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
ii
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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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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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
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