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WORKING FLUID SELECTION AND DESIGN OF SMALL-SCALE WASTE HEAT RECOVERY SYSTEMS BASED ON ORGANIC RANKINE CYCLES

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WORKING FLUID SELECTION AND DESIGN OF SMALL-SCALE WASTE HEAT RECOVERY SYSTEMS BASED ON ORGANIC RANKINE CYCLES ( working-fluid-selection-and-design-small-scale-waste-heat-re )

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119 solver to have a prediction on the flow field in the stator and rotor. The results obtained with different supersonic stators indicated that convergent-divergent nozzles introduce uniform flow at the straight part of the nozzle in a region before the stator trailing edge. However, the stator blade trailing edge has a significant effect on the flow after the oc- currence of two oblique shock waves, their reflections, and the viscous wake. The shock waves and viscous wake causes a non-uniform flow field and fluctuations on the flow an- gle at the stator exit. The results showed that the flow is more tangential in off-design conditions, and the fluctuation in the flow angle increases due to non-uniform flow field. This might cause flow separation and low loading at the turbine rotor blades in off-design conditions. Different stator design methods could be studied and further developed in the future in order to reach more uniform flow angle and velocity distribution at the stator outlet in design and off-design conditions. The CFD simulations for different turbine rotors predicted slightly higher pressure ratio over the turbine when compared to the pressure ratio in the rotor 1D design. In addition to higher pressure ratios, the temperature drop in the turbine rotor is predicted to be higher by the CFD simulations when compared to the estimation of 1D turbine design. A flow separation region at the rotor blade suction side was predicted with all the studied geome- tries. In addition, the angle of relative velocity at the rotor inlet and the flow velocity at the rotor inlet were slightly different when compared to the 1D design and the results obtained in stator simulations, causing a flow separation at the blade pressure side at the rotor blade leading edge. It is recommended based on the results obtained in this study to perform additional simulations in the future in which the stator and rotor are coupled together in order to study the effect of rotor inlet conditions on the flow field and performance in more details. The effect of the number of rotor blades on the flow separation in the rotor could be studied in the future. In addition, the flow field in the turbine rotor should be studied in off-design conditions as well. Unsteady simulations for similar turbine should be carried out in the future in order to study the loss mechanisms related to the interaction between the turbine stator and rotor blades. The performance of the designed radial turbine will be measured with experiments that will take place in 2014-2015 to provide more informa- tion on the design and performance of small-scale and high expansion ratio ORC turbines. The potential for electricity production from the waste heat of large-scale reciprocating engines was studied in this thesis as well. The results showed that the highest potential is related to the exhaust gas heat recovery, but also the charge air heat was identified as a potential for additional power production. The fluids with a high critical temperature represented the highest performances in the exhaust gas heat recovery and the fluids with a lower critical temperature represented the highest performances in the charge air heat recovery. A case study was performed for a 16.6 MW gas-fired diesel engine, and the results showed that the power output of the selected engine can be increased by 11.4 % by utilizing exhaust gas heat and 2.4 % by utilizing the charge air heat. The results also in- dicated that the charge air heat utilization would give approximately 2-4 times larger heat transfer area per produced kW when compared to the exhaust gas heat utilization leading to economically more unfeasible processes. A more detailed analysis should be carried

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WORKING FLUID SELECTION AND DESIGN OF SMALL-SCALE WASTE HEAT RECOVERY SYSTEMS BASED ON ORGANIC RANKINE CYCLES

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