Second-law performance of heat exchangers for waste heat recovery

Exergy change rate in an ideal gas flow or an incompressible flow can be divided into a thermal exergy change rate and a mechanical exergy loss rate. The mechanical exergy loss rates in the two flows were generalized using a pressure-drop factor. For heat exchangers using in waste heat recovery, the consumed mechanical exergy is usually more valuable than the recovered thermal exergy. A weighing factor was proposed to modify the pressure-drop factor. An exergy recovery index (η_II) was defined and it was expressed as a function of effectiveness (?), ratio of modified heat capacity rates (C^∗), hot stream-to-dead-state temperature ratio, cold stream-to-dead-state temperature ratio and modified overall pressure-drop factor. This η_II–? relation can be used to find the η_II value of a heat exchanger with any flow arrangement. The η_II−Ntu and η_II−Ntu_h relations of cross-flow heat exchanger with both fluids unmixed were established respectively. The former provides a minimum Ntu design principle and the latter provides a minimum Ntu_h design principle. A numerical example showed that, at a fixed heat capacity rate of the hot stream, the heat exchanger size yielded by the minimum Ntu_h principle is smaller than that yielded by the minimum Ntu principle.     

Experimental investigation on heat recovery from diesel engine exhaust using finned shell and tube heat exchanger and thermal storage system

The exhaust gas from an internal combustion engine carries away about 30% of the heat of combustion. The energy available in the exit stream of many energy conversion devices goes as waste, if not utilized properly. The major technical constraint that prevents successful implementation of waste heat recovery is due to its intermittent and time mismatched demand and availability of energy. In the present work, a shell and finned tube heat exchanger integrated with an IC engine setup to extract heat from the exhaust gas and a thermal energy storage tank used to store the excess energy available is investigated in detail. A combined sensible and latent heat storage system is designed, fabricated and tested for thermal energy storage using cylindrical phase change material (PCM) capsules. The performance of the engine with and without heat exchanger is evaluated. It is found that nearly 10–15% of fuel power is stored as heat in the combined storage system, which is available at reasonably higher temperature for suitable application. The performance parameters pertaining to the heat exchanger and the storage tank such as amount of heat recovered, heat lost, charging rate, charging efficiency and percentage energy saved are evaluated and reported in this paper.     

蛋白粉尾气余热回收喷淋塔的热工特性研究

大豆蛋白粉干燥工艺过程产生的高温尾气中蕴含着大量显热和潜热,而无填料、垂直逆流喷淋塔可以深度回收尾气中的余热。对此建立了喷淋塔的数值模型,并通过实验验证其准确性;应用所建模型,分析喷淋高度、入口水温、喷淋密度、尾气流速和尾气入口湿球温度对喷淋塔热回收性能的影响规律,进而获得了喷淋塔在实验工况范围内的换热效率曲线及经验关联式,为尾气喷淋热回收塔的优化设计与工程应用提供了分析工具。     

Energetic and exergetic analysis of waste heat recovery from a microturbine using organic Rankine cycles

This article examines the exhaust waste heat recovery potential of a microturbine (MT) using an organic Rankine cycle (ORC). Possible improvements in electric and exergy efficiencies as well as specific emissions by recovering waste heat from the MT exhaust gases are determined. Different dry organic working fluids are considered during the evaluation (R113, R123, R245fa, and R236fa). In general, it has been found that the use of an ORC to recover waste heat from MTs improves the combined electric and exergy efficiencies for all the evaluated fluids, obtaining increases of an average of 27% when the ORC was operated using R113 as the working fluid. It has also been found that higher ORC evaporator effectiveness values correspond to lower pinch point temperature differences and higher exergy efficiencies. Three different MT sizes were evaluated, and the results indicate that the energetic and exergetic performance as well as the reduction of specific emissions of a combined MT‐ORC is better for small MT power outputs than for larger MTs. This article also shows how the electric efficiency can be used to ascertain under which circumstances the use of a combined MT‐ORC will result in better cost, primary energy consumption, or emission reduction when compared with buying electricity directly from electric utilities. Copyright © 2012 John Wiley & Sons, Ltd.     

Thermohydraulic performance of a new internal twisted ribs automobile exhaust heat exchanger for waste heat recovery applications

The performance of the thermoelectric-based waste heat recovery (WHR) system in an automobile greatly depends on the amount of heat extracted by the exhaust heat exchanger (EHE). In the present study, the thermohydraulic performance of the EHE having twisted ribs and the pressure drop across the entire heat exchanger have been experimentally investigated. The experiments were repeated for the various geometric parameters such as twist ratio (4-8), angle of attack (30°-90°), and pitch ratio (6-10) on the Reynolds number within the range of 2300 to 25,000. The heat transport and fluid flow characteristics were compared with an internally smooth EHE using the thermohydraulic performance parameter. The maximum heat transfer rate was improved at 164.22%. However, the specification of the twisted rib for superior performance has been obtained at twist ratio of 4 and pitch ratio of 8 with 60° angle of attack. The highest thermohydraulic performance parameter value revealed as 1.93 at the same configuration. With the change in twist ratio, the pitch ratio, angle of attack, and the heat transfer rate increased by 39.52%, 60.85%, and 40.70%, respectively. Thus, the efficient heat transfer with the twisted rib would improve the extent of WHR in automobiles.     

复合相变换热技术在锅炉排烟余热回收中的应用

复合相变换热技术是一种回收锅炉排烟余热的新型技术,其壁温可控可调,具有防止烟气侧低温腐蚀的突出优势.介绍了宝钢采用该技术回收利用本厂内一台低压锅炉排烟余热生产生活热水的节能项目,该项目于2013年5月投运,至今运行良好.运行结果表明,该复合相变换热器可使锅炉排烟温度由194℃降至138℃,同时获得90℃热水19.1 t·h-1.通过实施该节能项目可回收烟气余热约1 400 k W,年节约标准煤约1 300 t,推进了宝钢节能减排.     

燃气轮机内环水余热回收研究

通过对燃机内环水所携带热量的研究,设计换热器,论证了用内环水加热燃机天然气进气的可行性,从而达到回收内环水余热,节约能源的目的。     

Experimental and theoretical study of waste heat recovery from a refrigeration system using a finned helical coil heat exchanger

This paper is an experimental and theoretical study that aimed at conserving energy by utilizing the waste heat generated from a refrigeration system by calculating the range of condensation after the compression stage for the refrigerant (R410A). A helical coil tube‐shell heat exchanger was designed as a heat recovery unit to use the waste heat from an air conditioner 1TR (split type) in the outdoor unit between the compressor and the condenser to produce hot water and increase the coefficient of performance (COP) of the refrigeration cycle. Two experimental types of the helical coil heat exchanger (conventional and finned) were used in attempts to induce absorption of the rejected heat into tap water. The increase in the COP ranges from 12.5% to 40%, an increase in the water outlet temperatures difference reaches 12°C. A cost–benefit analysis in terms of the net present value and the payback period (PP) has been performed. From the analysis, it has been observed that the use of the designed heat recovery unit will save electrical consumption to produce the required hot water with a PP of about 11.7 months for the conventional heat exchanger and 17.5 months for the finned helical coil heat exchanger.     

空调排风热回收在我国应用节能潜力分析

介绍空调排风热回收系统的工作原理,对不同地区的室外温度、焓值的逐时变化参数进行分析.在气象数据基础上动态分析我国不同典型气候区域城市热回收的适应性及热回收方式的选择,并对热回收节能潜力进行分析,进而得出热回收系统在我国不同气候区域的适应范围,研究表明排风热回收装置在我国节能效果明显.     

Thermal performance analysis of plate heat exchanger with different configurations for the heat recovery system in buildings

Due to the scarcity of conventional energy sources, a lot of efforts need to be taken regarding energy conservation in the buildings, including heat recovery of air ventilation systems. The present paper focuses on new methods to improve the thermal performance of the heat recovery system by investigating the heat transfer characteristics and the flow development in a flat-plate heat exchanger (FPHE) using three different rib-grooved surfaces (trapezoidal, triangle and semi-circular), the numerical simulations were carried out for uniform wall heat flux equal to 290 W/m² for air as the working fluid, the Reynolds number varies from 500 to 2000 for three different channel heights. The numerical results indicated that, rib-grooved surfaces have a significant impact on heat transfer enhancement with an increase in the pressure drop through the channel. The effect of rib-grooved patterns on the heat transfer and the fluid flow is more significant in a narrow channel especially for trapezoidal and triangle corrugated surfaces, because they have sharp edges. Based on the present research, the FPHEs with the added rib-grooved surfaces are recommended to provide an efficient and compact heat recovery system. Moreover, it was found that by applying the new design, a considerable amount of energy and power could be saved.     

Quantitative analysis of fuel-saving potential for waste heat recovery system integrated with hybrid electric vehicle

Hybrid electric vehicles (HEVs) with low fuel consumption, low emissions, and long driving range are the ideal transition models between conventional fuel vehicles and pure electric vehicles. The growing demand for increased vehicle efficiency has motivated the introduction of waste heat recovery (WHR) technology in the automotive industry, with the organic Rankine cycle (ORC) as the most promising measure for recycling waste energy. Currently, only a few studies have been conducted to couple HEV and WHR systems. These studies have mainly focused on the hybrid powertrain control strategy, but lack quantitative methods to comprehensively analyze the fuel-saving potential due to the WHR system. In this study, an HEV-WHR integrated system that includes a mechanism-based dynamic model of ORC and a hybrid diesel-electric truck model is established. Further, a quantitative evaluation method that simultaneously considers the negative integrated effects (increased vehicle weight and increased exhaust back pressure) and the positive impact values of the engine, motor, and WHR system on the fuel-saving potential is proposed. Finally, the influence of two environmental factors (wind speed and ambient temperature) on the fuel-saving performance is analyzed. The results reveal that under the standard highway driving cycle (HWY), the negative integrated effects reduce the ideal fuel-saving potential of the HEV-WHR system from 6.10% to 5.42%. However, the optimized performances of the engine, motor, and WHR system improve the fuel-saving rate by 0.39%, 1.81%, and 3.22%, respectively. The results also indicate that the fuel-saving potential increases from 1.62% to 8.60% with increasing wind speed and decreases from 6.70% to 4.25% with increasing ambient temperature.     

An Experimental Study on Latent Heat Recovery of Exhaust Wet Flue Gas

The experiment was conducted to investigate the heat transfer performance of wet flue gas in a vertical tube. The factors influencing the convective condensation of wet flue gas were experimentally investigated. The measured results indicate that the convective heat transfer of bulk flow and condensation heat transfer of vapor have significant contribution to the total heat transfer and the dominant transport mechanism is dependent upon the vapor fraction in mixture.     

Analysis of exhaust waste heat recovery from a dual fuel low temperature combustion engine using an Organic Rankine Cycle

This paper examines the exhaust waste heat recovery potential of a high-efficiency, low-emissions dual fuel low temperature combustion engine using an Organic Rankine Cycle (ORC). Potential improvements in fuel conversion efficiency (FCE) and specific emissions (NO_x and CO₂) with hot exhaust gas recirculation (EGR) and ORC turbocompounding were quantified over a range of injection timings and engine loads. With hot EGR and ORC turbocompounding, FCE improved by an average of 7 percentage points for all injection timings and loads while NO_x and CO₂ emissions recorded an 18 percent (average) decrease. From pinch-point analysis of the ORC evaporator, ORC heat exchanger effectiveness (?), percent EGR, and exhaust manifold pressure were identified as important design parameters. Higher pinch point temperature differences (PPTD) uniformly yielded greater exergy destruction in the ORC evaporator, irrespective of engine operating conditions. Increasing percent EGR yielded higher FCEs and stable engine operation but also increased exergy destruction in the ORC evaporator. It was observed that hot EGR can prevent water condensation in the ORC evaporator, thereby reducing corrosion potential in the exhaust piping. Higher ? values yielded lower PPTD and higher exergy efficiencies while lower ? values decreased post-evaporator exhaust temperatures below water condensation temperatures and reduced exergy efficiencies.     

Study on waste heat recovery from exhaust smoke in cogeneration system using woody biomass fuels

In recent years, fossil fuels such as petroleum, coal, and natural gas have become limited resources. In addition, bad effects caused by excessive carbon dioxide (CO₂) emissions have now begun destroying our global environment seriously. Since current living and economical standards depend strongly on the fossil fuels, it is necessary to realize a new society that utilizes biomass as one of major sources of energy. In this background, we manufactured a practical Stirling engine using woody biomass fuels for the first time in Japan in 2005. Further we proposed a unique cogeneration system with the Stirling engine that uses woody biomass fuels such as sawdust, firewood, and wood pellets. In this cogeneration system, 43% of the input energy is wasted as heat loss from the exhaust smoke into the atmosphere. Therefore we tried to recover the waste heat by using a thermoelectric conversion module in this study. In this report, the results of basic performance test and demonstration experiment as a cogeneration system combined the waste heat recovery with a power generating system are reported. © 2011 Wiley Periodicals, Inc. Heat Trans Asian Res; Published online in Wiley Online Library ( wileyonlinelibrary.com/journal/htj ). DOI 10.1002/htj.20390     

The latent heat recovery from boiler exhaust flue gas using shell and corrugated tube heat exchanger: A numerical study

The excessively increasing environmental concerns along with reducing fossil fuel resources introduce the trend of increasing the efficiency of boiler via implementing waste heat recovery. In the present study, the potential of latent heat recovery is investigated in the middle‐size boiler exhaust flue gas using the shell and corrugated tube heat exchanger. The main purpose of the present study is efficiency growth in flue gases using latent heat recovery of the steam energy. The heat recovery analysis is evaluated by a validated computational fluid dynamics model by a commercial software. For this study, the effect of different tube arrangements, number of tubes, and flow direction in the shell on heat transfer and pressure drop were investigated. The results showed that in‐line arrangement of the tubes in the shell presents better thermal performance and also high pressure drop among the other arrangements. As a result, by considering the thermal performance and pressure drop, radial arrangement shows higher performance. According to the obtained results from Section 2 of the present study, by considering the radial arrangement of tubes in the shell, as the number of tube rises, the thermal performance declines.     

Thermodynamic analysis of an LNG fuelled combined cycle power plant with waste heat recovery and utilization system

This paper has proposed an improved liquefied natural gas (LNG) fuelled combined cycle power plant with a waste heat recovery and utilization system. The proposed combined cycle, which provides power outputs and thermal energy, consists of the gas/steam combined cycle, the subsystem utilizing the latent heat of spent steam from the steam turbine to vaporize LNG, the subsystem that recovers both the sensible heat and the latent heat of water vapour in the exhaust gas from the heat recovery steam generator (HRSG) by installing a condensing heat exchanger, and the HRSG waste heat utilization subsystem. The conventional combined cycle and the proposed combined cycle are modelled, considering mass, energy and exergy balances for every component and both energy and exergy analyses are conducted. Parametric analyses are performed for the proposed combined cycle to evaluate the effects of several factors, such as the gas turbine inlet temperature (TIT), the condenser pressure, the pinch point temperature difference of the condensing heat exchanger and the fuel gas heating temperature on the performance of the proposed combined cycle through simulation calculations. The results show that the net electrical efficiency and the exergy efficiency of the proposed combined cycle can be increased by 1.6 and 2.84% than those of the conventional combined cycle, respectively. The heat recovery per kg of flue gas is equal to 86.27 kJ s^?1. One MW of electric power for operating sea water pumps can be saved. The net electrical efficiency and the heat recovery ratio increase as the condenser pressure decreases. The higher heat recovery from the HRSG exit flue gas is achieved at higher gas TIT and at lower pinch point temperature of the condensing heat exchanger. Copyright © 2006 John Wiley & Sons, Ltd.     

A review and selection of engine waste heat recovery technologies using analytic hierarchy process and grey relational analysis

In this paper, a brief review and comparison of the engine waste heat recovery technologies have been made. These five technologies are electric turbocompounding systems (ETC), thermodynamic organic Rankine cycle (ORC), thermoelectric generators (TEG), hydrogen generation by using exhaust gas heat energy, and hybrid pneumatic power systems (HPPS). According to comparison results, the HPPS system can achieve the highest fuel economy improvement among the five technologies. Though there are their own benefits by utilizing these different technologies, their disadvantages prevent the application of these advanced technologies to different extent. Besides, a combined evaluation method consisting of grey relational analysis and analytic hierarchy process has been applied to assess the five new engine waste heat recovery technologies from the perspective of technical, economic, and environmental aspect. Based on the final results of the new evaluation method, the HPPS was found to be the most promising WHR technology for vehicle engines. But because of the emphasis on economic benefit, TEG was found to be more favorable for working conditions, like power plant and marine engine. What is more, as is shown in the sensibility analysis, the weighing of the environment relevant factors can prominently influence the comparison results between ETC and HPPS. Copyright © 2014 John Wiley & Sons, Ltd.     

Optimization of finned-tube heat exchangers for diesel exhaust waste heat recovery using CFD and CCD techniques

In this paper, response surface methodology (RSM) based on central composite design (CCD) is applied to obtain an optimization design of finned type heat exchangers (HEX) to recover waste heat from the exhaust of a diesel engine. The design is performed for a single point operation (1600 rpm and 60 N m) of an OM314 diesel engine obtained from experimental measurements. Based on the CCD principle, fifteen HEX cases with different fins height, thickness and number are modeled numerically and the optimization is done to have the maximum heat recovery amount and minimum of pressure drop along the heat exchanger.     

Application of high porosity metal foams as air-cooled heat exchangers to high heat load removal systems

A numerical study has been conducted to investigate the fluid flow and heat transfer of an air-cooled metal foam heat exchanger under the high speed laminar jet confined by two parallel walls for which the range of the Reynolds number is 600–1000. Two independent numerical solvers were used and cross-validated being a FORTRAN code and the commercially available software CFD-ACE. The effects of local thermal non-equilibrium, thermal dispersion, porosity, and pore density on the heat transfer augmentation are examined for different Reynolds numbers. Application of energy flux vectors, for convection visualization, is also illustrated for a more comprehensive analysis of the problem. Finally, the performance of the metal foam heat exchanger is compared to that of conventional finned design. It is observed that the heat removal rate can be greatly improved at almost no excess cost.