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97 7 Waste heat recovery of large scale reciprocating engine In this chapter, waste heat utilization in large-scale reciprocating engines is studied by means of thermodynamic analysis. In large reciprocating engines, the most significant waste heat stream can be identified as exhaust gas heat. There are also lower temperature waste heat streams, mainly heat in the pressurized charge air after the turbocharger, as well as heat in engine jacket cooling water and lubrication oil cooling circuit. The aim of this computational study is to investigate the potential of waste heat recovery from ex- haust gases (EG) and charge air (CA) by means of ORC. Despite previous studies related to the utilization of waste heat of large-scale reciprocating engines, studies analyzing the possibility of utilizing the charge air heat are lacking at the moment. This study repre- sents and discusses the possibility of replacing the charge air cooler (CAC) of a large turbocharged engine with an ORC evaporator, utilizing the heat from about 180 ◦C to 220 ◦C charge air in additional power production. Additionally, the aim is to study the overall power production improvement potential by means of heat recovery. The studied engine combined cycle is presented in Figure 7.1. The utilization of the heat from engine jacket water cooling and lubrication oil cooling was excluded from this study, due to the low temperature level of about 90 ◦C. Turbocharger Exhaust gas Hot charge air Cooled charge air Exhaust gas Reciprocating engine Air Figure 7.1: The principle of the studied engine combined cycle. Exhaust gases (EG) and charge air (CA) heat are utilized by means of ORC. The ORC simulations were performed with several heat source temperatures, and the minimum pinch-point temperature difference in the ORC evaporator was limited to 15 ◦C, and a condensing temperature of 50 ◦C was used in most of the simulations. In addi- tion, the effect of minimum pinch-point temperature difference in the evaporator, as well as the effect of condensing temperature on the process performance was included in the analysis. The evaporation pressure of the process was optimized based on the criteria that the minimum allowed pinch-point temperature difference in the evaporator was reached, or in case the temperature difference in the evaporator remained sufficient, the limit of pev/pcr=0.95 was used for the evaporation pressure. The main process specifications and component efficiencies used in the thermodynamic analysis are shown in Table 7.1. Pres- sure losses were excluded from the thermodynamic analysis. EG ORC CA ORCPDF Image | WORKING FLUID SELECTION AND DESIGN OF SMALL-SCALE WASTE HEAT RECOVERY SYSTEMS BASED ON ORGANIC RANKINE CYCLES
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