STUDY OF A VOLUMETRIC EXPANDER SUITABLE FOR WASTE HEAT RECOVERY FROM AN AUTOMOTIVE IC ENGINE USING AN ORC WITH ETHANOL
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1 SUDY OF A VOLUMERIC EXPANDER SUIABLE FOR WASE HEA RECOVERY FROM AN AUOMOIVE IC ENGINE USING AN ORC WIH EHANOL ASME ORC rd International Seminar on ORC Power Systems October 2015, Brussels, Belgium 1
2 P P P P FS ORC facility. Mock up Exhaust gas IC engine emp. sensor boiler Evaporator P Ethanol FS Pres. sensor Flow sensor expander brake Electric motor & freq. var. Pump FS ank Expander vessel Expander Brake expander vessel Condenser P pump P Cooling water FS 2
3 ORC facility. Expander Swash-plate characteristics Working fluid ethanol Pistons working 3 Bore 40 mm Stroke 31 mm Maximum expander speed 4500 rpm 3
4 ORC facility. Working points Ford Explorer 2 liter turbocharged gasoline engine Point 84km/h Point 114km/h Vehicle speed (km/h) Engine speed (rpm) Fuel power (kw) Engine power output (kw) Inlet temperature of the exhaust gas ( C) Mass flow exhaust gas (g/s)
5 cooling water (37%) heat losses (1%) exhaust gasses (10%) heat losses (1.16%) heat losses (0.6%) cooling water (16.9%) ICE mechanical power (32%) Stationary conditions. Experimental results Point 114km/h (25 kw heat power) mechanical power (1.4%) fuel power (100%) ICE exhaust gasses (31%) Exhaust line exhaust gasses (30%) Evaporator ethanol (19%) Expander ethanol (17%) Condenser ethanol (0.16%) electric pump power (0.16%) Pump heat losses (0.1%) ethanol (0.1%) Ambient conditions 25 ºC and 1 bar 5
6 Stationary conditions. Model 6
7 Stationary conditions. Model 7
8 Stationary conditions. Model validation Point 114km/h (25 kw heat power) 2000 rpm 3000 rpm 8
9 Stationary conditions. Model validation Point 114km/h (25 kw heat power) 9
10 Dynamic conditions. Control ṁ E EG ṁ EG P EG Stationary maps ṁe_sp_st PID 1 Kp=cte Ki=cte SUM ṁe_sp Pump speed frequency ΔṁE_sp_tr E_B_out_sp_st E_B_out Adaptive control for transient conditions Expander speed 10
11 Dynamic conditions est 84 km/h km/h in 5 sec 11
12 Dynamic conditions est 84 km/h km/h in 5 sec 12
13 Speed (km/h) Power (kw) Dynamic conditions. est NEDC NEDC Ecoboost Explorer Vehicle speed (km/h) Power Boil EG Power Boil E vapor conditions begins at boiler outlet ime (s)
14 Vehicle speed (km/h) Exhaust gas mass flow (kg/h) Expander power (W) Dynamic conditions. est NEDC extra urban NEDC Extra-Urban Vehicle speed (km/h) Exhaust gas mass flow (kg/h) Power expander (W) ime (s) 200
15 Conclusions Currently, a realistic estimation of the increase of IC engine efficiency due to the use of ORC systems can be close to 2%. If evaporator efficiency and expander efficiency are improved this value could reach to 4.5%, as some theoretical studies predict. Despite being a multivariable system, the ORC may be controlled in transient conditions typical of an IC engine by using a simple control system with PIDs uncoupled and some open-loop controls. hese ORC systems are more efficient on extra-urban conditions (vehicle speeds higher than 50 km/h approx). On the other hand, on urban driving conditions (speeds below 50km/h), these systems have not enough power to start the cycle. 15
16 hanks for your attention 16
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