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Energies 2020, 13, 5846 12 of 23 8. Component #8 is the holder of the data initialization as the charge and the temperature and pressure of working fluid. In particular, the charge of the working fluid can be varied in order to predict the effect on plant performance if a different quantity of working fluid is charged in the plant. Thanks to this component, the model can be retained as charge sensitive. For the experimental case considered, the mass of the working fluid charged inside the plant is 6.5 kg. 2.3. Experimental Validation The model validation is carried out using the data from an extensive experimental campaign conducted on the test rig reported in Figure 1. Thus, fixing the following boundary conditions: • Mass flow rate sent by the pump. The first parameter is fixed once the revolution speed was defined, in fact, being the pump of a volumetric pipe, in this case, the mass flow rate is known. • Mass flow rate and temperature of exhaust gas at the evaporator inlet. This information is related to the operating point of the ICE as it depends on its torque and the revolution speed. In the validation procedure, they are measured on the ICE dynamic test bench, which allows reproducing the real operating conditions encountered by the vehicle. In this way, the ORC plant can be tested for a wide variation of the high thermal source, and its performance can be evaluated under off-design conditions. • Expander revolution speed. This condition can be entered through Component #5 and depends on the dynamic equilibrium at the expander shaft. As mentioned previously, if the expander is connected to the electric network, this speed is fixed, while if an inverter is employed, the velocity can be changed. It is worth noting that the expander reaches a certain operating condition quickly because the dynamics of the expander are fast relative to the other components. • Mass flow rate and temperature of the coolant at the condenser inlet. This information defines the heat sink. In the experimental case considered, there is a pump that circulates the cooling water with a mass flow rate equal to 1.5 kg/s at a temperature of 15–25 ◦C. • Charge of working fluid inside the plant. The mass of working fluid is introduced in Component #8 together with the initial temperature and pressure of the working fluid. The inlet and outlet pressure and temperature of the working fluid at the evaporator, expander, and condenser are predicted and compared to the experimental data. The mechanical power at the expander and pump shaft are predicted and compared with the measured data. Figure 7 shows the errors in the pressure at the evaporator inlet (Figure 7a), expander inlet (Figure 7b), expander outlet (Figure 7c), and condenser inlet (Figure 7d). The model allows capturing the hydraulic behavior of the power plant, with a deviation and a root mean square error (RMSE) below 10% and 5%, respectively. Furthermore, the model is able to represent with satisfying accuracy the temperature at the evaporator inlet (Figure 8a), at the expander inlet (Figure 8b), and at the expander outlet (Figure 8c). Indeed, as it can be observed from Figure 5, the average absolute deviations are respectively 4.3 ◦C for the evaporator inlet temperature, 5.0 ◦C for the expander inlet temperature, and 5.2 ◦C for the expander outlet temperature. It is worth noticing that the condenser inlet temperature was not reported, since it is quite coincident with the expander outlet temperature. Figure 8d shows the accuracy of the working fluid mass flow rate prediction, with a 5% maximum deviation and a 1.8% RMSE. The low errors in terms of the mass flow rate (Figure 8d) and pressure upstream and downstream of the main components (Figure 7) demonstrate the model’s ability to represent the real hydraulic behavior of the plant. Indeed, according to Equation (5), the permeability is defined as the pressure in correspondence of a certain component for a given mass flow rate circulating inside the plant. The model reproduces the mechanical power needed by the pump to process the working fluid (Figure 9a) and the one produced by the expander (Figure 9b) with an RMSE equal to 7% and 8.6%, respectively. On the other hand, the maximum deviation is equal to 12% and 24%, respectively.PDF Image | Design of ORC Plant for Low-Grade Waste Heat Recovery
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