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Thermodynamic optimisation of a high-electrical efficiency integrated internal combustion engine – Organic Rankine cycle combined heat and power system

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  • Chatzopoulou, Maria Anna
  • Markides, Christos N.

Abstract

Organic Rankine cycle (ORC) engines are suitable for heat recovery from internal combustion engines (ICE) for the purpose of secondary power generation in combined heat and power (CHP) systems. However, trade-offs must be considered between ICE and ORC engine performance in such integrated solutions. The ICE design and operational characteristics influence its own performance, along with the exhaust-gas conditions available as heat source to the ORC engine, impacting ORC design and performance, while the heat-recovery heat exchanger (ORC evaporator) will affect the ICE operation. In this paper, an integrated ICE-ORC CHP whole-system optimisation framework is presented. This differs from other efforts in that we develop and apply a fully-integrated ICE-ORC CHP optimisation framework, considering the design and operation of both the ICE and ORC engines simultaneously within the combined system, to optimise the overall system performance. A dynamic ICE model is developed and validated, along with a steady-state model of subcritical recuperative ORC engines. Both naturally aspirated and turbocharged ICEs are considered, of two different sizes/capacities. Nine substances (covering low-GWP refrigerants and hydrocarbons) are investigated as potential ORC working fluids. The integrated ICE-ORC CHP system is optimised for either maximum total power output, or minimum fuel consumption. Results highlight that by optimising the complete integrated ICE-ORC CHP system simultaneously, the total power output increases by up to 30% in comparison to a nominal system design. In the integrated CHP system, the ICE power output is slightly lower than that obtained for optimal standalone ICE application, as the exhaust-gas temperature increases to promote the bottoming ORC engine performance, whose power increases by 7%. The ORC power output achieved accounts for up to 15% of the total power generated by the integrated system, increasing the system efficiency by up to 11%. When only power optimisation is performed, the specific fuel consumption increases, highlighting that high-power output comes at the cost of higher fuel consumption. In contrast, when specific fuel consumption is used as the objective function (minimised), fuel consumption drops by up to 17%, thereby significantly reducing the operating fuel costs. This study proves that by taking a holistic approach to whole-system ICE-ORC CHP design and operation optimisation, more power can be generated efficiently, with a lower fuel consumption. The findings are relevant to ICE and ORC manufacturers, integrators and installers, since it informs component design, system integration and operation decisions.

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  • Chatzopoulou, Maria Anna & Markides, Christos N., 2018. "Thermodynamic optimisation of a high-electrical efficiency integrated internal combustion engine – Organic Rankine cycle combined heat and power system," Applied Energy, Elsevier, vol. 226(C), pages 1229-1251.
    • Handle: RePEc:eee:appene:v:226:y:2018:i:c:p:1229-1251
    DOI: 10.1016/j.apenergy.2018.06.022
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    Cited by:

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    2. Acha, Salvador & Le Brun, Niccolo & Damaskou, Maria & Fubara, Tekena Craig & Mulgundmath, Vinay & Markides, Christos N. & Shah, Nilay, 2020. "Fuel cells as combined heat and power systems in commercial buildings: A case study in the food-retail sector," Energy, Elsevier, vol. 206(C).
    3. Babras Khan & Man-Hoe Kim, 2022. "Energy and Exergy Analyses of a Novel Combined Heat and Power System Operated by a Recuperative Organic Rankine Cycle Integrated with a Water Heating System," Energies, MDPI, vol. 15(18), pages 1-19, September.
    4. Li, Xiaoya & Tian, Hua & Shu, Gequn & Zhao, Mingru & Markides, Christos N. & Hu, Chen, 2019. "Potential of carbon dioxide transcritical power cycle waste-heat recovery systems for heavy-duty truck engines," Applied Energy, Elsevier, vol. 250(C), pages 1581-1599.
    5. White, M.T. & Oyewunmi, O.A. & Chatzopoulou, M.A. & Pantaleo, A.M. & Haslam, A.J. & Markides, C.N., 2018. "Computer-aided working-fluid design, thermodynamic optimisation and thermoeconomic assessment of ORC systems for waste-heat recovery," Energy, Elsevier, vol. 161(C), pages 1181-1198.
    6. Le Brun, Niccolo & Simpson, Michael & Acha, Salvador & Shah, Nilay & Markides, Christos N., 2020. "Techno-economic potential of low-temperature, jacket-water heat recovery from stationary internal combustion engines with organic Rankine cycles: A cross-sector food-retail study," Applied Energy, Elsevier, vol. 274(C).
    7. Charles E. Sprouse, 2024. "Review of Organic Rankine Cycles for Internal Combustion Engine Waste Heat Recovery: Latest Decade in Review," Sustainability, MDPI, vol. 16(5), pages 1-74, February.
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    9. Simpson, Michael C. & Chatzopoulou, Maria Anna & Oyewunmi, Oyeniyi A. & Le Brun, Niccolo & Sapin, Paul & Markides, Christos N., 2019. "Technoeconomic analysis of internal combustion engine – organic Rankine cycle systems for combined heat and power in energy-intensive buildings," Applied Energy, Elsevier, vol. 253(C), pages 1-1.
    10. Chatzopoulou, Maria Anna & Lecompte, Steven & Paepe, Michel De & Markides, Christos N., 2019. "Off-design optimisation of organic Rankine cycle (ORC) engines with different heat exchangers and volumetric expanders in waste heat recovery applications," Applied Energy, Elsevier, vol. 253(C), pages 1-1.
    11. Chatzopoulou, Maria Anna & Simpson, Michael & Sapin, Paul & Markides, Christos N., 2019. "Off-design optimisation of organic Rankine cycle (ORC) engines with piston expanders for medium-scale combined heat and power applications," Applied Energy, Elsevier, vol. 238(C), pages 1211-1236.
    12. Aziz, Faraz & Salim, Mohammad Saad & Kim, Man-Hoe, 2019. "Performance analysis of high temperature cascade organic Rankine cycle coupled with water heating system," Energy, Elsevier, vol. 170(C), pages 954-966.
    13. Liu, Peng & Shu, Gequn & Tian, Hua, 2019. "How to approach optimal practical Organic Rankine cycle (OP-ORC) by configuration modification for diesel engine waste heat recovery," Energy, Elsevier, vol. 174(C), pages 543-552.
    14. Pantaleo, Antonio M. & Camporeale, Sergio M. & Sorrentino, Arianna & Miliozzi, Adio & Shah, Nilay & Markides, Christos N., 2020. "Hybrid solar-biomass combined Brayton/organic Rankine-cycle plants integrated with thermal storage: Techno-economic feasibility in selected Mediterranean areas," Renewable Energy, Elsevier, vol. 147(P3), pages 2913-2931.
    15. Yıldız Koç & Hüseyin Yağlı & Ali Koç, 2019. "Exergy Analysis and Performance Improvement of a Subcritical/Supercritical Organic Rankine Cycle (ORC) for Exhaust Gas Waste Heat Recovery in a Biogas Fuelled Combined Heat and Power (CHP) Engine Thro," Energies, MDPI, vol. 12(4), pages 1-22, February.
    16. Emadi, Mohammad Ali & Chitgar, Nazanin & Oyewunmi, Oyeniyi A. & Markides, Christos N., 2020. "Working-fluid selection and thermoeconomic optimisation of a combined cycle cogeneration dual-loop organic Rankine cycle (ORC) system for solid oxide fuel cell (SOFC) waste-heat recovery," Applied Energy, Elsevier, vol. 261(C).
    17. Praveen Cheekatamarla & Ahmad Abu-Heiba, 2020. "A Comprehensive Review and Qualitative Analysis of Micro-Combined Heat and Power Modeling Approaches," Energies, MDPI, vol. 13(14), pages 1-26, July.
    18. Zhang, Chenghu & Lin, Jiyou & Tan, Yufei, 2019. "A theoretical study on a novel combined organic Rankine cycle and ejector heat pump," Energy, Elsevier, vol. 176(C), pages 81-90.

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