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Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) Philipp Petr, Christian Schrder, Prof. Dr.-Ing. Jrgen Khler, Dr. Manuel Grber ASME ORC 2015 - 3rd Seminar on ORC Systems, Brussels, October

  1. Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) Philipp Petr, Christian Schröder, Prof. Dr.-Ing. Jürgen Köhler, Dr. Manuel Gräber ASME ORC 2015 - 3rd Seminar on ORC Systems, Brussels, October 14 th 2015

  2. Waste Heat Recovery System in a Long Distance Bus Total vehicle model (thermal, longitudinal dynamics) Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 2

  3. Waste Heat Recovery System in a Long Distance Bus Modelled ORC Concept (design stage) Working fluid: Ethanol Evaporator type: Fin-and-Tube Expander type: Effiency Based Condenser type: Tube-and-Tube Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 3

  4. Waste Heat Recovery System in a Long Distance Bus Control concept Expander inlet pressure controlled by expander speed Expander inlet enthalpy controlled by pump speed Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 4

  5. Why Do We Need Advanced Control Strategies? 1. Transient heat source temperature and mass flow rates Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 5

  6. Why Do We Need Advanced Control Strategies? 1. Transient heat source temperature and mass flow rates 2. Interactions between different subsystems Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 6

  7. Why Do We Need Advanced Control Strategies? 1. Transient heat source temperature and mass flow rates 2. Interactions between different subsystems 3. Predicted states offer futher potential for energy recovery Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 7

  8. Why Do We Need Advanced Control Strategies? 1. Transient heat source temperature and mass flow rates 2. Interactions between different subsystems 3. Predicted states offer futher potential for energy recovery 4. ORCs shows a high grade of nonlinear behavior in transient operation  Linear approaches not feasible in all operating conditions  Nonlinear approaches are beneficial, but complex  Nonlinear Model Predictive Control (NMPC) is one method to take this challenge  NMPC is a repetetive solving of an optimal control problem for finite prediction horizons Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 8

  9. Brief Overview on Presented Research Development of a transient mathematical long-distance bus model with a waste heat recovery system Development of a software tool chain for NMPC Development of a differentiable High-Speed Model of the ORC for NMPC Virtual test drive in the European Transient Cycle to test the concept Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 9

  10. Block Diagram of the Nonlinear Model Predictive Control NMPC High-Speed- Model Controlled System Control Optimization Variables 𝑣 State Variables 𝑦 Sophisticated ORC-Model Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 10

  11. Block Diagram of the Nonlinear Model Predictive Control NMPC Nonlinear fast system model High-Speed- Model Controlled System Control Optimization Variables 𝑣 State Variables 𝑦 Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 11

  12. Block Diagram of the Nonlinear Model Predictive Control NMPC Computation of the optimal Target function control variable trajectory High-Speed- Constraining Model Controlled System conditions Control Exhaust gas Optimization Variables 𝑣 enthalpy flow rate State Variables 𝑦 Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 12

  13. Software Tool Chain NMPC ORC High-Speed Model Target function DYMOLA Constraining TILMedia Controlled System conditions FMI Suite DYMOLA Exhaust gas TILMedia enthalpy flow rate TISC Optimizer Sophisticated TISC ORC-Model Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 13

  14. Computation Time Differential and algebraic states Cycle Time ComputationTime (Intel Core i7-4930K @ 3.40GHz) (ETC) 30 min 49 10 8 2 min 3 5 s High-Speed- Sophisticated Sophisticated High-Speed- Model ORC-Model ORC-Model Modell Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 14

  15. Benchmarking NMPC in Partial Load Conditions System is shut down in partial Constant load conditions due to low mass Set Point flow rates Steady Linear control approach. Gain State scheduled controller parameter Optimized developed with AMIGO approach Set Points Nonlinear Prediction Horizon: 4s Model (real-time capable) Predictive Control Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 15

  16. Results of the Virtual Test Drive (Urban Section of the European Transient Cycle) Expander inlet pressure Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 16

  17. Results of the Virtual Test Drive (Urban Section of the European Transient Cycle) Expander inlet enthalpy Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 17

  18. Results of the Virtual Test Drive (Urban Section of the European Transient Cycle) Expander power Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 18

  19. Results of the Virtual Test Drive (Urban Section of the European Transient Cycle) Pump work Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 19

  20. Results of the Virtual Test Drive (Urban Section of the European Transient Cycle)  Higher net power output due to (optimized) ORC part load operation + 15 % 7% + 8 % Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 20

  21. Conclusion and Outlook  Implementation of advanced control strategies are necessary for small ORC systems operating under transient boundary conditions  Development of a software tool chain to realize a prototype NMPC  Development of an ORC High-Speed Model  Virtual Test Drive of a long distance bus proved the potential of NMPC in the part load section of the European Transient Cycle (ETC) Outlook  Improvement of the High-Speed Model regarding computational time and accuracy  Implementation of physically motivated expander models  Proof of concept by means of an ORC test rig Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 21

  22. Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) Philipp Petr, Christian Schröder, Prof. Dr.-Ing. Jürgen Köhler, Dr. Manuel Gräber ASME ORC 2015 - 3rd Seminar on ORC Systems, Brussels, October 14 th 2015

  23. Contact Information Philipp Petr Dr.-Ing. Wilhelm Tegethoff Mail. P.Petr@tu-braunschweig.de Mail. W.Tegethoff@tlk-thermo.com Tel. +49 (0) 531 391 - 7895 Tel. +49 (0) 531 390 - 7611 Technische Universität Braunschweig TLK-Thermo GmbH Institut für Thermodynamik Hans-Sommer-Str. 5 Hans-Sommer-Str. 5 38106 Braunschweig 38106 Braunschweig Germany Germany www.tlk-thermo.de www.ift.tu-bs.de Optimal Control of Waste Heat Recovery Systems Applying Nonlinear Model Predictive Control (NMPC) ASME ORC 2015 | 14.10.2015 | Philipp Petr | Slide 23

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