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Transient modeling and thermal analysis of an innovative dual-loop Rankine–organic Rankine heat recovery system integrated with a gas engine

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Abstract

Transient modeling of an innovative dual-loop Rankin–organic Rankin (RC–ORC) heat recovery and power generation system integrated with a gas engine is performed here. The transient behavior of dual-loop cycles is not investigated so far, and hence the present work is an essential tool for predicting and controlling the performance of the RC–ORC dual-loop cycle during the start-up and the gas engine load change conditions. Transient energy conservation equations for heat exchangers are solved in discretized form. Quasi-dynamic equations are also considered for pumps, steam turbines, and expanders by the use of existing empirical relations. The model is developed in MATLAB software and validated using available data. Variations with time of operational parameters are presented and analyzed for both loops of RC and ORC. The results for the start-up period show a relatively sharp increase in parameters in time interval 500–1200 s. RC evaporator working fluid outlet temperature changes from 159 to 254 °C, RC net power output changes from 147 to 308 kW, and ORC net power output changes from 165 to 300 kW. Furthermore, RC and ORC working fluid mass flow rates changes from 0.25 to 0.50 kg s−1 and from 2.2 to 4.65 kg s−1 respectively. Moreover, results show that the turbine reached the steady state condition faster (1200 s) than that for evaporator (1750 s), RC loop reached steady state condition later than ORC loop (1750 s in comparison with 1300 s), and a single-loop ORC cycle reached steady state condition faster than RC–ORC dual-loop cycle (820 s in comparison with 1750 s).

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Abbreviations

\(A\) :

Heat transfer surface area (m2)

\(C_\text{P}\) :

Specific heat capacity (kJ kg−1 K−1)

\(d\) :

Diameter of the tubes (cm)

\(h\) :

Specific enthalpy (kJ kg−1)

\({\rm Ja}\) :

Jacob number

\(K\) :

Thermal conductivity (W m−1 K−1)

\(\dot{m}\) :

Mass flow rate (kg s−1)

\({\rm Nu}\) :

Nusselt Number

\(P\) :

Pressure (Pa)

\({\rm Pr}\) :

Prandtle number

\(\dot{Q}\) :

Heat transfer rate (kW)

\({\text{Re}}\) :

Reynolds number

\(T\) :

Temperature (°C)

\(t\) :

Time (s)

\(V\) :

Volume of fluid (m3)

\(X_{{{\text{tt}}}}\) :

Martinelly factor

\(x\) :

Steam quality

\(\dot{W}\) :

Work produced/consumed rate (kW)

\(\alpha\) :

Heat transfer coefficient (W m−2 K−1)

\(\varepsilon\) :

Electromechanical efficiency of pump

\(\Delta\) :

Delta operator

\(\rho\) :

Density (kg m−3)

\(\eta\) :

Mechanical efficiency of pump

\(\mu\) :

Dynamics viscosity (Pa. s)

\(Cond.\) :

Conduction heat transfer mechanism

\(Conv.\) :

Convection heat transfer mechanism

\(DLORC\) :

Dual-loop organic Rankine cycle

\(fa\) :

Hot or cold source fluid

\(HRSG\) :

Heat recovery steam generator

\(i\) :

Inner

\(JCW\) :

Jacket cooling water

\(ORC\) :

Organic Rankine cycle

\(o\) :

Outer

\(RC\) :

Steam Rankine cycle

\(w\) :

Tube wall

\(wf\) :

Working fluid

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  1. Energy Systems Improvement Laboratory (ESIL), School of Mechanical Engineering, Iran University of Science and Technology (IUST), Narmak, Tehran, 16844, Iran

    Sepehr Sanaye & Ali Ghaffari

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Appendix 1 Heat transfer coefficients in heat exchangers

Appendix 1 Heat transfer coefficients in heat exchangers

See Tables

Table 10 Convective heat transfer coefficient in evaporator
Full size table

10,

Table 11 Convective heat transfer coefficient in condenser, economizer, superheater and preheater
Full size table

11.

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Sanaye, S., Ghaffari, A. Transient modeling and thermal analysis of an innovative dual-loop Rankine–organic Rankine heat recovery system integrated with a gas engine. J Therm Anal Calorim 148, 10951–10971 (2023). https://doi.org/10.1007/s10973-023-12435-3

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