ORC for Heavy Duty Trucks M. Hombsch a , K. Shariatmadar a , D. Maes - - PowerPoint PPT Presentation

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ORC for Heavy Duty Trucks M. Hombsch a , K. Shariatmadar a , D. Maes - - PowerPoint PPT Presentation

Nov 07, 2022 4.57k likes •4.86k views

Experimental Investigation of Waste Heat Recovery Using an ORC for Heavy Duty Trucks M. Hombsch a , K. Shariatmadar a , D. Maes b , P. Garsoux c a Dana Belgium NV, b Flanders Make VZW, c Bosal Emissions Control Systems NV 4 th Engine ORC

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SLIDE 1

4th Engine ORC Consortium Workshop November 15 - 17, Detroit, Michigan

Experimental Investigation of Waste Heat Recovery Using an ORC for Heavy Duty Trucks

  • M. Hombscha, K. Shariatmadara,
  • D. Maesb, P. Garsouxc

a Dana Belgium NV, b Flanders Make VZW, c Bosal Emissions Control Systems NV

4th EORCC Workshop, Detroit 2017

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SLIDE 2

Experimental ORC - WHR for Heavy Duty Trucks

Design methodology and system optimization tool – Flanders Make

ORC design challenges Working fluids

  • Water
  • Ethanol
  • Butane
  • Refrigerant

4th EORCC Workshop, Detroit 2017

Fuel Energy

Brake Power Friction /

  • Misc. Losses

Heat Transfer Exhaust Energy

42% 8% 24% 26% 100%

Engine Cooling

Charge Air Cooling

80-100°C 20-60°C EGR Cooling Tailpipe 200-750°C 200-600°C Waste Heat Quality Low Waste Heat Quality High

2 Evaporator ( heat source) 4 Condenser ( heat sink) 1 Pum p 3 Expander

Engine heat sources

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SLIDE 3

Experimental ORC - WHR for Heavy Duty Trucks

Design methodology and system optimization tool

Use case specification

Heat sources (averaged)

  • Exhaust

0.204 kg/s, 354 °C

  • EGR

0.081 kg/s, 520 °C Heat sink (averaged)

  • Cooling water

1.5 kg/s, 60°C Topological variations

  • Six evaporator configurations
  • Recuperator not useful
  • EGR replacement

(cost saving from existing cooler)

4th EORCC Workshop, Detroit 2017

Exhaust only EGR only Exhaust first EGR first Parallel EGR split

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SLIDE 4

403 days* . 225 days*. .

Optimization

  • Changes components size and thermal cycle
  • Constrained nonlinear programming
  • Exhaustive search over fluids and topologies

Maximize expander power Minimize cost / net power

Experimental ORC - WHR for Heavy Duty Trucks

Design methodology and system optimization tool

4th EORCC Workshop, Detroit 2017 *assuming 11 hour driving per day

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SLIDE 5

Dynamic model in Amesim Experimental ORC - WHR for Heavy Duty Trucks

Design methodology and system optimization tool

4th EORCC Workshop, Detroit 2017

3 4 Condenser p

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SLIDE 6

Experimental ORC - WHR for Heavy Duty Trucks

Design methodology and system optimization tool

4th EORCC Workshop, Detroit 2017

2 Evaporator ( heat source) 4 Condenser ( heat sink) 1 Pum p 3 Expander

Control Design

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SLIDE 7

Experimental ORC - WHR for Heavy Duty Trucks

Design methodology and system optimization tool

4th EORCC Workshop, Detroit 2017

Control Design

  • Control of evaporator pressure

PI + feedforward + decoupling Model based control simplest to implement better constraint handling

32 31 30 29 28 500 1000 1500 2000 2500 Time in seconds 27 26 25 32 31 30 29 28 500 1000 1500 2500 Time in seconds 27 26 25 2000 2000

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SLIDE 8

Experimental ORC - WHR for Heavy Duty Trucks

Heat exchanger development – Bosal

Non-dimensional evaporator sizing

  • NTU method (Number of Tranfer Units)
  • Non dimensional numbers, 𝑂𝑈𝑉 = 𝑔 𝑠

𝑑𝑞, 𝐷𝑠, 𝑇𝑢, 𝐾𝑏−1, Δ𝑈

𝑡ℎ ∞

−Δ𝑈

𝑡𝑑 , …

– Heat capacity ratio 𝑠

𝑑𝑞, heat cap. rate ratio 𝐷𝑠, Stanton number 𝑇𝑢

– Inverse Jacob number 𝐾𝑏−1 (phase change) – Ratio of superheating to subcooling

Δ𝑈

𝑡ℎ ∞

−Δ𝑈

𝑡𝑑

  • No working fluid “hard coded” in calculations

4th EORCC Workshop, Detroit 2017

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SLIDE 9

Experimental ORC - WHR for Heavy Duty Trucks

Heat exchanger development – Bosal

Evaporator size optimization for HD trucks

  • Target: minimum pay-back for total WHR system
  • Inputs

– Tool developed by Flanders Make – Bosal evaporator model – Bosal cost model – European operating conditions

  • Assumptions

– Exhaust & EGR evaporators – Working fluid: Alcohol based – Volumetric expander

– ...

Evaporator size minimizing €/W

4th EORCC Workshop, Detroit 2017

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SLIDE 10

Experimental ORC - WHR for Heavy Duty Trucks

Heat exchanger development – Bosal

Stability of evaporation process

  • Slope of -2 (-20dB/decade), indicating higher frequency massflow
  • scillations do not affect the outlet temperature significantly

4th EORCC Workshop, Detroit 2017 Time [s] Temperature

Raw signal, Temperature oscillation

Frequency [Hz]

Air Massflow oscillation dmair

Power Frequency [Hz]

Water Massflow oscillation dmair

Power

Frequency [Hz]

Transfer function

Amplification

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SLIDE 11

Experimental ORC - WHR for Heavy Duty Trucks

Heat exchanger development – Bosal

Heat exchanger performance

  • More than 50 sensors (T, p,ṁ)
  • Heat transfer validation in 2-phase flow

4th EORCC Workshop, Detroit 2017

Set of operating points Sequenced perturbations

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SLIDE 12

Experimental ORC - WHR for Heavy Duty Trucks

Flow validation – Voxdale

CFD validation

  • Pipe bundle replaced with porous blocks
  • Heat exchange inside blocks
  • Nonlinear pressure drop in X and Y direction
  • Wall temperature given as boundary condition

Results

  • Flow uniformity
  • Bypass duct optimization

www.voxdale.be info@voxdale.be

4th EORCC Workshop, Detroit 2017

Bypass HEX core

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SLIDE 13

Experimental ORC - WHR for Heavy Duty Trucks

Heat exchanger development – Bosal

Hardware built: Evaporator

  • Modular design, different working fluids possible
  • High Pressure operation (60 bar)
  • Proven in-field operation
  • To be integrated in Euro VI muffler
  • Add-on with bypass

4th EORCC Workshop, Detroit 2017

Gas Fluid

Evaporator Bypass Euro VI truck muffler WHR add-on

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SLIDE 14

Experimental ORC - WHR for Heavy Duty Trucks

Test bench and experimental results

4th EORCC Workshop, Detroit 2017

Coolant tank

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SLIDE 15

Experimental ORC - WHR for Heavy Duty Trucks

Test bench and experimental results

Prototypes: Bosal evaporators Exoès expander

Tube & shell heat exchanger double-acting swashplate piston expander

4th EORCC Workshop, Detroit 2017

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SLIDE 16

Experimental ORC - WHR for Heavy Duty Trucks

Test bench and experimental results

Experimental results

4th EORCC Workshop, Detroit 2017 10 20 30 40 50 60 32 132 232 332 432 532 632 732 50 100 150 200 250 300 350 400

  • 36

164 364 564 764 964 1,164 1,364 Power P transferred to the cycle fluid [kW] Temperature T [°F] Temperature T [°C] Cycle fluid enthalpy h [kJ/kg]

Experiment

2 Evaporator ( heat source) 4 Condenser ( heat sink) 1 Pum p 3 Expander

1 2 3 4

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SLIDE 17

Experimental ORC - WHR for Heavy Duty Trucks

Test bench and experimental results

Thermal efficiency Net fuel savings

4th EORCC Workshop, Detroit 2017

2 4 6 8 10 12

0% 2% 4% 6% 8% 10% 12%

50 100 150 Raw output power [kW] Raw thermal efficiency Waste heat exploited [kW] Engine back pressure, Pump consumption Maximum Power tested (Conservative assumption)

0% 1% 2% 3% 4% 5% 50 100 150 200 250 300

Fuel savings Equivalent shaft power [kW] Includes:

  • Engine back pressure loss
  • Pump consumption

Conservative Maximum Power assumption

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SLIDE 18

Experimental ORC - WHR for Heavy Duty Trucks

Test bench and experimental results

Sankey diagram for highway cruise

4th EORCC Workshop, Detroit 2017

Fuel: 100%

Brake power: 45% Coolant: 29%

EGR: 12% Exhaust 12% Turbine 17% WHR: 17%

2% WHR gain, 11% from WHR input 4% from brake power

Brake power + WHR: 47%

Charge air 5%

Coolant: 44% Ambient: 53%

6%

1%

Exhaust manifold: 29%

2%

6% 11% 15%

3%

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SLIDE 19

Experimental ORC - WHR for Heavy Duty Trucks

Test bench and experimental results

Drive cycle analysis: GEM model

  • 340 kW (455 hp) model year 2018 engine, 6x4 configuration
  • Applied fuel usage weighting to time spent in given power
  • Weighted average of

three drive cycles:

– Urban – 55 mph with slopes – 65 mph with slopes

4th EORCC Workshop, Detroit 2017

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SLIDE 20

Experimental ORC - WHR for Heavy Duty Trucks

Test bench and experimental results

Drive cycle analysis: average fuel savings

4th EORCC Workshop, Detroit 2017

Mean fuel savings 3.5%

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SLIDE 21

Experimental ORC - WHR for Heavy Duty Trucks

Test bench and experimental results

Yearly savings, US sleeper cab

190,200

𝑙𝑛 𝑧𝑓𝑏𝑠

118,200

𝑛𝑗𝑚𝑓𝑡 𝑧𝑓𝑏𝑠, first three years, sleeper cab*

∗ 33.3

𝑚 100𝑙𝑛

7.06 𝑛𝑞𝑕, Model Year 2018 GEM simulation ∗ 1.04

$ 𝑚

3.94

$ 𝑕𝑏𝑚 EIA 2025 retail +10.5% local tax

∗ 3.5% WHR system fuel econemy improvement

  • $ 105

€ 100 maintenance = $ 𝟑𝟑𝟏𝟏 Yearly savings  Payback time ca. 2 years

4th EORCC Workshop, Detroit 2017

Today 2.65 $/gal+28¢ local tax = 2.93 $/gal 2025 3,56 $/gal + 10.5% local tax = 3.94 $/gal

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SLIDE 22

Experimental ORC - WHR for Heavy Duty Trucks

Conclusions

  • Design methodology tool developed for ORC WHR

– Pre-design tool for selection and size of components – Optimizing total cost of ownership – Steady-state design with dynamic evaluation – Introduction of possible control strategies

  • Hardware

– ORC Test bench running on Diesel exhaust – Exhaust heat exchanger prototypes from Bosal, sized using TCO analysis – Expander prototype from Exoès, tailored for HD truck market

  • Test results

– Amesim model calibrated using static and dynamic tests – Peak thermal efficiency of 11%, net drivecycle fuel saving 3.5% – Payback time of 2 years for a WHR system

4th EORCC Workshop, Detroit 2017

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SLIDE 23

Experimental ORC - WHR for Heavy Duty Trucks

Questions

4th EORCC Workshop, Detroit 2017

Maximilian Hombsch maximilian.hombsch@dana.com Keivan Shariatmadar keivan.shariatmadar@dana.com Davy Maes davy.maes@flandersmake.be Stephan Schlimpert stephan.schlimpert@flandersmake.be Stefan Pas stefan.pas@ext.bosal.com Filip Dörge filip.dorge@bosal.com