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Energies 2020, 13, 5846 19 of 23 Hence, there is a trade-off between the operating conditions, in terms of mass flow rate, for net ORC power and plant efficiency maximization that should be sought. Nonetheless, both the power and efficiency curves show a flat trend in correspondence of the maximum: satisfyingly high performances can be reached for a wide mass flow rate range. 4. Further Discussion The adoption of the proposed optimization strategies has been shown to increase the net thermal efficiency of the ORC plant investigated in this work, on average, from 1.5% to 3.5% and the maximum generated power from 400 to 1100 W, respectively. The performance of the ORC plant in the present work was comparable to that performance of ORC plants in similar applications by various investigators, which has been experimentally assessed and reported in the literature. For example, in Ref. [54], an ORC plant with an intermediate oil circuit and radial turbine achieved an efficiency of 4% with a turbine efficiency of 35%. In Ref. [55], a swash-plate expander was adopted, and the ORC plant reached an efficiency of 6% with an expander efficiency of 38% when recovering heat from a 2-L ICE. Furthermore, the ORC plant developed and reported in Ref. [56] adopting a single-screw expander was demonstrated to have an efficiency of up to 6.3%, while the expander reached an efficiency of 58%, and an ORC plant recovering heat from a 3-L diesel engine reached an efficiency of up to 4% when employing a scroll expander [53]. In the application considered in Ref. [57], which involves the adoption of a 190 W sliding vane expander, the ORC plant efficiency was 1.6%. Thus, despite the efficiency and power produced by the optimized ORC plant being in these performance ranges, there is still room for plant performance improvement, which rests on improved pump and expander design according the optimization criteria found in this work. 5. Conclusions ORC plants for the waste heat recovery of internal combustion engine exhaust gases are characterized by severe off-design working conditions due to the intrinsic unsteady behavior of the high and low thermal sources. For this reason, a reliable mathematical model that allows predicting the off-design behavior of the plant is fundamental to define the optimization strategy for the ORC system development. Nevertheless, ORC plants are very complex systems; thus, all the real components and plant features should be considered to obtain reliable results. In order to reach this objective, in this paper, a comprehensive model of an ORC power plant was developed, merging the plant and the thermodynamic analysis of the system. The model was validated based on an extensive experimental campaign on an ORC plant for heat recovery from the exhaust gases of a supercharged 3-L diesel IVECO F1C engine. The accuracy of simulated pressures predicted by the combined 0-D/1-D GT-SuiteTM model is found to be within 2% in terms of the maximum RMSE and up to 5–10% in terms of the maximum deviation from the measured pressures. Furthermore, the average absolute error on the simulated temperatures is within the range of 5–6 ◦C, with a maximum deviation within 9 ◦C. The pump and expander power are reproduced with a 7% and 8.6% RMSE, respectively. The validated model served as a computational design platform for assessing the benefits on the net power and efficiency of the plant, which are associated with (i) a lower expander permeability; and (ii) the benefits of sliding vane rotary pump optimization. A lower permeability was found to increase the pressure ratio at the expander for a given mass flow rate and, consequently, the expander power. An additional advantage is associated with the higher volumetric performance of the expander. An optimized pump can allow a lower pumping power requirement and eventually lead to a lower backwork ratio (50% lower than the one in the baseline case). These optimization strategies are developed thanks to a novel concept of plant modeling. In fact, the new approach aims to integrate the cycle and plant analysis, thus reproducing the real phenomena taking place in the plant due to the components and pipes layout employed. The combination of these strategies can increase the ORC plant net power and efficiency by up to 50% compared with the baseline case.PDF Image | Design of ORC Plant for Low-Grade Waste Heat Recovery
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