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Experimental and numerical analyses of a 5 kWe oil-free open-drive scroll expander for small-scale organic Rankine cycle (ORC) applications

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  • Ziviani, Davide
  • James, Nelson A.
  • Accorsi, Felipe A.
  • Braun, James E.
  • Groll, Eckhard A.

Abstract

Organic Rankine cycles (ORCs) are thermodynamic power cycles designed to generate work from a wide range of heat source conditions. In particular, low-grade waste heat recovery (WHR) (<150 °C) can be effectively exploited with such systems. The efficiency of an ORC is highly dependent on its expander performance. In the low power output range (<10 kW), scroll expanders are cost-effective. Although a number of researchers have investigated the use of scroll compressors as expanders, very little work has been carried out in modeling and investigating the performance of oil-free expanders. In this work, an experimental evaluation of a newly designed open-drive oil-free scroll expander was performed. The expander had a nominal capacity of 5 kW, built-in volume ratio of 3.5, and was integrated into an ORC test-rig with R245fa as working fluid. The experimental data consisted of 75 data points that were used to map the oil-free operation of the scroll expander over five expander rotational speeds (from 800 rpm to 3000 rpm). Two heat sources inlet temperature, i.e. 85 °C and 110 °C, were investigated. The scroll expander achieved a maximum overall isentropic efficiency of 0.58 for the temperature source of 110 °C, for the imposed specific volume ratio of 6.12 at rotational speed of 1600 rpm. For the same heat source, the maximum expander power output was 3.75 kW for an imposed specific volume ratio of 6.55 and rotational speed of 2500 rpm. Besides the experimental work, the performance of the expander was characterized by means of a semi-empirical model to break-down the different loss terms. A well known model available in the literature was extended to account for the major frictional losses in a scroll machine, i.e. bearings, tip-seals and other sources of friction. Additionally, an Artificial Neural Network (ANN) modeling approach was also proposed to achieve higher accuracy in mapping expander performance for use in system simulation. The experimental data and model source codes are provided as supplementary materials.

Suggested Citation

  • Ziviani, Davide & James, Nelson A. & Accorsi, Felipe A. & Braun, James E. & Groll, Eckhard A., 2018. "Experimental and numerical analyses of a 5 kWe oil-free open-drive scroll expander for small-scale organic Rankine cycle (ORC) applications," Applied Energy, Elsevier, vol. 230(C), pages 1140-1156.
    • Handle: RePEc:eee:appene:v:230:y:2018:i:c:p:1140-1156
    DOI: 10.1016/j.apenergy.2018.09.025
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    5. Oh, Jinwoo & Jeong, Hoyoung & Kim, Joonbyum & Lee, Hoseong, 2020. "Numerical and experimental investigation on thermal-hydraulic characteristics of a scroll expander for organic Rankine cycle," Applied Energy, Elsevier, vol. 278(C).
    6. Gábor Györke & Axel Groniewsky & Attila R. Imre, 2019. "A Simple Method of Finding New Dry and Isentropic Working Fluids for Organic Rankine Cycle," Energies, MDPI, vol. 12(3), pages 1-11, February.
    7. Chen, Heng & Alzahrani, Huda A. & Amin, Mohammed A. & Sun, Minghui, 2023. "Towards sustainable development through the design, multi-aspect analyses, and multi-objective optimization of a novel solar-based multi-generation system," Energy, Elsevier, vol. 267(C).
    8. Campana, Claudio & Cioccolanti, Luca & Renzi, Massimiliano & Caresana, Flavio, 2019. "Experimental analysis of a small-scale scroll expander for low-temperature waste heat recovery in Organic Rankine Cycle," Energy, Elsevier, vol. 187(C).
    9. Naseri, Ali & Moradi, Ramin & Norris, Stuart & Subiantoro, Alison, 2022. "Experimental investigation of a revolving vane expander in a micro-scale organic Rankine cycle system for low-grade waste heat recovery," Energy, Elsevier, vol. 253(C).
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    11. Ping, Xu & Yang, Fubin & Zhang, Hongguang & Xing, Chengda & Pan, Yachao & Zhang, Wujie & Wang, Yan, 2023. "Nonlinear modeling and multi-scale influence characteristics analysis of organic Rankine cycle (ORC) system considering variable driving cycles," Energy, Elsevier, vol. 265(C).
    12. Zhuxian Liu & Zhong Wu & Yonghong Xu & Hongguang Zhang & Jian Zhang & Fubin Yang, 2022. "Performance Investigation of Single–Piston Free Piston Expander–Linear Generator with Multi–Parameter Based on Simulation Model," Energies, MDPI, vol. 15(23), pages 1-28, November.
    13. Ping, Xu & Yang, Fubin & Zhang, Hongguang & Xing, Chengda & Zhang, Wujie & Wang, Yan, 2022. "Evaluation of hybrid forecasting methods for organic Rankine cycle: Unsupervised learning-based outlier removal and partial mutual information-based feature selection," Applied Energy, Elsevier, vol. 311(C).
    14. Kutlu, Cagri & Erdinc, Mehmet Tahir & Li, Jing & Su, Yuehong & Pei, Gang & Gao, Guangtao & Riffat, Saffa, 2020. "Evaluate the validity of the empirical correlations of clearance and friction coefficients to improve a scroll expander semi-empirical model," Energy, Elsevier, vol. 202(C).
    15. Tian, Zhen & Gan, Wanlong & Zou, Xianzhi & Zhang, Yuan & Gao, Wenzhong, 2022. "Performance prediction of a cryogenic organic Rankine cycle based on back propagation neural network optimized by genetic algorithm," Energy, Elsevier, vol. 254(PB).
    16. Emhardt, Simon & Tian, Guohong & Song, Panpan & Chew, John & Wei, Mingshan, 2022. "CFD analysis of the influence of variable wall thickness on the aerodynamic performance of small scale ORC scroll expanders," Energy, Elsevier, vol. 244(PA).
    17. Feng, Yong-qiang & Xu, Jing-wei & He, Zhi-xia & Hung, Tzu-Chen & Shao, Meng & Zhang, Fei-yang, 2022. "Numerical simulation and optimal design of scroll expander applied in a small-scale organic rankine cycle," Energy, Elsevier, vol. 260(C).
    18. Lei, Biao & Yu, Hai-bin & Li, Guo-qiang & Wu, Yu-Ting & Wang, Wei, 2022. "Thermodynamic investigations on internal generator cooling for hermetic expanders in Organic Rankine Cycles," Energy, Elsevier, vol. 251(C).
    19. Guo, Zhiyu & Zhang, Cancan & Wu, Yuting & Lei, Biao & Yan, Dong & Zhi, Ruiping & Shen, Lili, 2020. "Numerical optimization of intake and exhaust structure and experimental verification on single-screw expander for small-scale ORC applications," Energy, Elsevier, vol. 199(C).
    20. Bianchi, M. & Branchini, L. & De Pascale, A. & Melino, F. & Ottaviano, S. & Peretto, A. & Torricelli, N., 2019. "Application and comparison of semi-empirical models for performance prediction of a kW-size reciprocating piston expander," Applied Energy, Elsevier, vol. 249(C), pages 143-156.

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    Keywords

    Scroll expander; Oil-free; Organic Rankine cycle; R245fa; ANN;
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