications

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Designing the Dynamic Response of Organic Rankine Cycle Evaporators in Waste Heat Recovery Applications This document is downloaded from DR‑NTU (https://dr.ntu.edu.sg) Nanyang Technological University, Singapore. Designing the dynamic response of Organic Rankine Cycle evaporators in waste heat recovery applications Jiménez‑Arreola, Manuel 2019 Jiménez‑Arreola, M. (2020). Designing the dynamic response of Organic Rankine Cycle evaporators in waste heat recovery applications. Doctoral thesis, Nanyang Technological University, Singapore. https://hdl.handle.net/10356/140132 https://doi.org/10.32657/10356/140132 This work is licensed under a Creative Commons Attribution‑NonCommercial 4.0 International License (CC BY‑NC 4.0). Downloaded on 28 Sep 2021 01:53:53 SGT DESIGNING THE DYNAMIC RESPONSE OF ORGANIC RANKINE CYCLE EVAPORATORS IN WASTE HEAT RECOVERY APPLICATIONS MANUEL JIMÉNEZ ARREOLA Interdisciplinary Graduate School Energy Research Institute @ NTU 2019 DESIGNING THE DYNAMIC RESPONSE OF ORGANIC RANKINE CYCLE EVAPORATORS IN WASTE HEAT RECOVERY APPLICATIONS MANUEL JIMÉNEZ ARREOLA INTERDISCIPLINARY GRADUATE SCHOOL A thesis submitted to the Nanyang Technological University in partial fulfilment of the requirement for the degree of Doctor of Philosophy 2019 Statement of Originality I hereby certify that the work embodied in this thesis is the result of original research, is free of plagiarised materials, and has not been submitted for a higher degree to any other University or Institution. 02 August 2019 . Date Manuel Jiménez Arreola Supervisor Declaration Statement I have reviewed the content and presentation style of this thesis and declare it is free of plagiarism and of sufficient grammatical clarity to be examined. To the best of my knowledge, the research and writing are those of the candidate except as acknowledged in the Author Attribution Statement. I confirm that the investigations were conducted in accord with the ethics policies and integrity standards of Nanyang Technological University and that the research data are presented honestly and without prejudice. 02 August 2019 . Date Asst. Prof. Alessandro Romagnoli Authorship Attribution Statement This thesis contains material from 4 papers published in the following peer-reviewed journals and conference proceeding where I was the first author. Chapter 2 is published partially as M. Jiménez-Arreola, R. Pili, F. Dal Magro, C. Wieland, S. Rajoo and A. Romagnoli. Thermal power fluctuations in waste heat to power systems: an overview on the challenges and current solutions. Applied Thermal Engineering 134, 576–584 (2018). DOI: 10.1016/j.applthermaleng.2018.02.033. The contributions of the co-authors are as follows: • I prepared the manuscript drafts. The manuscript was revised by Prof. Alessandro Romagnoli, Dr. Christoph Wieland and Prof. Srithar Rajoo • I compounded the literature review, performed the technical assessments, designed the sections layout and prepared and formatted all figures. • Mr. Roberto Pili provided the methods and calculations of the economics considerations section. • Dr. Fabio Dal Magro provided guidance on the technical assessment. Chapter 4 is published partially as M. Jiménez-Arreola, C. Wieland and A. Romagnoli. Response time characterization of Organic Rankine Cycle evaporators for dynamic regime analysis with fluctuating load. Energy Procedia 129, 427–434 (2017). DOI: 10.1016/j.egypro.2017.09.131. The contributions of the co-authors are as follows: • I wrote the drafts of the manuscript. The manuscript was revised by Prof. Alessandro Romagnoli and Dr. Christoph Wieland • I performed all the dynamic simulations, built the response time maps and provided the discussion and interpretation of results. • Dr. Christoph Wieland and Alessandro Romagnoli assisted with ideas for the development of the response time maps. Chapter 5 is published as M. Jiménez-Arreola, R. Pili, C. Wieland and A. Romagnoli. Analysis and comparison of dynamic behavior of heat exchangers for direct evaporation in ORC waste heat recovery applications from fluctuating sources. Applied Energy 216, 724- 740 (2018). DOI: 10.1016/j.apenergy.2018.01.085. The contributions of the co-authors are as follows: • I wrote the drafts of the manuscript. The manuscript was revised by Prof. Alessandro Romagnoli, Dr. Christoph Wieland and Mr. Roberto Pili • I performed all the dynamic simulations, built the response time maps, performed the application case study and provided the discussion and interpretation of results. • Mr. Roberto Pili assisted on the interpretation of the results. • Dr. Christoph Wieland and Alessandro Romagnoli assisted with ideas for the development of the methodology Chapter 6 is published as M. Jiménez-Arreola, C. Wieland and A. Romagnoli. Direct vs indirect evaporation in Organic Rankine Cycle (ORC) systems: A comparison of the dynamic behavior for waste heat recovery of engine exhaust. Applied Energy 242, 439-452 (2018). DOI: 10.1016/j.apenergy.2019.03.011 The contributions of the co-authors are as follows: • I wrote the drafts of the manuscript. The manuscript was revised by Prof. Alessandro Romagnoli and Dr. Christoph Wieland • I performed all the dynamic simulations, built the response time maps, performed the application case study, developed the concepts of the amplitude ratio and provided the discussion and interpretation of results. • Dr. Christoph Wieland and Alessandro Romagnoli assisted with ideas for the development of the methodology 02 August 2019 . Date Manuel Jiménez Arreola Abstract Abstract This dissertation investigates an alternative method for Organic Rankine Cycle (ORC) systems to manage thermal power fluctuations in waste heat recovery (WHR) applications. Organic Rankine Cycle is one of the most prominent technologies for power generation from waste heat sources. However, due to their nature as residual energy from an upstream process waste heat sources typically present a fluctuating behavior that makes the recovery of the heat for power generation a challenging task. On ORC systems in particular, the high variability of the waste heat thermal power can lead to system inefficiencies due to off- design conditions and in extreme cases to chemical decomposition of the ORC fluid or to expander damage due to liquid droplets. Because of this thermal power fluctuations, an adequate control system may be required to maintain reliable operation of the ORC system. However, that may not be sufficient and additional measures are often put in place to ensure operation within safe boundaries. The most common is the implementation of heat transfer fluid as an intermediary for the heat transfer process of the waste heat to the ORC effectively damping the fluctuations. Another option is the addition of an external thermal energy storage unit. However, intermediary heat transfer fluids or external energy storages increase the complexity of the system, reduce its potential for high thermal efficiency and increase the weight and volume of the system, which is limiting factor in some applications such as the mobile. This dissertation explores a different approach. It proposes that the thermal inertia of the heat exchanger that is used as the evaporator in the Organic Rankine Cycle can be customized by design in order to obtain a dynamic behavior that provides a more robust system to the changes in thermal power and enables the possibility of a potentially more efficient system with lower footprint and complexity. For these purposes, the evaporator design is reimagined in order to include its thermal inertia as an essential factor to be considered. Abstract In order to investigate the dynamic behavior and performance of different ORC evaporators and their thermal inertia, a full dynamic model must be used. This model is successfully validated against experimental data to increase the confidence on the results. The model is used then to simulate the dynamic behavior of different candidate evaporators. Based on extensive simulation results of different types and geometries of heat exchangers, a methodology for the evaporator design, with an emphasis on dynamic behavior, is progressively developed and finally integrated into a cohesive procedure. The novel methodology incorporates new tools and concepts such as the response time maps, dynamic regimes and amplitude ratios. Notably, the results and the methodology developed in this dissertation are not bound by any specific case and can be applied to any situation of ORC systems recovering waste heat. Lay Summary Lay Summary The objective of this thesis is to aid in the development of more sustainable energy systems. One way to increase the sustainability of energy systems and processes is by increasing their energy conversion efficiency and to reduce the waste of energy resources. A method to reduce waste of energy resources is by recuperating residual heat -from sources such as industrial processes or engines- which is normally discarded to the ambient and left unused. This residual heat is called waste heat. The energy of the recuperated waste heat can be transformed to produce electrical power which is an energy form that is more versatile and easier to utilize. One particular technology that is used to transform unused waste heat into electrical power is called Organic Rankine Cycle (ORC) and is studied in this thesis. Although this technology is very well stablished there are still some limiting factors that hinder its applicability. One of those limiting factors is the fact that the waste heat content is typically intermittent and has a fluctuating nature. Since ORCs work better when the supply of waste heat
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