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

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
Shekh N. Hossain ◽  
S. Bari
Keyword(s):  
Power Generation ◽  
Heat Exchanger ◽  
Diesel Engine ◽  
Heat Exchangers ◽  
Parallel Flow ◽  
Working Fluid ◽  
Exhaust Gas ◽  
Working Pressure ◽  
Tube Heat Exchanger ◽  
Shell And Tube

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.

scholarly journals Study on Shell-and-Tube Heat Exchanger Models with Different Degree of Complexity for Process Simulation and Control Design

2018 ◽  
Author(s):  
Javier Bonilla
Keyword(s):  
Heat Exchanger ◽  
Molten Salt ◽  
Heat Exchangers ◽  
Control Strategies ◽  
Thermal Storage ◽  
Working Fluid ◽  
Tube Heat Exchanger ◽  
Test Loop ◽  
Shell And Tube ◽  
Thermal Oil

Many commercial solar thermal power plants rely on indirect thermal storage systems in order to provide a stable and reliable power supply, where the working fluid is commonly thermal oil and the storage fluid is molten salt. The thermal oil - molten salt heat exchanger control strategies, to charge and discharge the thermal storage system, strongly affect the performance of the whole plant. Shell-and-tube heat exchangers are the most common type of heat exchangers used in these facilities. With the aim of developing advanced control strategies accurate and fast dynamic models of shell-and-tube heat exchangers are essential. For this reason, several shell-and-tube heat exchanger models with different degrees of complexity have been studied, analyzed and validated against experimental data from the CIEMAT-PSA molten salt test loop for thermal energy systems facility. Simulation results are compared in steady-state as well as transient predictions in order to determine the required complexity of the model to yield accurate results.

scholarly journals Experimental Investigation and Comparison of Shell Tube and Plate Heat Exchanger used in Water Chillers

2021 ◽  
Vol 23 (1) ◽  
Author(s):  
Shamkuwar S.C ◽  
◽  
Nitin Chopra ◽  
Mihir Kulkarni ◽  
Nikhil Ahire ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Experimental Investigation ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Plate Heat Exchanger ◽  
Working Fluid ◽  
Plate Heat ◽  
Tube Heat Exchanger ◽  
Overall Heat Transfer Coefficient ◽  
Shell And Tube

The main objective of the paper is to compare the performance of Shell and tube heat exchanger (STHE) and Plate heat exchanger (PHE) used in chillers. The paper deals with experimental investigation and comparison, which is based on actual testing of STHE and PHE. Both heat exchangers were designed and tested for a heat load of 6000 kcal/hr. In both types of heat exchangers, the primary working fluid used is Refrigerant R22 and secondary working fluid used is water. Theoretical analysis shows that PHE has a 9.67 % less heat transfer area than STHE. Experimental results show that overall heat transfer coefficient (OHTC) for PHE is higher than STHE by 30.96%. The paper also includes a comparison of the heat transfer rate (Q) of the two heat exchangers experimentally.

Effect of Heat Exchanger Orientations to Recover Heat From the Exhaust of a Diesel Generator Using Rankine Cycle (RC)

2015 ◽  
Author(s):  
S. Bari ◽  
Shekh N. Hossain
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Rankine Cycle ◽  
Working Fluid ◽  
Diesel Generator ◽  
Working Pressure ◽  
Exhaust Heat ◽  
Parallel Arrangement ◽  
Shell And Tube ◽  
Geometric Variables

The heat from the exhaust gas of diesel engines can be an important heat source to provide additional power and improve overall engine efficiency. Studies related to the applications of recoverable heat to produce additional power using separate Rankine cycle are scare. To recover heat from the exhaust of an engine, an efficient heat exchanger is necessary. For this type of application, the heat exchangers are needed to be designed in such a way that it can handle the heat load with reasonable size, weight and pressure drop. In this project, experiments were conducted to measure the exhaust heat available from a 40 kW diesel generator at different loads. Shell and tube heat exchangers were purchased and installed into the engine. The performance of the heat exchangers using water as the working fluid was then conducted. With the available data, computer simulation was carried out using CFD software CFX to improve the design of the heat exchangers. Geometric variables including length, number and diameter of tubes, and baffle design were all tested separately. Upon investigating how these parameters influenced the heat exchangers’ effectiveness, optimum design of shell and tube heat exchangers was proposed. The proposed heat exchangers were manufactured and experiment was conducted. Two heat exchangers were used to generate superheated steam. These two heat exchangers were arranged in two orientations namely, series and parallel. The proposed heat exchanger was able to produce 2.71 kW additional power using water as the working fluid at an optimum working pressure of 15 bar using parallel arrangement. It was found that parallel arrangement generated 10% more additional power than the series arrangement.

Waste Heat Recovery From the Exhaust of a Diesel Generator Using Shell and Tube Heat Exchanger

2013 ◽  
Author(s):  
Shekh N. Hossain ◽  
Saiful Bari
Keyword(s):  
Computer Simulation ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Heat Recovery ◽  
Rankine Cycle ◽  
Working Fluid ◽  
Diesel Generator ◽  
Tube Heat Exchanger ◽  
Hfc 134A ◽  
Shell And Tube

The heat from exhaust gas of diesel engines can be an important heat source to provide additional power and improve overall engine efficiency. Bottoming Rankine Cycle (RC) is one of the promising techniques to recover heat from the exhaust. One derivative of RC known as Organic Rankine Cycle (ORC) is also suitable for heat recovery for moderate and small size engines as the exhaust heat content and temperature of these engines are low. To recover heat from the exhaust of the engine, an efficient heat exchanger is necessary. In this current research, a shell and tube heat exchanger is optimized by computer simulation for two working fluids, water and HFC-134a. Two shell and tube heat exchangers were purchased and installed into a 40 kW diesel generator. The performance of the heat exchangers using water as the working fluid was then conducted. With the available data, computer simulation was carried out using CFD software ANSYS CFX14.0 to improve the design of the heat exchanger for both fluids. Geometric variables including length, number of tubes, and baffle design are all tested separately. Using the optimized heat exchangers simulation was conducted to estimate the possible additional power generation considering 80% isentropic turbine efficiency. The proposed heat exchanger was able to produce 11% and 9.4 % additional power using water and HFC-134a as the working fluid at maximum working pressure of 15 and 40 bar respectively. This additional power results into 12% and 11% improvement in brake-specific fuel consumption (bsfc) by using water and HFC-134a respectively. This indicates that besides water, organic fluids can also be a suitable option to recover heat from the exhaust of diesel engine.

scholarly journals Comparison of Heat Transfer rates for Water and Ethylene Glycol mixtures for Diesel engine exhaust gas heat recovery using Shell and Tube Heat Exchanger.

2021 ◽  
Author(s):  
Ashok S Hadli ◽  
◽  
S. A. Alur ◽  
D.D. Chillal ◽  
N. R Banapurmath ◽  
...  
Keyword(s):  
Heat Exchanger ◽  
Diesel Engine ◽  
Ethylene Glycol ◽  
Heat Recovery ◽  
Exhaust Gas ◽  
Shell Side ◽  
Exhaust Gases ◽  
Tube Heat Exchanger ◽  
Recovery Capacity ◽  
Shell And Tube

Most of the researchers have claimed that high compression engines (diesel engines) are performing slightly above of 1/3rd of their potential and remaining heat energy is wasted in the form of exhaust gas. Efforts are going on to improve the design of these engines and investigations are being carried out to recover this waste energy from exhaust gases and utilize for different applications.In the present work, initially water is used as a heat exchange medium for three different loads on diesel engine viz., 50%, 60% and 70%, which extracts heat energy to evaluate the exhaust heat attainable from exhaust gases of the engine. The exhaust gas is passed through the tube side of the heat exchanger which is obtained from an exhaust manifold of a four stroke single cylinder diesel engine. Water is passed through the shell side of the shell and tube heat exchanger. Later this work is repeated for two different cooling medium i.e. water-ethylene glycol mixtures with 25% and 50%. The results are compared for 60% engine load conditions. The counter flow type heat exchanger arrangement is considered for the analysis. The temperatures were recorded for hot gases and cold medium at inlet and outlet points of the shell side and tube side flow. Heat calculations are carried out for each combination and detailed in the result–discussion and conclusion chapter. The objective of this work is to assess the exhaust gas heat recovery capacity using the ethylene glycol-water mixture and come out with a mixture for higher heat recovery capacity. This work is undertaken with segmental baffle heat exchanger of zero degree inclination. Also the work is repeated for inclined baffle heat exchangers of 10-degree and 20-degree baffle inclination to assess the effectiveness of liquid in recovering the heat from exhaust gases. It is observed that the water and Ethylene glycol mixtures have performed satisfactorily in all three baffle setups showing only 1.5% - 2.0% less heat recovery when compared with only water.

scholarly journals Theoretical and Experimental Analysis of Waste Heat Recovery Effectiveness of a Diesel Engine

2019 ◽  
pp. 1-17
Author(s):  
A. Adeyanju Anthony ◽  
K. Manohar
Keyword(s):  
Heat Exchanger ◽  
Diesel Engine ◽  
Flow Rate ◽  
Waste Heat ◽  
Volumetric Flow Rate ◽  
Rankine Cycle ◽  
Exhaust Gas ◽  
Tube Heat Exchanger ◽  
Shell And Tube ◽  
Volumetric Flowrate

The study utilized the exhaust gas from a diesel engine to preheat water in the constructed shell and tube heat exchanger. The theoretical analysis of the heat exchanger was carried out using the Log Mean Temperature Difference (LMTD) method. The Volumetric flowrate of the water was manipulated using a valve and the resulting output temperature of water leaving the heat exchanger was recorded. Experimentation was carried out to determine the effects of volumetric flow rate on the output temperature and the effectiveness of the heat exchanger. After the test and data analysis, it was discovered that that at flow rate of 3.0 Liter per minute (LPM) the effectiveness of the heat exchanger was peak at 43.34%. The volumetric flow rate of water is inversely proportional to the output temperature of water and it was also established that the effectiveness of the heat exchanger depends on output temperature of and the mass flow rate of the water. Also it was proven that by preheating water before it enters the boiler of the Rankine cycle the efficiency of the cycle increases.

scholarly journals Thermal Analysis of the Effects of Multifaceted Conditions on Performance of Shell-and-Tube Heat Exchanger

2021 ◽  
Vol 6 (1) ◽  
pp. 69-75
Author(s):  
Taiwo O. Oni ◽  
Ayotunde A. Ojo ◽  
Daniel C. Uguru-Okorie ◽  
David O. Akindele
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Parallel Flow ◽  
Hot Water ◽  
Inlet Temperature ◽  
Fiber Glass ◽  
Counter Flow ◽  
Tube Heat Exchanger ◽  
Shell And Tube ◽  
Flow Configurations

A shell-and-tube heat exchanger which was subjected to different flow configurations, viz. counter flow, and parallel flow, was investigated. Each of the flow configurations was operated under two different conditions of the shell, that is, an uninsulated shell and a shell insulated with fiber glass. The hot water inlet temperature of the tube was reduced gradually from 60 oC to 40 oC, and performance evaluation of the heat exchanger was carried out. It was found that for the uninsulated shell, the heat transfer effectiveness for hot water inlet temperature of 60, 55, 50, 45, and 40 oC are 0.243, 0.244, 0.240, 0.240, and 0.247, respectively, for the parallel flow arrangement. For the counter flow arrangement, the heat transfer effectiveness for the uninsulated shell are 2.40, 2.74, 5.00, 4.17, and 2.70%, respectively, higher than those for the parallel flow. The heat exchanger’s heat transfer effectiveness with fiber-glass-insulated shell for the parallel flow condition with tube hot water inlet temperatures of 60, 55, 50, 45, and 40 oC are 0.223, 0.226, 0.220, 0.225, and 0.227, respectively, whereas the counter flow condition has its heat transfer effectiveness increased by 1.28, 1.47, 1.82, 1.11, and 1.18%, respectively, over those of the parallel flow.

Economic Optimization of Shell and Tube Heat Exchanger Based on Constructal Theory

2010 ◽  
Author(s):  
Majid Amidpour ◽  
Abazar Vahdat Azad
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Constructal Theory ◽  
Economic Optimization ◽  
Total Cost ◽  
Tube Heat Exchanger ◽  
Capital Costs ◽  
Operational Energy ◽  
Shell And Tube

In this paper, the new approach of Constructal theory has been employed to design shell and tube heat exchangers. Constructal theory is a new method for optimal design in engineering applications. The purpose of this paper is optimization of shell and tube heat exchangers by reduction of total cost of the exchanger using the constructal theory. The total cost of the heat exchanger is the sum of operational costs and capital costs. The overall heat transfer coefficient of the shell and tube heat exchanger is increased by the use of constructal theory. Therefore, the capital cost required for making the heat transfer surface is reduced. Moreover, the operational energy costs involving pumping in order to overcome frictional pressure loss are minimized in this method. Genetic algorithm is used to optimize the objective function which is a mathematical model for the cost of the shell and tube heat exchanger and is based on constructal theory. The results of this research represent more than 50% reduction in costs of the heat exchanger.

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