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.     

Second law analysis of a diesel engine waste heat recovery with a combined sensible and latent heat 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. The major technical constraint that prevents successful implementation of waste heat recovery is due to intermittent and time mismatched demand for and availability of energy. The present work deals with the use of exergy as an efficient tool to measure the quantity and quality of energy extracted from a diesel engine and stored in a combined sensible and latent heat storage system. This analysis is utilized to identify the sources of losses in useful energy within the components of the system considered, and provides a more realistic and meaningful assessment than the conventional energy analysis. The energy and exergy balance for the overall system is quantified and illustrated using energy and exergy flow diagrams. In order to study the discharge process in a thermal storage system, an illustrative example with two different cases is considered and analyzed, to quantify the destruction of exergy associated with the discharging process. The need for promoting exergy analysis through policy decision in the context of energy and environment crisis is also emphasized.     

Waste heat recovery using heat pipe heat exchanger for heating automobile using exhaust gas

The feasibility of using heat pipe heat exchangers for heating applying automotive exhaust gas is studied and the calculation method is developed. Practical heat pipe heat exchanger is set up for heating HS663, a large bus. Simple experiments are carried out to examine the performance of the heat exchanger. It is shown that the experimental results, which indicate the benefit of exhaust gas heating, are in good agreement with numerical results.     

Compact potential of exhaust heat exchangers for engine waste heat recovery using metal foams

To improve the practicability of the waste heat recovery system for internal combustion engines, the compact potential of exhaust heat exchangers using metal foams is investigated. In the present study, the performance of compact exhaust heat exchangers is compared with that of a conventional shell and tube heat exchanger in a real test bench. Both heat transfer and pressure drop performance are considered when assessing the performance of heat exchangers because these two factors normally show a trade‐off relationship when designing exhaust heat exchangers. Compared with the conventional heat exchanger, the compact heat exchanger can achieve a similar pressure drop, and at the same time the heat transfer is increased by 30%, whereas the volume and the weight are each reduced by 2/3. The performance of compact heat exchangers with six types of Ni metal foams is also investigated under different mass flow rates and thicknesses of the porous layer. Results show that the optimum compact heat exchanger enhances the comprehensive performance 1.9 times compared with original one. This study shows that metal foams have great potential in realizing a compact exhaust heat exchanger for engine waste heat recovery.     

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.     

Effects of secondary combustion on efficiencies and emission reduction in the diesel engine exhaust heat recovery system

An experimental study on the effects of secondary combustion on efficiencies and emission reduction in the diesel engine exhaust heat recovery system has been undertaken. The co-generation concept is utilized in that the electric power is produced by the generator connected to the diesel engine, and heat is recovered from both combustion exhaust gases and the engine by the fin-and-tube and shell-and-tube heat exchangers, respectively. A specially designed secondary combustor is installed at the engine outlet in order to reburn the unburned fuel from the diesel engine, thereby improving the system’s efficiency as well as reducing air pollution caused by exhaust gases. The main components of the secondary combustor are coiled Nichrome wires heated by the electric current and diesel oxidation catalyst (DOC) housed inside a well insulated stainless steel shell. The performance tests were conducted at four water flow rates of 5, 10, 15 and 20 L/min and five electric power outputs of 3, 5, 7, 9 and 11 kW. The results show that at a water flow of 20 L/min and a power generation of 9 kW, the total efficiency (thermal efficiency plus electric power generation efficiency) of this system reaches a maximum 94.4% which is approximately 15–20% higher than that of the typical diesel engine exhaust heat recovery system. Besides, the use of the secondary combustor and heat exchangers results in 80%, 35% and 90% reduction of carbon monoxide (CO), nitrogen oxide (NO_x) and particulate matter (PM), respectively.     

Augmentation of solar-assisted humidification-dehumidification water desalination system using heat recovery and thermal energy storage system

In previous investigations, humidification-dehumidification (HDH) solar-assisted desalination systems were designed produce the daily fresh water during sun hours which lead to big sizes and unsteady systems. In the present study, integration of solar-assisted HDH desalination system with heat recovery and thermal energy storage unit is developed to enhance system productivity, reduces auxiliary power consumptions and system size and assure system continuous operation. The mathematical modelling based on energy and mass conservation equations is presented and solved using iterative techniques by C++ and engineering equation solver software. Detailed parametric study of the developed system is conducted for wide ranges of operating conditions and design parameters to study the effects of integrating the HDH system with solar collectors, heat recovery and thermal energy storage units on the system performance. The results revealed that (i) this integration improves system productivity and reduces operating cost, (ii) increasing air to water mass ratio and sea water temperature and decreasing ambient humidity decrease water productivity and gained output ratio (GOR) and increase operating cost parameter (OCP) and (iii) increasing air inlet temperature and sea water flow rates increase GOR and decrease OCP. Comparison with previous systems showed that the proposed system reduces the electric heating power of the system at solar noon by 37% at MR = 0.5 and gives daily fresh water productivity (123.7 kg/h) two times more than previous systems with comparable OCP (0.099 $/kg).     

Thermal performance of a solar-assisted heat pump drying system with thermal energy storage tank and heat recovery unit

Thermal performance parameters for a solar-assisted heat pump (SAHP) drying system with underground thermal energy storage (TES) tank and heat recovery unit (HRU) are investigated in this study. The SAHP drying system is made up of a drying unit, a heat pump, flat plate solar collectors, an underground TES tank, and HRU. An analytical model is developed to obtain the performance parameters of the drying system by using the solution of heat transfer problem around the TES tank and energy expressions for other components of the drying system. These parameters are coefficient of performances for the heat pump (COP) and system (COPs), specific moisture evaporation rate (SMER), temperature of water in the TES tank, and energy fractions for energy charging and extraction from the system. A MATLAB program has been prepared using the expressions for the drying system. The obtained results for COP, COPs, and SMER are 5.55, 5.28, and 9.25, respectively, by using wheat mass flow rate of 100 kg h⁻¹, Carnot efficiency of 40%, collector area of 100 m², and TES tank volume of 300 m³ when the system attains periodic operation duration in fifth year onwards for 10 years of operation. Annual energy saving is 21.4% in comparison with the same system without using HRU for the same input data.     

High temperature latent heat thermal energy storage using heat pipes

A thermal network model is developed and used to analyze heat transfer in a high temperature latent heat thermal energy storage unit for solar thermal electricity generation. Specifically, the benefits of inserting multiple heat pipes between a heat transfer fluid and a phase change material (PCM) are of interest. Two storage configurations are considered; one with PCM surrounding a tube that conveys the heat transfer fluid, and the second with the PCM contained within a tube over which the heat transfer fluid flows. Both melting and solidification are simulated. It is demonstrated that adding heat pipes enhances thermal performance, which is quantified in terms of dimensionless heat pipe effectiveness.     

Impact of exhaust gas recirculation (EGR) on the oxidative reactivity of diesel engine soot

This paper expands the consideration of the factors affecting the nanostructure and oxidative reactivity of diesel soot to include the impact of exhaust gas recirculation (EGR). Past work showed that soot derived from oxygenated fuels such as biodiesel carries some surface oxygen functionality and thereby possesses higher reactivity than soot from conventional diesel fuel. In this work, results show that EGR exerts a strong influence on the physical properties of the soot which leads to enhanced oxidation rate. HRTEM images showed a dramatic difference between the burning modes of the soot generated under 0 and 20% EGR. The soot produced under 0% EGR strictly followed an external burning mode with no evidence of internal burning. In contrast, soot generated under 20% EGR exhibited dual burning modes: slow external burning and rapid internal burning. The results demonstrate clearly that highly reactive soot can be achieved by manipulating the physical properties of the soot via EGR.     

An experimental investigation on engine performance and emissions of a single cylinder diesel engine using hydrogen as inducted fuel and diesel as injected fuel with exhaust gas recirculation

Fast depletion of fossil fuels is demanding an urgent need to carry out research work to find out the viable alternative fuels for meeting sustainable energy demand with minimum environmental impact. In the future, our energy systems will need to be renewable and sustainable, efficient and cost-effective, convenient and safe. The technology for producing hydrogen from a variety of resources, including renewable, is evolving and that will make hydrogen energy system as cost-effective. Hydrogen safety concerns are not the cause for fear but they simply are different than those we are accustomed to with gasoline, diesel and other fossil fuels. For the time being full substitution of diesel with hydrogen is not convenient but use of hydrogen in a diesel engine in dual fuel mode is possible. So Hydrogen has been proposed as the perfect fuel for this future energy system. The experiment is conducted using diesel–hydrogen blend. A timed manifold induction system which is electronically controlled has been developed to deliver hydrogen on to the intake manifold. The solenoid valve is activated by the new technique of taking signal from the rocker arm of the engine instead of cam actuation mechanism. In the present investigation hydrogen-enriched air has been used in a diesel engine with hydrogen flow rate at 0.15 kg/h. As diesel is substituted and hydrogen is inducted, the NO_x emission is increased. In order to reduce NO_x emission an EGR system has been developed. In the EGR system a lightweight EGR cooler has been used instead of bulky heat exchanger. In this experiment performance parameters such as brake thermal efficiency, volumetric efficiency, BSEC are determined and emissions such as oxides of nitrogen, carbon dioxide, carbon monoxide, hydrocarbon, smoke and exhaust gas temperature are measured. Dual fuel operation with hydrogen induction coupled with exhaust gas recirculation results in lowered emission level and improved performance level compared to the case of neat diesel operation.     

Engine performance and emissions of a diesel engine operating on diesel-RME (rapeseed methyl ester) blends with EGR (exhaust gas recirculation)

The effects of biodiesel (rapeseed methyl ester, RME) and different diesel/RME blends on the diesel engine NO_x emissions, smoke, fuel consumption, engine efficiency, cylinder pressure and net heat release rate are analysed and presented. The combustion of RME as pure fuel or blended with diesel in an unmodified engine results in advanced combustion, reduced ignition delay and increased heat release rate in the initial uncontrolled premixed combustion phase. The increased in-cylinder pressure and temperature lead to increased NO_x emissions while the more advanced combustion assists in the reduction of smoke compared to pure diesel combustion. The lower calorific value of RME results in increased fuel consumption but the engine thermal efficiency is not affected significantly. When similar percentages (% by volume) of exhaust gas recirculation (EGR) are used in the cases of diesel and RME, NO_x emissions are reduced to similar values, but the smoke emissions are significantly lower in the case of RME. The retardation of the injection timing in the case of pure RME and 50/50 (by volume) blend with diesel results in further reduction of NO_x at a cost of small increases of smoke and fuel consumption.     

Experimental study of engine performance and emissions for hydrogen diesel dual fuel engine with exhaust gas recirculation

With an alarming enlargement in vehicular density, there is a threat to the environment due to toxic emissions and depleting fossil fuel reserves across the globe. This has led to the perpetual exploration of clean energy resources to establish sustainable transportation. Researchers are continuously looking for the fuels with clean emission without compromising much on vehicular performance characteristics which has already been set by efficient diesel engines. Hydrogen seems to be a promising alternative fuel for its clean combustion, recyclability and enhanced engine performance. However, problems like high NOx emissions is seen as an exclusive threat to hydrogen fuelled engines. Exhaust gas recirculation (EGR), on the other hand, is known to overcome the aforementioned problem. Therefore, this study is conducted to study the combined effect of hydrogen addition and EGR on the dual fuelled compression ignition engine on a single cylinder diesel engine modified to incorporate manifold hydrogen injection and controlled EGR. The experiments are conducted for 25%, 50%, 75% and 100% loads with the hydrogen energy share (HES) of 0%, 10% and 30%. The EGR rate is controlled between 0%, 5% and 10%. With no substantial decrement in engine's brake thermal efficiency, high gains in terms of emissions are observed due to synergy between hydrogen addition and EGR. The cumulative reduction of 38.4%, 27.4%, 33.4%, 32.3% and 20% with 30% HES and 10% EGR is observed for NOx, CO2, CO, THC and PM, respectively. Hence, the combination of hydrogen addition and EGR is observed to be advantageous for overall emission reduction.     

Experimental investigations on a hydrogen diesel homogeneous charge compression ignition engine with exhaust gas recirculation

In this experimental study, hydrogen was inducted along with air and diesel was injected into the cylinder using a high pressure common rail system, in a single cylinder homogeneous charge compression ignition engine. An electronic controller was used to set the required injection timing of diesel for best thermal efficiency. The influences of hydrogen to diesel energy ratio, output of the engine and exhaust gas recirculation (EGR) on performance, emissions and combustion were studied in detail. An increase in the amount of hydrogen improved the thermal efficiency by retarding the combustion process. It also lowered the exhaust emissions. Large amounts of hydrogen and EGR were needed at high outputs for suppressing knock. The range of operation was brake mean effective pressures of 2–4 bar. The levels of HC and CO emitted were not significantly influenced by the amount of hydrogen that was used.     

Performance and emission characteristics of a diesel engine with Diesel Premixed Compression Ignition and exhaust gas recirculation

In the present work, diesel was used as a premixed fuel along with the conventional injection of diesel with a premixed ratio of 0.25. The premixed charge was burned in the cylinder along with the fuel directly injected into the cylinder by a conventional injection system. To control nitrogen oxide(s) (NO_x) emissions, Exhaust Gas Recirculation (EGR) was adopted and the exhaust gas was varied from 10% to 30% in steps of 10%. The performance and emission characteristics were compared with conventional 100% diesel injection in the main chamber. Based on the experiments conducted on a Compression Ignition Direct Injection (CIDI) engine, it was found that unburnt hydrocarbons, carbon monoxide, and soot emissions increase. Soot emission decreases with up to 20% EGR and increases when EGR was increased beyond 20%. Hence 20% EGR was found to be the optimum use for DPMCI mode with a premixed ratio of 0.25. Due to the lean operation, significant reduction in NO_x was achieved with the DPMCI combustion mode. Brake thermal efficiency was marginally decreased compared to CIDI mode.     

Energy recovery from diesel engine exhaust gases for performance enhancement and air conditioning

The utilisation of exhaust waste heat is now well known and the forms the basis of many combined cooling and power installations. The exhaust gases from such installations represent a significant amount of thermal energy that traditionally has been used for combined heat and power applications. This paper explores the theoretical performance of four different configurations of a turbocharger diesel engine and absorption refrigeration unit combination when operating in a high ambient day temperature of 35 °C. The simulation is performed using “SPICE”, a well known programme commonly used for engine performance predictions. The paper examines the interfacing of the turbocharged diesel engine with an absorption refrigeration unit and estimates the performance enhancement. The influence of the cycle configuration and performance parameters on the performance of the engine operating as a power supply with an auxiliary air conditioning plant is examined. It is demonstrated that a pre- and inter-cooled turbocharger engine configuration cycle offers considerable benefits in terms of SFC, efficiency and output for the diesel cycle performance.     

Optimization of diesel engine performances for a hybrid wind–diesel system with compressed air energy storage

Electricity supply in remote areas around the world is mostly guaranteed by diesel generators. This relatively inefficient and expensive method is responsible for 1.2 million tons of greenhouse gas (GHG) emission in Canada annually. Some low- and high-penetration wind-diesel hybrid systems (WDS) have been experimented in order to reduce the diesel consumption. We explore the re-engineering of current diesel power plants with the introduction of high-penetration wind systems together with compressed air energy storage (CAES). This is a viable alternative to major the overall percentage of renewable energy and reduce the cost of electricity. In this paper, we present the operative principle of this hybrid system, its economic benefits and advantages and we finally propose a numerical model of each of its components. Moreover, we are demonstrating the energy efficiency of the system, particularly in terms of the increase of the engine performance and the reduction of its fuel consumption illustrated and supported by a village in northern Quebec.     

Combined heat and power plant integrated with mobilized thermal energy storage (M-TES) system

Energy consumption for space and tap water heating in residential and service sectors accounts for one third of the total energy utilization in Sweden. District heating (DH) is used to supply heat to areas with high energy demand. However, there are still detached houses and sparse areas that are not connected to a DH network. In such areas, electrical heating or oil/pellet boilers are used to meet the heat demand. Extending the existing DH network to those spare areas is not economically feasible because of the small heat demand and the large investment required for the expansion. The mobilized thermal energy storage (M-TES) system is an alternative source of heat for detached buildings or sparse areas using industrial heat. In this paper, the integration of a combined heat and power (CHP) plant and an M-TES system is analyzed. Furthermore, the impacts of four options of the integrated system are discussed, including the power and heat output in the CHP plant. The performance of the M-TES system is likewise discussed.     

Effect of injection timing on the exhaust emissions of a diesel engine using diesel–methanol blends

Environmental concerns and limited resource of petroleum fuels have caused interests in the development of alternative fuels for internal combustion (IC) engines. For diesel engines, alcohols are receiving increasing attention because they are oxygenated and renewable fuels. Therefore, in this study, the effect of injection timing on the exhaust emissions of a single cylinder, naturally aspirated, four-stroke, direct injection diesel engine has been experimentally investigated by using methanol-blended diesel fuel from 0% to 15% with an increment of 5%. The tests were conducted for three different injection timings (15°, 20° and 25 °CA BTDC) at four different engine loads (5 Nm, 10 Nm, 15 Nm, 20 Nm) at 2200 rpm. The experimental test results showed that Bsfc, NO_x and CO₂ emissions increased as BTE, smoke opacity, CO and UHC emissions decreased with increasing amount of methanol in the fuel mixture. When compared the results to those of original injection timing, NO_x and CO₂ emissions decreased, smoke opacity, UHC and CO emissions increased for the retarded injection timing (15 °CA BTDC). On the other hand, with the advanced injection timing (25 °CA BTDC), decreasing smoke opacity, UHC and CO emissions diminished, and NO_x and CO₂ emissions boosted at all test conditions. In terms of Bsfc and BTE, retarded and advanced injection timings gave negative results for all fuel blends in all engine loads.     

Intermittency-friendly and high-efficiency cogeneration: Operational optimisation of cogeneration with compression heat pump,flue gas heat recovery,and intermediate cold storage

This paper develops, implements, and applies a mathematical model for economic unit dispatch for a novel cogeneration concept (CHP-HP-FG-CS (CHP with compression heat pump and cold storage using flue gas heat)) that increases the plant’s operational flexibility. The CHP-HP-FG-CS concept is a high-efficiency and widely applicable option in distributed cogeneration better supporting the co-existence between cogenerators and intermittent renewables in the energy system.The concept involves integrating an efficient high-temperature compression heat pump that uses only waste heat recovered from flue gases as low-temperature heat source, and an intermediate cold thermal storage allowing for non-concurrent operation of the cogeneration unit and the heat pump unit.The model is applied for a paradigmatic case study that shows how the integration of a heat pump affects the operational strategy of a cogeneration plant. It is found that CHP-HP-FG-CS offers significant reductions in fuel consumption (?8.9%) and operational production costs (?11.4%). The plant’s fuel-to-energy efficiency increases from 88.9 to 95.5%, which is state-of-the-art.The plant’s intermittency-friendliness coefficient Rc improves only marginally due to the constrained nature of the low-temperature heat source and the associated small capacity of the heat pump unit. Significant improvements in Rc are found when increasing the heat pump capacity assuming the availability of an unconstrained heat source.