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h
H
k
m
N
Ns
P
pi
po
Pr
Qin
Qout
Q
Re
SCO2
s
si
t
Tcold
Thot
VF
w
WR
Nomenclature
b
D
Dh
Ds
pump width, m
diameter, m
hydraulic diameter, m
characteristic diameter, m
carnot
effectiveness, %
heat transfer coefficient, W/m^2-K, specific
enthalpy, kJ/kg
head, m
thermal conductivity, W/mK
SCO2 flow rate, kg/sec
pump revolution, rpm
specific speed, dimensionless
power, kW
initial pressure, MPa
final pressure, MPa
Prandtl number, dimensionless
heat flux into the system, W/m2
heat flux leaving the system, W/m2
Energy, kW
Reynolds number, dimensionless
Supercritical Carbon Dioxide, kg
entropy, kJ/kgK
isentropic entropy, kJ/kgK
plate thickness, m
cold temperature, C
hot temperature, C
volumetric flow rate, m3
Plate width, m, specific work, kJ/kg
Work, kJ
Power, kW
cycle efficiency, %
Carnot efficiency, %
power coefficient, dimensionless
max
density, kg/m3
maximum stress, MPa
flow coefficient., dimensionless
head coefficient, dimensionless
1. Introduction
According the American Council on Renewable
Energy (ACORE) [2], there is an abundant source of
emission-free power in the U.S. which is currently
being overlooked. This source of power is known as
waste heat, a by-product of industrial manufacturing
processes which can potentially revitalize U.S.
manufacturing, stimulate economic growth, lower the
cost of energy, and reduce the carbon imprint due to
emissions used for electricity generation. If not
harnessed to generate emission-free, renewable
equivalent power, waste heat is released into the
atmosphere via stacks, vents, and other mechanical
equipment. Waste Heat to Power (WHP) captures
waste heat with a recovery unit, and converts the
waste heat into electricity through a heat exchange
process. WHP produces not emissions because no fuel
is burned. The American Council on Renewable Energy
(ACORE) estimates that there are approximately 575
MW of installed WHP capacity in the US alone, while
the EPA [3] estimates that there is approximately 10
GW of WHP capacity in the U.S., enough to power 10
million U.S. homes. From the Heat is Power (HiP)
Association [4], WHP is included in 15 state renewable
energy portfolio standards. By using WHP to generate
emission-free power, users can re-route the power
back to the local infrastructure grid or sell it to the host
grid in order to support clean energy production,
distribution and usage. The primary technologies
employed by WHP systems are Organic Rankine Cycle
(ORC), Supercritical Carbon Dioxide (SCO2), the Kalina
Cycle, the Stirling Engine, and other emerging
technologies such as thermo-electrics. In this current
paper, we demonstrate the use of SCO2 technology as a
viable resource for the generation of emission-free
electricity, which is clearly a renewable energy
breakthrough.
Supercritical Carbon Dioxide, SCO2 has been
considered a viable alternative working fluid for power
cycles since the 1960s because it provides several
advantages over steam and helium [5-9]. The density of
Compressor:
h2, s h1
h2 h1
W c m h2 h1
(1)
(2)
Expander:
h4 h5
h4 h4,s
W e m h4 h5
(3)
(4)
Waste Heat:
Q in m h4 h3
(5)
Condenser:
Q out m h6 h1
(6)
W e W c
m
(7)
W e W c
Q in
(8)
Cycle Efficiency:
h5 h6
h3 h2
(9)
3. Mathematical Modeling
carnot
1 Tcold
Thot
(10)
Figure 3. Plot generated from parametric analysis to determine cycle efficiency based on temperature
drop over heat exchanger.
T
(K)
P
(MPa)
(kg/m3)
h
(kJ/kg)
308
12.4
776.61
278.19
s
(kJ/kgK)
1.23
319
20
810.4
289.38
1.24
417
20
338.83
513.32
1.86
473
20
258.82
597.79
2.05
436
12.4
176.78
577.23
2.08
328
12.4
537.76
353.29
1.47
N VF
H 3/4
(11)
DH 1/4
Ds
VF
(12)
Ns
VF
ND3
H
y= 2 2
N D
P
x=
r N 3D5
h=
Figure 4. Conventional vs. Piecewise Method for heat
exchanger analysis.
fy
x
(13)
(14)
(15)
(16)
4. Component Selection
4.1. Pump
Supercritical Carbon Dioxide, SCO2 systems present
not only thermal design challenges but also gives rise
to special considerations for the pump. There have
been multiple attempts that address the optimization
of a pump for SCO2 applications [15, 29, 31, 32] that
indicate an efficiency of 85% to be reasonable and
conservative. Efficiency may often be increased
through later optimization, however, for the purpose of
this paper an 85% efficiency is assumed to determine
the work required to compress the SCO2 from 12 MPa
to 20 MPa. In order to determine an initial pump design
the concepts of the Cordier diagram are used
determine an optimal type of pump for the cycle. By
comparing non-dimensional parameters such as the
flow coefficient , head coefficient , and power
h( p i , s i ) h ( p o , s i )
(17)
4.2. Expander
The SCO2 in the expander undergoes near isentropic
expansion in order to create mechanical energy to turn
a permanent magnet alternator. The initial design was
a toroidal engine with opposing pistons however, this
architecture was found to be too difficult to fabricate.
Therefore the expander design was revised into a more
linear hexagonal variation. The latest iteration of the
expander design is shown in Figure 6. This type of
expander was chosen over a more conventional turbine
expander due to the low volumetric flow rates within
the cycle and results from calculating the specific speed
and specific diameter similar to the pump selection
methodology shown in Figure 5. The expander
alternates intake and exhaust cycles to create axial
piston movement. Each bank of three pistons is
attached to a mounting plate that converts axial motion
into rotational motion. A cam and a gear system is
implemented to output power to a permanent magnet
alternator. The design is still undergoing revision in
order to optimize the expander for SCO2.
References
[1]
(18)
[2]
max
0.3078wb 2
t2
[3]
[4]
[5]
(19)
[6]
5. Conclusions
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
[19]
[20]
[21]
[22]
[23]
[24]
[25]
[26]
[27]
[28]
[29]
[30]
[31]
[32]
[33]
[34]
10