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In combination with a bottoming cycle, operated with a pure fluid in transcritical mode, the usage of a zeotropic mixture as a working fluid appears to be exergetically favorable for power cycle efficiency in cascaded two-stage organic Rankine cycles (CORC). A CORC is set up and initially tested with cyclopentane and propane as working fluids in its high temperature and low temperature cycle, respectively. A thermal oil cycle serves as the heat source and is powered electrically with a maximum heat flow of 158 kW. The design of this experimental setup allows for a rapid replacement of individual components and for a wide range of conditions in terms of fluids and thermodynamic states. The components of all cycles and the measurement and control technology are described in detail. A testing procedure is presented, followed by a discussion of the measurement results, where it is shown that the intended concept of two cascaded organic Rankine cycles is operational and that the measured data are consistent.
Thermodynamic simulation and experimental validation of a cascaded two-stage organic Rankine cycle
(2015)
The organic Rankine cycle (ORC) is an established thermodynamic process that converts waste heat to electric energy. Due to the wide range of organic working fluids available the fluid selection adds an additional degree of freedom to the early design phase of an ORC process. Despite thermodynamic aspects such as the temperature level of the heat source, other technical, economic and safety aspects have to be considered. For the fluid selection process in this paper, 22 criteria were identified in six main categories while distinguishing between elimination and tolerance criteria. For an ORC design, the suggested method follows a practical engineering approach and can be used as a structured way to limit the number of interesting working fluids before starting a detailed performance analysis of the most promising candidates. For the first time the selection process is applied to a two-stage reference cycle which uses the waste heat of a large reciprocating engine for cogeneration power plants. It consists of a high temperature and a low temperature cycle in which the condensation heat of the high temperature (HT) cycle provides the heat input of the low temperature (LT) cycle. After the fluid selection process the detailed thermodynamic cycle design is carried out with a thermodynamic design tool that also includes a database for organic working fluids. The investigated ORC cycle shows a net thermal efficiency of about 17,4% in the high temperature cycle with Toluene as the working fluid and 6,2% in low temperature cycle with iso-Butane as the working fluid. The electric efficiency of the cogeneration plant increases from 40,4% to 46,97% with the both stages of the two-stage ORC in operation.
Mit Hilfe eines Finite-Volumen-Verfahrens wird die dreidimensionale reibungsbehaftete Stroemung um einen schlagenden Fluegel berechnet. Die Bewegungsparamter sind dabei vergleichbar mit den Bedingungen im Reiseflug grosser Voegel. Das numerische Verfahren wird fuer den gezeigten Anwendungsfall, indem eine Methode zur Realisierung von beliebigen periodischen Bewegungen implemetiert wird. Eine Verifizierung erfolgt durch den Vergleich mit analytischen, numerischen und experimentellen Ergebnissen aus der Literatur. Mit dem verifizierten Verfahren werden die instationaeren Groessen wie Druck und Geschwindigkeiten in der Umgebung des bewegten Fluegels berechnet. Daraus ergeben sich ferner die zeitlich gemittelten Groessen wie Schub und Wirkungsgrad des Schlagfluges. Ausserdem wird die Interaktion von Laengs- und Querwirbeln im Nachlauf des schlagenden Fluegels untersucht. Es zeigt sich ein dominanter Einfluss der pulsierenden Randwirbel aufgrund der endlichen Spannweite, waehrend die Anfahr- und Stoppwirbel, verursacht durch die Fluegelbewegung, im Reiseflug grosser Voegel nahezu vernachlaessigbar erscheinen.
Undergraduate students in engineering often have little exposure to the world of scientific publishing and the culture of sharing research work. While the beneficial exchange between research and teaching is well promoted, while the benefits of conference participation for students have already been surveyed and while courses on scientific writing are readily available, the concept of mini-conferences as part of the curriculum combines all three aspects into one. Therefore, the course "Engineering Conferences" was developed and installed as a mandatory part of a master program for engineering students. The idea is to go beyond simply teaching the standards of academic writing and skills for using scientific publications. By using a learner-centered approach, the students are engaged in typical activities around an active attendance of a real conference. Based on their bachelor thesis, they write a paper complying with common academic standards, submit the paper and review submissions of their fellow students. They also produce a poster and defend their work in a poster session held publicly on campus. This contribution is based on the experience from the first four terms teaching the course. It explains the didactic rationale behind the concept and individual teaching modules, it comprises the collection of useful resources for teaching and organizing scientific publishing and it includes the consequences drawn from course evaluation results.
The ability to understand and predict the pressure losses of orifices is important in order to improve the air flow within the secondary air system. This experimental study investigates the behavior of the discharge coefficient for circular orifices with inlet cross flow which is a common flow case in gas turbines. Examples of this are at the inlet of a film cooling hole or the feeding of air to a blade through an orifice in a rotor disk. Measurements were conducted for a total number of 38 orifices, covering a wide range of length-to-diameter ratios, including short and long orifices with varying inlet geometries. Up to five different chamfer-to-diameter and radius-to-diameter ratios were tested per orifice length. Furthermore, the static pressure ratio across the orifice was varied between 1.05 and 1.6 for all examined orifices. The results of this comprehensive investigation demonstrate the beneficial influence of rounded inlet geometries and the ability to decrease pressure losses, which is especially true for higher cross flow ratios where the reduction of the pressure loss in comparison to sharp-edged holes can be as high as 54%. With some exceptions, the chamfered orifices show a similar behavior as the rounded ones but with generally lower discharge coefficients. Nevertheless, a chamfered inlet yields lower pressure losses than a sharp-edged inlet. The obtained experimental data were used to develop two correlations for the discharge coefficient as a function of geometrical as well as flow properties.
In energieeffizienten Gebäuden spielt der Bedarf an Energie für die Raumheizung gegenüber der benötigten Energie für Warmwasser und zum Antrieb elektrischer Geräte eine zusehends untergeordnete Rolle. Die thermische Energie für elektrische Haushaltsgeräte, wie Waschmaschine, Kühlschrank etc., wird für gewöhnlich dezentral im Gerät erzeugt. Vor diesem Hintergrund ist das Ziel eines Forschungsprojekts der Bau und der Test eines Funktionsmusters zur funktionalen und energetischen Kopplung der Haushaltsgeräte und der Heizungs- und Lüftungstechnik des Gebäudes. Grundgedanke dabei ist die Nutzung von Synergien bei Komponenten und Wärmeströmen, wie der Wärmepumpe als Kälteaggregat für den Kühlschrank, und die effiziente Nutzung von Abwärme der Haushaltsgeräte für die Warmwasserbereitung und Raumheizung.
The organic Rankine cycle (ORC) is an established thermodynamic process that converts waste heat to electric energy. Due to the wide range of organic working fluids available the fluid selection adds an additional degree-of-freedom to the early design phase of an ORC process. Despite thermodynamic aspects such as the temperature level of the heat source, other technical, economic, and safety aspects have to be considered. For the fluid selection process in this paper, 22 criteria were identified in six main categories while distinguishing between elimination (EC) and tolerance criteria (TC). For an ORC design, the suggested method follows a practical engineering approach and can be used as a structured way to limit the number of interesting working fluids before starting a detailed performance analysis of the most promising candidates. For the first time, the selection process is applied to a two-stage reference cycle, which uses the waste heat of a large reciprocating engine for cogeneration power plants. It consists of a high temperature (HT) and a low temperature (LT) cycle in which the condensation heat of the HT cycle provides the heat input of the LT cycle. After the fluid selection process, the detailed thermodynamic cycle design is carried out with a thermodynamic design tool that also includes a database for organic working fluids. The investigated ORC cycle shows a net thermal efficiency of about 17.4% in the HT cycle with toluene as the working fluid and 6.2% in LT cycle with isobutane as the working fluid. The electric efficiency of the cogeneration plant increases from 40.4% to 46.97% with the both stages of the two-stage ORC in operation.
Um bauliche Veränderungen in bestehenden Kraftwerksprozessen auf ihre Wirkungsweise untersuchen und thermodynamisch beziehungsweise wirtschaftlich bewerten zu können, werden thermische Kraftwerksprozesse mit geeigneter Simulationssoftware abgebildet und in verschiedenen Detaillierungsstufen ausgelegt oder nachgerechnet. Im Folgenden wird ein Weg aufgezeigt, wie mit Hilfe einer stationären Simulationssoftware die Gesamtjahresbilanz eines Kraftwerks vorausberechnet werden kann. Mit Hilfe von Prozessdaten aus Vorjahren wird nachgewiesen, dass das Berechnungsmodell das bestehende Kraftwerk mit einer Abweichung von weniger als drei Prozent bezüglich erzeugter elektrischer Leistung und Brennstoffeinsatz und bei bekannter Dampfproduktion abbilden kann. Das so verifizierte Modell kann zur Untersuchung von Zubaumaßnahmen oder Veränderungen im Kraftwerksprozess eingesetzt werden.
High heat losses via exhaust gas and coolant in internal combustion engines (ICE) are the basis for numerous investigations regarding downstream processes for power generation. The most promising concepts are Organic Rankine Cycles (ORC) and Steam Rankine Cycles (SRC). In previous work of the Center of Innovative Energy Systems, Düsseldorf (Germany), the technical and economic feasibility of a low pressure SRC has been investigated and the advantages in comparison to organic Rankine cycles are highlighted. A distinctive feature of the cycle is the use of the ICE coolant heat for evaporation, which limits the cycles maximum steam pressure to values below atmospheric pressure. This work presents first results of a test rig with data reconciliation according to DIN 2048 to validate the simulation results and design calculations. As a basis for the experimental investigations, a gas fired CHP plant was selected. The design of the test rig is optimized for the operation in the laboratory, where the coolant heat is emulated by a tempering device and the exhaust heat of the CHP plant is emulated by a gas burner. With the designed test rig, it is possible to control the volume flow and the temperatures of the coolant and exhaust gas, so that different load conditions of the gas fired CHP plant can be investigated. For initial tests, the turbine in the SRC is replaced by a throttle to achieve the pressure drop of the turbine. The experimental results show, that the exhaust and coolant heat of a 36 kWel CHP plant can be emulated and the performance expectations of the cycle can be met in stable steady-state conditions. Based on the measurement results and the turbine design calculations an electric power output of the cycle of 3.8 kW will be possible, which results in a cycle efficiency of about 6.5 % and an increase of the electrical power output of the CHP plant of about 10 %. The results show that the plant concept is technically feasible and, with further optimization, also represents an alternative to ORC plants in terms of increasing the efficiency of a cogeneration plant.
Striving for smaller losses in turbomachinery has led to many advancements in the design of seals. Modern sealing concepts such as brush seals hold a great potential to increase the efficiency of both flight engines and stationary turbines. At the same time, in order to maintain stable operating conditions of the rotor, swirl-induced forces must be kept at a minimum in the sealing channels. Therefore, the influence of the permeable and flexible bristle pack of brush seals on the flow around the rotor surface must be known. In this paper the swirl flow in the cavities of two different seal geometries is studied experimentally and numerically. A conventional three-tooth labyrinth serves as a reference. A second seal arrangement with a bristle pack upstream of two teeth is compared with the reference labyrinth. The swirl is evaluated experimentally from total and static pressure measurements in various axial and circumferential positions. Additionally, the axial swirl distribution is calculated using computational fluid dynamics (CFD). Here, the numerical model of the brush seal is based on the porous medium approach and is calibrated using the experimental values of the leakage and the bristle clearance by adjusting the thickness of the bristle pack. The calibrated CFD model is then used to study the impact of the brush seal on the swirl component of the sealing flow. The observed significant decrease of the swirl by the brush seal shows good agreement with the experimental data. The impact of changes in bristle pack clearance on the swirl is also investigated and compared with experimental evidence. The aim is to show that the brush seals have a natural tendency to interrupt seal swirl. They can therefore be used for swirl control in order to create a beneficial impact on the dynamic stability of turbomachines.