Experimental Investigations on CO 2 -Based Transcritical Rankine Cycle (CTRC) for Waste Heat Recovery of Diesel Engine

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1 Experimental Investigations on CO 2 -Based Transcritical Rankine Cycle (CTRC) for Waste Heat Recovery of Diesel Engine Lingfeng Shi, Gequn Shu, Hua Tian et al. State Key Laboratory of Engines (SKLE), Tianjin University, Tianjin, China shilingfeng@tju.edu.cn / thtju@tju.edu.cn

2 Outline 1. Background 2. System and Method 3. Results 4. Summary

3 Background-Why Engine WHR? 3 Energy Saving Power or Work Thermodynamic Cycle Turbocharging Thermoelectric generator WHR Thermodynamic Cycle: High efficiency Well thermal match Good feasibility

4 Backgroud-Why CTRC? 4 CO 2 is a natural working fluid Safe: non-toxic, non-corrosive, inflammable, non-explosive Environmentally friendly: ODP=0, GWP=1 High thermal stability: direct contact with HT exhaust gas Supercritical CO 2 has unique thermophysical properties Tcrit=31.1 ; Pcrit=7.38 MPa High density, low viscosity Compact turbine, Compact HE Small expansion ration

5 Backgroud-Why CTRC? 5 CTRC could achieve miniaturization Meet the demand of mobile applications CTRC could better recover exhaust and coolant energy simultaneously (Applied Energy, 2016, 176: ) Even both utilization rate of 1 ORC Engine Coolant Exhaust Gas CTRC Low Utilizaiton rate of engine coolant for ORC Utilization rate comparison between CTRC and ORC (R123) Heat absorption capbility between CO 2 and R123

6 Thermal efficiency comparison between CTRC and ORCs ((Zhang et al. Appl. Eng. 88 (2011) )) Background-Basic CTRC 6 B-CTRC Components: Pump B-CTRC: CTRC with Basic Configuration Gas heater Turbine & Generator Condenser Drawback of B-CTRC: Low thermal efficiency Low power output

7 Background-Modified CTRC Efficient Solution: Modified Configurations 1. Add energy input from outside: engine coolant as preheat source 2. Add energy input from inside: high temp. exhaust CO 2 3. Both of 1 and 2 7 P-CTRC: CTRC with Preheated Configuration R-CTRC: CTRC with Regenerated Configuration PR-CTRC: CTRC with Preheated and Regenerated Configuration Object of study (experimental way): Compare thermodynamic performance between four CTRC configurations and find improved degree by modified CTRC

8 Outline 1. Background 2. System and Method 3. Results 4. Summary

9 System Layout 9 Main design parameters: Power output:4.5kw Maximum pressure : 11MPa Maximum temperature : 230 Cold EC Supplement EC Flowmeter2 T P ec,3 T P Engine coolant system Damper ec,4 EC Tank EC Pump2 Diesel Engine EC Flowmeter1 T EC Pump1 g,2 ec,2 T g,1 ec,1 1 2 Valve5 8 3 CO 2 Flowmeter Preheater Gas Heater g,0 Valve1 Valve2 Diesel engine system 7 CO 2 Pump Regenrator CTRC system Cooling Jacket Expansion Valve Valve3 Valve4 Filter 6 5 CO 2 Tank T Condenser T c,1 c,2 9 Precooler T c,3 Valve6 4 Exhaust Gas Engine Coolant (EC) T & P Sensor T Display Cooling Water Flowmeter Refrigeration Unit CO 2 Cooling Water P Display Valve

10 CTRC system System Photos Gas heater Pump 10 The other HEs Expansion Valve/ Turbine Control, Record and Alarm

11 Four CTRC Switch 11 Cold EC Supplement EC Flowmeter2 T P ec,3 T P Control EC Pump1: On: With Preheating off: Without Preheating Damper ec,4 EC Tank EC Pump2 Diesel Engine EC Flowmeter1 T EC Pump1 g,2 ec,2 T g,1 ec,1 1 2 Valve5 8 3 CO 2 Flowmeter Preheater Gas Heater g,0 Valve1 Valve2 Control Valve1-4: On: With IHX Off: Without IHX 7 CO 2 Pump Regenrator Cooling Jacket 6 5 Filter CO 2 Tank T Condenser T c,1 c,2 9 Precooler T c,3 Expansion Valve Valve3 Valve4 Valve6 4 Exhaust Gas T & P Sensor Engine Coolant (EC) T Display Cooling Water Flowmeter Refrigeration Unit CO 2 Cooling Water P Display Valve Four CTRC configurations can be tested in this bench: B-CTRC R-CTRC P-CTRC PR-CTRC EC Pump1 Off Off On On Valve1-4 Off On Off On

12 Experimental Strategy 12 Same Boundary Conditions for Four CTRCs Heat sources: 1) Same operating conditions of engine (1100rpm,50%load) 2) Same EC temperature (87 ) and EC pump speed (8.75Hz) Fluid flow rate: Same pump speed (80Hz) Operating Conditions for Four CTRCs Cold EC Supplement EC Flowmeter2 ec,3 Damper ec,4 EC Tank EC Pump2 Diesel Engine EC Flowmeter1 T EC Pump1 g,2 ec,2 T g,1 ec,1 1 2 Valve5 8 3 Gas Heater CO2 Flowmeter Preheater g,0 Valve1 Valve2 High and low pressures 7 Filter CO2 Pump Cooling Jacket 6 CO2 Tank T Condenser T c,1 c,2 Cooling Water Flowmeter 5 Precooler T c,3 Refrigeration Unit 9 Valve3 Valve6 Regenrator Exhaust Gas Cooling Water Expansion Valve Engine Coolant (EC) CO2 Valve4 4 T & P Sensor T Display P Display Cold source: Same pump speed and similar water temperature control Valve Pressure ratio range: B-CTRC: R-CTRC: P-CTRC: PR-CTRC:

13 Outline 1. Background 2. System and Method 3. Results { Energy Input Net Power Output (estimation) Cooling load 4. Summary

14 Energy Input Heat Absorption Quantity (Q a,total ) Maximum Temp. of CO 2 14 PR-CTRC(199) > P-CTRC > R-CTRC > B-CTRC (99) Inlet Temp. of Gas Heater Versus the B-CTRC, increase of Q a,total : R-CTRC: 18% P-CTRC:34% PR-CTRC :57%. After adding the preheater and regenerator: 1. more energy input, especially the preheater 2. affect utilization rate of exhaust gas. Inlet temp. of CO 2 affects final temp. of exhaust gas.

15 Net Power Output (Estimation) 15 Net Power Output (Estimation,W net,est ) Efficiency Increase of Engine Pressure ratio of 1.65 Versus the B-CTRC, increase of W net,est : R-CTRC: 24% P-CTRC:60% PR-CTRC :101%. Versus the B-CTRC, increase of Q a,total : R-CTRC: 18% P-CTRC:34% PR-CTRC :57% R-CTRC: 1.33 P-CTRC:1.76 PR-CTRC :1.77 PR-CTRC: increases from 39.4% to 41.4% 2.0% absolute increase After adding the preheater and regenerator: 1. about double net power output is achieved; 2. preheater makes more contribution.

16 Cooling Load of Combined System 16 Except output increase, the cooling load reduction of combined system (engine+ctrc) is another benefit after adding preheater or regenerator Cooling Load of Combined System Preheater: reduces the cooling load at the engine side. Utilization Rate of Engine Cooalnt Engine CTRC 45.1%~55.6%, the residual is still the cooling load of engine. Regenerator: reduces the cooling load at the CTRC side. Both of them: the minimum cooling load of combined system

17 Outline 1. Background 2. System and Method 3. Results 4. Summary

18 Summary By adding a preheater or a regenerator for CTRC system, benefits are achieved as following: 1 Compared with the B-CTRC, the PR-CTRC, the P-CTRC and the R-CTRC obtain net power output increase of 101%, 60%, 24%, respectively. Preheater makes more contributions to output than the regenerator. The PR-CTRC promotes engine efficiency from 39.4% to 41.4%. More Power Output 2 Preheater and regenerator has active impact on cooling load of combined system. Adding both of them, cooling load decreases from 80.7kW to 66.1kW. Less Cooling Load

19 Acknowledgements: State Key Program of National Natural Science Foundation of China (No ) Team member: (Ph.D.) Xiaoyali, Guangdai Huang, Tianyu Chen (Master) Liwen Chang, Daiqiang Li, Yue Wang / thtju@tju.edu.cn

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