ALBERT

Description: Organic Rankine cycles (ORCs) are an established technology to convert waste heat to electricity. Although several commercial implementations exist, there is still considerable potential for thermo-economic optimization. As such, a novel framework for designing optimized ORC systems is proposed based on a multi-objective optimization scheme in combination with financial appraisal in a post-processing step. The suggested methodology provides the flexibility to quickly assess several economic scenarios and this without the need of knowing the complex design procedure. This novel way of optimizing and interpreting results is applied to a waste heat recovery case. Both the transcritical ORC and subcritical ORC are investigated and compared using the suggested optimization strategy.

Description: Two differently-produced open-cell aluminum foams were compared to a commercially available finned heat sink. Further, an aluminum plate and block were tested as a reference. All heat sinks have the same base plate dimensions of four by six inches. The first foam was made by investment casting of a polyurethane preform and has a porosity of 0.946 and a pore density of 10 pores per linear inch. The second foam is manufactured by casting over a solvable core and has a porosity of 0.85 and a pore density of 2.5 pores per linear inch. The effects of orientation and radiative heat transfer are experimentally investigated. The heat sinks are tested in a vertical and horizontal orientation. The effect of radiative heat transfer is investigated by comparing a painted/anodized heat sink with an untreated one. The heat flux through the heat sink for a certain temperature difference between the environment and the heat sink’s base plate is used as the performance indicator. For temperature differences larger than 30 °C, the finned heat sink outperforms the in-house-made aluminum foam heat sink on average by 17%. Furthermore, the in-house-made aluminum foam dissipates on average 12% less heat than the other aluminum foam for a temperature difference larger than 40 °C. By painting/anodizing the heat sinks, the heat transfer rate increased on average by 10% to 50%. Finally, the thermal performance of the horizontal in-house-made aluminum foam heat sink is up to 18% larger than the one of the vertical aluminum foam heat sink.

Description: Worldwide interest in low grade heat valorization using organic Rankine cycle (ORC) technologies has increased significantly. A new small-scale ORC with a net capacity of 3 kW was efficiently integrated with a concentrated solar power technology for electricity generation. The excess heat source from Photovoltaic (PV) collectors with a maximum temperature of 100 °C was utilized through a supercritical heat exchanger that uses R-404A as working medium. By ensuring supercritical heat transfer leads to a better thermal match in the heat exchanger and improved overall cycle efficiency. A helical coil heat exchanger was designed by using heat transfer correlations from the literature. These heat transfer correlations were derived for different conditions than ORCs and their estimated uncertainty is ~20%. In order to account for the heat transfer correlation uncertainties this component was oversized by 20%. Next, a prototype was built and installed in an integrated concentrated photovoltaic/thermal (CPV/T)/Rankine system. The results from the measurements show that for better estimation of the sizing of the heat exchanger a more accurate correlation is required in order to design an optimal configuration and thus employ cheaper components.

Description: This paper reviews the available methods to study thermal applications with open-cell metal foam. Both experimental and numerical work are discussed. For experimental research, the focus of this review is on the repeatability of the results. This is a major concern, as most studies only report the dependence of thermal properties on porosity and a number of pores per linear inch (PPI-value). A different approach, which is studied in this paper, is to characterize the foam using micro tomography scans with small voxel sizes. The results of these scans are compared to correlations from the open literature. Large differences are observed. For the numerical work, the focus is on studies using computational fluid dynamics. A novel way of determining the closure terms is proposed in this work. This is done through a numerical foam model based on micro tomography scan data. With this foam model, the closure terms are determined numerically.

Description: Despite the increasing interest in organic Rankine cycle (ORC) systems and the large number of cycle models proposed in the literature, charge-based ORC models are still almost absent. In this paper, a detailed overall ORC simulation model is presented based on two solution strategies: condenser subcooling and total working fluid charge of the system. The latter allows the subcooling level to be predicted rather than specified as an input. The overall cycle model is composed of independent models for pump, expander, line sets, liquid receiver and heat exchangers. Empirical and semi-empirical models are adopted for the pump and expander, respectively. A generalized steady-state moving boundary method is used to model the heat exchangers. The line sets and liquid receiver are used to better estimate the total charge of the system and pressure drops. Finally, the individual components are connected to form a cycle model in an object-oriented fashion. The solution algorithm includes a preconditioner to guess reasonable values for the evaporating and condensing temperatures and a main cycle solver loop which drives to zero a set of residuals to ensure the convergence of the solution. The model has been developed in the Python programming language. A thorough validation is then carried out against experimental data obtained from two test setups having different nominal size, working fluids and individual components: (i) a regenerative ORC with a 5 kW scroll expander and an oil flooding loop; (ii) a regenerative ORC with a 11 kW single-screw expander. The computer code is made available through open-source dissemination.

Description: It is long known that for high-velocity fluid flow in porous media, the relation between the pressure drop and the superficial velocity is not linear. Indeed, the classical Darcy law for shear stress dominated flow needs to be extended with a quadratic term, resulting in the empirical Darcy–Forchheimer model. Another approach is to simulate the foam numerically through the volume averaging technique. This leads to a natural separation of the total drag force into the contribution of the shear forces and the contribution of the pressure forces. Both representations of the total drag lead to the same result. The physical correspondence between both approaches is investigated in this work. The contribution of the viscous and pressure forces on the total drag is investigated using direct numerical simulations. Special attention is paid to the dependency on the velocity of these forces. The separation of the drag into its constituent terms on experimental grounds and for the volume average approach is unified. It is shown that the common approach to identify the linear term with the viscous forces and the quadratic term with the pressure forces is not correct.

Description: The organic Rankine cycle (ORC) is a mature technology for the conversion of waste heat to electricity. Although many energy intensive industries could benefit significantly from the integration of ORC technology, its current adoption rate is limited. One important reason for this arises from the difficulty of prospective investors and end-users to recognize and, ultimately, realise the potential energy savings from such deployment. In recent years, electric arc furnaces (EAF) have been identified as particularly interesting candidates for the implementation of waste heat recovery projects. Therefore, in this work, the integration of an ORC system into a 100 MWe EAF is investigated. The effect of evaluations based on averaged heat profiles, a steam buffer and optimized ORC architectures is investigated. The results show that it is crucial to take into account the heat profile variations for the typical batch process of an EAF. An optimized subcritical ORC system is found capable of generating a net electrical output of 752 kWe with a steam buffer working at 25 bar. If combined heating is considered, the ORC system can be optimized to generate 521 kWe of electricity, while also delivering 4.52 MW of heat. Finally, an increased power output (by 26% with combined heating, and by 39% without combined heating) can be achieved by using high temperature thermal oil for buffering instead of a steam loop; however, the use of thermal oil in these applications has been until now typically discouraged due to flammability concerns.

Description: In this study, the performance of a helical coil heat exchanger operating at subcritical and supercritical conditions is analysed. The counter-current heat exchanger was specially designed to operate at a maximal pressure and temperature of 42 bar and 200 °C, respectively. The small-scale solar organic Rankine cycle (ORC) installation has a net power output of 3 kWe. The first tests were done in a laboratory where an electrical heater was used instead of the concentrated photovoltaic/thermal (CPV/T) collectors. The inlet heating fluid temperature of the water was 95 °C. The effects of different parameters on the heat transfer rate in the heat exchanger were investigated. Particularly, the performance analysis was elaborated considering the changes of the mass flow rate of the working fluid (R-404A) in the range of 0.20–0.33 kg/s and the inlet pressure varying from 18 bar up to 41 bar. Hence, the variation of the heat flux was in the range of 5–9 kW/m2. The results show that the working fluid’s mass flow rate has significant influence on the heat transfer rate rather than the operational pressure. Furthermore, from the comparison between the experimental results with the heat transfer correlations from the literature, the experimental results fall within the uncertainty range for the supercritical analysis but there is a deviation of the investigated subcritical correlations.