WASTED HEAT RECOVERY SYSTEM: HOW TO GAIN ENERGY

ABDUL MUHAIMIN BIN MOHD SHAFIE

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

SUPERVISOR DECLARATION

“I hereby declare that I have read this thesis and in my opinion this report in

sufficient in terms of scope and quality for the award of the degree of

Bachelor of Mechanical Engineering (Automotive).”

Signature : ……………………………..

Supervisor :DR. MUSTHAFAH BIN MOHD TAHIR

Date : ……………………………..

WASTED HEAT RECOVERY SYSTEM: HOW TO GAIN ENERGY

ABDUL MUHAIMIN BIN MOHD SHAFIE

This report is submitted in partial

fulfillment of the requirements for the award of a

Bachelor of Mechanical Engineering (Automotive)

Faculty of Mechanical Engineeing

Universiti Teknikal Malaysia Melaka

JUNE 2013

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DECLARATION

“I hereby declare that the work in this report is my own except for the summaries

and quotations which have been duly acknowledge.”

Signature :…………………..

Author :ABDUL MUHAIMIN B. MOHD SHAFIE

Date :..………………….

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Special for

Father and mother

Family

Lecture and friends

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ACKNOWLEDGEMENT

I would like to express my deepest appreciation to all of those who

provided me the possibility to complete this final year project report. A special

gratitude I give to my final year project super visor, Dr. Musthafah bin Mohd

Tahir, whose contribution in stimulating suggestion and encouragement, helped

me to coordinate my project especially in my writing this report.

Furthermore, I would like to acknowledge with much appreciation to my

institution, staff, and my faculty members who helped me a lot during my project

progress. I also extend my heartfelt thanks to my family and well-wishers.

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ABSTRACT

Waste heat is one of the sources that can produce energy. Furthermore,

waste energy produces no emission to the environment. In this study, a waste heat

recovery system is build up and an experiment is conducted to the system. An

Organic Rankine cycle is selected among the other Rankine cycle due to its

characteristics. This report also discussing about the component that is used in the

waste heat recovery system and their specification. Furthermore, an experiment

has been done in order to find the highest power gained and what is the different

in temperature when the power at peak. The working fluid used in the waste heat

recovery system is refrigerant R-134a as it is the most suitable to apply in the

system. The heat is gained from the engine before it is cooled at the radiator. In

order to transfer the heat from one working to other working fluid, heat exchanger

is used. The graphs of power and different in temperature versus time are used to

analyze the result. The maximum power gained from the experiment is 37.84 Watt.

That value stated means that the power that should be transfer from the radiator

coolant to the heat recovery system.

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ABSTRAK

Haba buangan adalah salah satu sumber tenaga yang dapat menghasilkan

tenaga.Selain itu, haba buangan juga tidak menghasilkan produk yang

mencemarkan alam sekitar. Kajian ini, sistem pemulihan haba buangan akan

dibina dan akan dilakukan eksperimen ke atasnya. Sistem kitaran Organik

Rankine telah dipilih dari kitaran Rankine yang lain diatas faktor-faktor yang

tertentu. Laporan ini juga membincangkan tentang komponen yang digunakan

didalam sistem pemulihan haba buangan dan juga spesifikasinya.Tambahan pula,

satu eksperimen telah dijalankan untuk mencari nilai kuasa yang tertinggi

diperolehi dan aoa perbezaan di antara suhu apabila berada pada puncak. Bendalir

kerja yang digunakan di dalam sistem pemulihan haba adalah penyejuk R-134a

kerana ia paling sesuai untuk sistem tersebut. Haba yang diperolehi dari enjin

sebelum ia disejukkan oleh radiator. Untuk memindahkan haba dari satu cacair

kerja kepada cecair kerja lain, plat penukar haba digunakan.Graf kuasa dan

perbezaan suhu berlawanan masa digunakan untuk dianalisis.Keputusan

menunjukkan kuasa maksimum yang diperolehi dari eksperimen adalah 37.84

Watt.Nilai yang dinyatakan bermaksud kuasa yang sepatutnya dipindahkan dari

cecair penyejuk kedalam sistem pemulihan haba.

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TABLE OF CONTENT

CHAPTER TITLE PAGES

DECLARATION ii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENT vii

LIST OF TABLE x

LIST OF FIGURE xi

LIST OF SYMBOLS xiii

LIST OF APPENDIX xiv

CHAPTER 1 INTRODUCTION 1

1.1 Overview 1

1.2 Problem Statement 2

1.3 Objective 3

1.4 Scope 3

1.5 Thesis Overview 4

CHAPTER 2 LITERATURE REVIEW 6

2.1 Theory of An Organic Rankine Cycle 6

2.1.1 Rankine Cycle System 6

2.1.2 Organic Rankine Cycle 9

2.2 Theoretical Equation For Organic Rankine Cycle 10

2.3 Waste Heat 13

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CHAPTER 3 METHODOLOGY 15

3.1 Overview. 15

3.2 Project Requirement 15

3.3 Project Flow Chart 16

3.4 Heat Recovery System 17

3.4.1 Schematic Diagram For Heat Recovery System 17

3.4.2 Components Justification System 18

a) Engine 18

b) Pump 19

c) Air Motor 21

d) Heat Exchanger 22

e) NIST Reference Fluid Thermodynamic and

Transport Properties (REFPROP) 23

f) Working Fluid 25

g) Sensors and Wiring 29

h) WINDAQ Software 31

i) Reservoir tank 33

j) Hose 35

3.4.3 System Installation 36

3.4.4 Procedure To Retrieve The Data 38

CHAPTER 4 RESULTS AND DISCUSSION 40

4.1 One Minutes After The Engine Started 42

4.2 5 Minutes After Engine Started 43

4.3 5 Minutes After The Engine Started With Fan Off 44

4.4 10 Minutes After The Engine Started With Fan Off 45

4.5 20 Minutes After The Engine Started 46

4.6 Important Findings 47

CHAPTER 5 CONCLUSION AND RECOMMENDATION 48

5.1 Conclusion 48

5.2 Recommendation 49

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REFERENCE 50

APPENDIX A 52

APPENDIX B 53

APPENDIX C 54

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LIST OF TABLE

NO TITLE PAGES

2.1 Table 2.1 : Wasted heat streams classified by temperature

(Neeharika, 2012). 7

3.1 Table 3.1 : Critical pressure and boiling point of working fluid. 25

4.1 Table 4.1 : Comparison between the graphs 47

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LIST OF FIGURE

NO TITLE PAGES

2.1 Figure 2.1 : Simple ideal Rankine cycle(power cycle, n.d). 9

2.2 Figure 2.2 : Schematic diagram for Rankine cycle (Geothermal

power, n.d). 10

2.3 Figure 2.3 : Pressure versus Enthalpy of a closed Rankine cycle

(Power cycle, n.d). 11

3.1 Figure 3.1 : Project flow chart 16

3.2 Figure 3.2 : Schematic diagram for heat recovery system 17

3.3 Figure 3.3: Engine used for this experiment 18

3.4 Figure 3.4:Illustration of the heat in the cooling system (Fauzan, n.d). 19

3.5 Figure 3.5: Pump used 20

3.6 Figure 3.6: Pump specification 21

3.7 Figure 3.7 : Air motor 22

3.8 Figure 3.8 : Heat exchanger (Brazed plate heat exchanger) 23

3.9 Figure 3.9 : Heat exchanger used in the experiment 23

3.10 Figure 3.10 : Initial display of REFPROP 24

3.11 Figure 3.11 : REFPROP used to find Enthalpy 25

3.12 Figure 3.12: Graph of pressure versus enthalpy for R-134a 28

3.13 Figure 3.13 : Graph of temperature versus Entropy for R-134a 28

3.14 Figure 3.14 : Sensors attach to the piping 29

3.15 Figure 3.15 : Wiring for Data logger 31

3.16 Figure 3.16 : Selecting the channel 32

3.17 Figure 3.17 : Calibration box 32

3.18 Figure 3.18 : Appearance of WINDAQ 33

3.19 Figure 3.19 : Changing the sample rate. 33

3.20 Figure 3.20: Reservoir tank used 34

3.21 Figure 3.21 : Installation of refrigerant 35

3.22 Figure 3.22 : Hose used 36

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3.23 Figure 3.23 : Installation of the system. 38

4.1 Figure 4.1 : Heat recovery system 40

4.2 Figure 4.2 : Leaking at the reservoir tank 41

4.3 Figure 4.3 : Graph after 1 minute 42

4.4 Figure 4.4 : Graph after 5 minutes 43

4.5 Figure 4.5 : Graph after 5 minutes engine started with fan off 44

4.6 Figure 4.6 : 10 minutes after engine started with fan off 45

4.7 Figure 4.7 : Graph after 20 minutes engine started with fan operate 46

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LIST OF SYMBOLS

°C Degree Celsius

W Watt (Power)

°F Degree Fahrenheit

qin heat in

qout heat out

wturb, out Work Turbine out

wpump, in Work pump in

h enthalpy

KJ/Kg Kilojoule per kilogram

MPa Mega Pascal

Psi Per square inch

�� Flow rate

��_�� Thermal efficiency

rpm Revolution per minute

kg/m3 Density

K Kelvin

W Work

xiv

LIST OF APPENDIX

NO TITLE PAGES

A Gantt chart 52

B Drawing 53

C Piping 54

CHAPTER 1

INTRODUCTION

1.1 OVERVIEW

Recently, the development of a country used a lot of energy consumption.

Industrial development, increasing in number of the vehicles in the road, and

domestic equipments used a large scale of energy to operate. There are many sources

that can convert into electric energy such as, fuel, hydro, wind, and others. Over the

time, crude oil and petroleum product will become limited, costly to find and

produce. At the same time, the demand for these sources is high. Moreover,

environmental problems also need to be considering in the development. Green

house effect and pollution are an example of the environmental problem recently.

An alternative ways to gain energy is required in order not only to reduce the

energy consumption but also to reduce the environmental problem. A low-grade heat

source is one of the sources that can be considered as a new energy sources. The

study of an interest for a low grade heat recovery has grown dramatically in recently

years. Usually, low-grade heat is a by-product of a system and these heats usually

wasted through a cooler which act to cool down the system. There are many sources

of low-grade heat that can be recovering such as biological waste heat, engine

exhaust gases, domestic boilers, solar thermal, power plant, and heat from vehicle’s

engine.

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Low-grade heat can produce an electric which can be used for another system.

In a cement power plant that is currently located in Switzerland, they use wasted heat

from the suspension preheated gas and clinker cooler waste air and convert them into

a clean electrical energy (Borrnet, 2011). These processes not only make the

efficiency of the power plant increase, but also reduce the production of the CO2

emission. Twenty percent of the consumption of the cement power plant also can be

save using low-grade wasted heat sources(Borrnet, 2011). Recovering wasted heat

can reduce the dependence on the crude oil, produce no additional risky emission

such as carbon and reduce the operating cost.

1.2 PROBLEM STATEMENT

Since a few years ago, development of a world’s economy leads to produce a

by-product commonly carbon dioxide which a sources of the green house effect.

Moreover, the usage of raw fuel seems to be increase over the time. People cannot

depend only on a raw fuel that will decrease slowly. They need to find new sources

that may reduce the usage of a raw fuel. Waste heat is one of the sources that can

produce energy without adding the carbon emission to the environment. Plus, waste

heat is one of the ways to reduce the dependence on the foreign oil.

Internal combustion engine (ICE) operates by converting chemical energy

which is fuel into kinetic energy. This process occurs when the engine operate

passing a spark into a compressed cylinder that contain a mixture of fuel and oxygen

gas. During the combustion process, cylinder temperature often reaches quite high

value. Overheating of the head cylinder may cause to overheated spark plug

electrodes causing pre-ignition that leads to power lost of the engine. Temperature

reach often affect the performance of the engine, and to reduce the engine’s

temperature to a desire temperature, radiator is used to remove the heat from the

engine into a surrounding. The fuel efficiency of the ICE is around 25 to 35%

(Ganesan, 2007). This means that only 25 to 35% of the fuel is used to drive the

vehicle. Another 65 to 75% is lost in term of heat, dissipated through exhaust, and

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friction. 30 to 35% of the total heat supplied by the fuel is removed through cooling

medium which is radiator by carried away the lubricating oil and heat to the

radiator(Ganesan, 2007).

Waste heat from the radiator can be used as new sources of energy by

converting the heat energy into an electrical energy. This can be done by building a

heat recovery system for a vehicle that can be used in the future. The usage of the

clean sources leads to produce a health environment.

1.3 OBJECTIVE

Main objective in this project is to build up a waste heat recovery system and

obtain energy form the wasted heat in this system. This study also will prove that the

theory that wasted heat can be recovered by heat recovery system. Moreover, the

ancillary objective in this study is to analyse the different of heat in the radiator that

will produce a high energy for the recovery system.

1.4 SCOPE

Heat from the vehicle’s radiator (60°C- 80°C in this study) is use as a waste

heat for the waste heat recovery system. In this study, the experimental equipment is

build up and the equipment is setup from the beginning by repairing the engine. Air

motor will use as the turbine in this experiment to shows that he energy is recover.

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1.5 THESIS OVERVIEW

These reports consist of 5 main chapters which are:

CHAPTER 1 - INTRODUCTION

Introducing the readers to the general background of the case study, the

objective of the project, scope of the project, and the problem statement that leads to

this study.

CHAPTER 2 - LITERITURE REVIEW

In this chapter, it consists of a study about this project about their theory. This

study are referred from the books, journals, thesis and internet.

CHAPTER 3 - METHODOLOGY

This chapter mainly about the progress of the project. This is shown using a

flow chart. In this chapter also including the process of collecting the data and

information from the previous study, collecting of data, drawing the system, process

and analyse the data to obtain the final result.

CHAPTER 4 - DISCUSSION

In this chapter, it consist of the discussion from the result obtain in the

previous chapter. It also has the result, graph and dimension of the system.

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CHAPTER 5 - CONCLUSION

This chapter will show the conclusion about the study and the recommendation for the future improvements.

CHAPTER 6 - REFERENCE

All of the reference used in this report will be located in this chapter. This chapter will include the references from the book, journals, internet, and others

CHAPTER 2

LITERATURE REVIEW

2.1 THEORY OF AN ORGANIC RANKINE CYCLE

In this chapter, Organic Rankine cycle (ORC), Wasted heat recovery system,

the component involved in the ORC will be introduced. All of the information stated

in this chapter is through a study that has been done for this project.

2.1.1 RANKINE CYCLE SYSTEM

There are three types of Rankine power cycle, which is Stream Rankine Cycle

(SRC), Organic Rankine cycle (ORC), and Kalina cycle (KC). Table 2.1 shows the

waste heat stream that is classified by temperature. In this table, the cycle that needs

to use as a reference for a system can be determine. For the Internal Combustion

Engine, the radiators usually produce the heat at range 60 to 80°C. This type of ICE

will use temperature that is classified as low temperature.

For a low temperature classification, there are two type of waste heat to

power the technologies, which is Organic Rankine Cycle and Kalina cycle. For this

study, Organic Rankine cycle is used to refer to the actual cycle. Kalina is not

suitable for this project because Kalina use a mixture of water and ammonias the

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working fluid (Neeharika, 2012). Although Kalina cycle is more efficient energy

extraction from the heat source and have an efficiency 15 to 25 percent more

efficient thanORC, Kalina is dangerous if the system installed in the vehicle when an

accident occurs.

Table 2.1 : Wasted heat streams classified by temperature (Neeharika, 2012).

Temperature

Classification

Waste Heat Source Characteristics Commercial Waste

Heat to Power

Technologies

High

(>927 °C)

• Furnaces

- steel electric arc

-steel heating

-basic oxygen

- glass melting

• Coke ovens

• Fume incinerators

• Hydrogen plants

• High quality heat

• High heat transfer

• High power-generation

efficiencies

• Chemical and

mechanical

contaminants

• Wasted heat

boilers and steam

turbines

Medium

(227-927 °C)

• Prime mover exhaust

streams

- gas turbine

- reciprocating

engine

• Heat-treating furnace

• Ovens

- Cement kilns

• Medium power-

generation efficiencies

• Chemical and

mechanical

contaminants (some

streams such as cement

kilns)

• Waste heat boilers

and stream turbine

(> 227°C)

• Organic Rankine

cycle (< 527°C)

• Kalian cycle (<

727°C)

Low

(<227 °C)

• Boilers

• Ethylene furnace

• Steam condensate

• Cooling water

- furnace doors

- annealing furnace

- air compressors

- IC engines

• Energy contained in

numerous small source

• Low power-generation

efficiencies

• Recovery of combustion

streams limited due to

acid concentration if

temperature reduce

• Organic Rankine

cycle (> 27°C

gaseous streams, >

-98°C liquid

streams)

• Kalian cycle (> -

73 °C)

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• Low-temperature

ovens

below -23 °C

Many of impracticalities associated with the carnot cycle can be eliminated

bysuperheating the steam in the boiler and condensing it completely in the condenser,

as shown in Figure 2.1, a schematically on a T-s diagram (Cengal and Boles, 2011,

p.551).Rankine cycle is the result of this case, which is the ideal cycle for the vapor

power plants. Heat is converted into a work or energy by Rankine cycle (RC). The

working fluid in the Rankine cycle is usually water or steam. The heat is supplied

into a Rankine cycle which is in close loop in order to operate. 90% of the electric

power generated in this world are comes from Rankine cycle(Wiser Wendell

H.,2000). Commonly, biomass, coal, solar thermal, and nuclear power plants used

Rankine cycle to regenerate the heat lost. For an ideal Rankine cycle, internal

irreversibility does not involve and consists of the following process:-

1 – 2 Isentropic compression in pump

2 – 3 Constant pressure heat addition in boiler

3 – 4 Isentropic expansion in turbine

4 – 1 Constant pressure heat rejection in a condenser