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Research Papers: Gas Turbines: Coal, Biomass, and Alternative Fuels

Additional Power Generation From Waste Energy of Diesel Engine Using Parallel Flow Shell and Tube Heat Exchanger

[+] Author and Article Information
Shekh N. Hossain

e-mail: shekh.rubaiyat@unisa.edu.au

S. Bari

Barbara Hardy Institute,
School of Engineering,
University of South Australia,
Mawson Lakes, SA 5095, Australia

1Corresponding author.

Contributed by the Coal, Biomass and Alternate Fuels Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received April 9, 2013; final manuscript received August 16, 2013; published online October 21, 2013. Assoc. Editor: Igor Pioro.

J. Eng. Gas Turbines Power 136(1), 011401 (Oct 21, 2013) (9 pages) Paper No: GTP-13-1099; doi: 10.1115/1.4025345 History: Received April 09, 2013; Revised August 16, 2013

High temperature diesel engine exhaust gas can be an important source of heat to operate a bottoming Rankine cycle to produce additional power. In this research, an experiment was performed to calculate the available energy in the exhaust gas of an automotive diesel engine. A shell and tube heat exchanger was used to extract heat from the exhaust gas, and the performance of two shell and tube heat exchangers was investigated with parallel flow arrangement using water as the working fluid. The heat exchangers were purchased from the market. As the design of these heat exchangers was not optimal, the effectiveness was found to be 0.52, which is much lower than the ideal one for this type of application. Therefore, with the available experimental data, the important geometric aspects of the heat exchanger, such as the number and diameter of the tubes and the length and diameter of the shell, were optimized using computational fluid dynamics (CFD) simulation. The optimized heat exchanger effectiveness was found to be 0.74. Using the optimized heat exchangers, simulation was conducted to estimate the possible additional power generation considering 70% isentropic turbine efficiency. The proposed optimized heat exchanger was able to generate 20.6% additional power, which resulted in improvement of overall efficiency from 30% to 39%. Upon investigation of the effect of the working pressure on additional power generation, it was found that higher additional power can be achieved at higher working pressure. For this particular application, 30 bar was found to be the optimum working pressure at rated load. The working pressure was also optimized at part load and found that 2 and 20 were the optimized working pressures for 25% and 83% load. As a result 1.8% and 13.3% additional power were developed, respectively. Thus, waste heat recovery technology has a great potential for saving energy, improving overall engine efficiency, and reducing toxic emission per kilowatt of power generation.

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Figures

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Fig. 1

Experimental setup

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Fig. 2

Heat exchanger (a) 50% baffle cut, (b) front view and (c) cross-sectional view

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Fig. 3

Mesh of computational domain (a) side view and (b) cross-sectional view

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Fig. 4

Exhaust gas temperature variation with engine power

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Fig. 5

Exergy variation with engine power

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Fig. 6

Effect of exhaust temperature on exergy

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Fig. 7

Heat exchanger effectiveness variation at different power

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Fig. 8

Overall efficiency of the engine

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Fig. 9

Simulation results validation with experimental results

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Fig. 10

Pressure drop across the heat exchanger at different engine loads

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Fig. 11

Additional power output variation with working pressure

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Fig. 12

Additional power and working pressure variation at different engine loads

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