• Energy Research

The topic of frost formation on the heat exchanger surface has been gaining interest since the late 1940s. Scientists and industrial engineers from many scientific and R&D units around the world have been trying to understand the nature of frosting and implement solutions to prevent such an unwanted phenomenon from having a significant impact on the performance of heat exchangers (such as a decrease in heat transfer efficiency, mechanical damage, and condensation risk). The aim of this article is to summarize the present state of knowledge dedicated to frost formation types and morphology, review, and discuss the most recent studies relevant to the challenge of frost formation, focusing on the evaporator of the domestic refrigerator. The different types of domestic refrigerators are summarized, as are the different types of evaporators inside them. Common methods of testing frost formation phenomena on the evaporator are revisited in this article, and the analysis of the most recent mathematical models is presented as well. The input and output parameters of these models are grouped, and a similar analysis is conducted for the CFD models.

Baking ovens are necessary to be installed in a paint shop of assembly automotive manufacturers for drying the paint of automotive bodies (i.e., in the coating process). In this process, a large amount of heat is provided by burning the natural gas in the gas burner. Practically, the design of the heat confinement in the oven is often poor, which results in considerable heat losses (i.e., waste heat) which are released during the drying process and significantly raise the temperature of a working environment thereby lowering the thermal comfort of the factory staff. To address this issue and limit the waste heat transfer to the surroundings, the application of a waste heat recovery system of a specific design employing the organic Rankine cycle (ORC) may be a viable alternative solution. A combined design of such a system utilizing an evaporator and thermal energy storage (TES) device in a simple ORC layout will be discussed in this article. The obtained simulation result was computed using MATLAB coupled with thermophysical properties libraries, i.e., CoolProp. The obtained results indicate that the sustainability of the studied system scheme appears to be favorably implemented in the selected paint shop and may benefit to lower the temperature of the working area, improve the thermal comfort of factory staff and at the same time produce electricity since some car/automotive manufacturers likely run the production for over 20 hours per day.

Small and micro energy sources are becoming increasingly important in the current environmental conditions. Especially, the production of electricity and heat in so-called cogeneration systems allows for significant primary energy savings thanks to their high generation efficiency (up to 90%). This article provides an overview of the currently used and developed technologies applied in small and micro cogeneration systems i.e., Stirling engines, gas and steam microturbines, various types of volumetric expanders (vane, lobe, screw, piston, Wankel, gerotor) and fuel cells. Their basic features, power ranges and examples of implemented installations based on these technologies are presented in this paper.

Small (10–100 kW) and micro (0.5–10 kW) Organic Rankine Cycle (ORC) power systems are nowadays considered for local and domestic power generation. Especially interesting are micropower applications for heat recovery from dispersed low potential (85–150 °C) waste and renewable heat sources. Designing and implementing an ORC system dedicated to energy recovery from such a source is difficult. A proper working fluid must be selected together with a suitable expander. Volumetric machines can be adopted as a turbine alternative in small-capacity applications under development, like, e.g., domestic cogeneration. Scroll and screw expanders are a common choice. However, scroll and screw expanders are complicated and expensive. Vane expanders are mechanically simple, commercially available and cheap. This paper documents a study providing the preliminary analysis of the possibility of employing vane-expanders in mini-ORC systems. The main objective of this research was therefore a comprehensive analysis of the use of a vane expander for continuous operation with a low-boiling working fluid. A test-stand was designed and set up starting from system models based on thermodynamic analysis. Then, a series of experiments was performed using the test-stand. Results of these experiments are presented here, together with a model of multivane expanders and a thermodynamic-based method to select the working fluid. The analysis presented in this paper indicates that multivane expanders are a cheap and mechanically simple alternative to other expansion devices proposed for small-capacity ORC systems.

This study proposes an innovative system for recovering waste heat from exhaust air after a regenerative thermal oxidiser process, integrating a Carnot battery and photovoltaic (PV) modules. The Carnot battery incorporates an organic Rankine cycle (ORC) with a recuperator, thermal energy storage (TES), and heat pump. Waste heat is initially captured in TES, with additional energy extracted by a heat pump to increase the temperature of a secondary fluid, effectively charging TES from both direct and indirect sources. The stored heat enables electricity generation via ORC. The result of this study shows a heat pump COP between 2.55 and 2.87, the efficiency of ORC ranging from 0.125 to 0.155, and the power-to-power of the Carnot battery between 0.36 and 0.40. Moreover, PV generates 1.35 GWh annually, primarily powering the heat pump and ORC system pump. The proposed system shows a total annual net generation of 4.30 GWh. Economic evaluation across four configurations demonstrates favourable outcomes, with a return on investment between 25% and 160%. The economic evaluation examined configurations with and without the PV system and recuperation process in the ORC. Results indicate that incorporating the PV system and recuperator significantly increases power output, offering a highly viable and sustainable energy solution.

The working fluid selection is one of the most important issues faced when designing Organic Rankine Cycle (ORC) systems. The choice of working fluid is dictated by different criteria. The most important of them are safety of use, impact on the environment, and physical and chemical parameters. The type of ORC system in which the working fluid is to be used and the type of expander applied in this system is also affecting the working fluid selection. Nowadays, volumetric expanders are increasingly used in ORC systems. In the case of volumetric expanders, in addition to the aforementioned working fluid selection criteria, additional parameters are considered during the selecting of the working fluid, such as the range of operating pressures and geometric dimensions (determining the volume of working chambers) affecting the achieved power and efficiency of the expander. This article presents a method of selecting a working medium for ORC systems using volumetric expanders. This method is based on the dimensionless rating parameters applied for the comparative analysis of different working fluids. Dimensionless parameters were defined for selected thermal properties of the working fluids, namely thermal capacity, mean temperature of evaporation, mean temperature of condensation, pressure and volumetric expansion ratio, volumetric expandability, as well as the heat of preheating, vaporization, superheating, cooling, and liquefaction. Moreover, isentropic expansion work was considered as the rating parameter. In this article, in addition to the working fluid selection method, computational examples related to the selection of the working fluid for the ORC system fed by a heat source featuring specified temperatures are presented. The results of calculations of rating parameters and their comparison gave an outlook on the selection of appropriate working fluids.

Abstract Emerging and promising ways of utilizing any heat sources from geothermal, solar, combustion, and industrial waste heat may be the application of power plants that are operating according to conventional Rankine cycle (RC), organic Rankine cycle (ORC), trilateral flash cycle (TFC) employing different types of expansion (i.e., volumetric expanders or turbine). In this paper, the studies about partially evaporated ORC (PE-ORC) was carried out; furthermore, it reports on novel results related to the comparison of thermodynamic efficiency of TFC, ORC and PE-ORC. These results were obtained by modelling the system operations computed with MATLAB and the thermal properties library taken from CoolProp and REFPROP. The calculation was based on selected different types of working fluid classified by A, C, Z, M, N points (conventionally categorized by dry, wet, and isentropic working fluids) and the upper-lower operating temperature. The obtained results explain a new point of view on the efficiency of TFC, ORC and PE-ORC plants, that in some of the conditions (i.e., one can find certain combinations of working fluid quality, maximal and minimal cycle temperature), the efficiency of PE-ORCs outperforms TFC and ORC. It means that at certain temperature ranges and conditions when starting the expansion step from a partially evaporated state, it may be recommended to improve the performance of the cycle. It seems that obtained results offer new insight to scientists and engineers in designing the thermal power plant working under a subcritical cycle with high-temperature heat sources or a low-temperature heat sinks employing the selection of working fluids and different types of expanders.

In order to lessen reliance on fossil fuels, a rise in interest in the utilization of fluctuating and intermittent heat sources derived from renewable energy (such as solar thermal, ocean thermal, and geothermal) and waste heat has been observed. These heat sources could be used to generate electricity at relatively low and medium temperatures, for example, through the organic Rankine cycle (ORC). In some case studies, various approaches have been developed to deal with and design ORCs in the desired operating condition utilizing suitable working fluids. This article aims to review some designs and integrated systems of ORC with thermal energy storage (TES) and a two-phase expansion system focusing on the utilization of medium- and low-temperature heat sources in which some subcritical ORCs are presented. Moreover, several possible control systems (both conventional and advanced ones) of ORC with TES and a two-phase expansion system are reported and compared. At the end of this article, the possible future developments of design and control systems are discussed to describe advanced ORC for utilizing low-grade heat sources. This study aims to provide researchers and engineers with an insight into the challenges involved in this process, making industrialization of ORC technology more extensive, in particular when combined with TES and a two-phase expansion system.

The effective waste heat recovery is one of the present-day challenges in the industry and power engineering. The energy systems dedicated for waste heat conversion into electricity are usually characterized by low efficiency and are complicated in the design. The possibility of waste heat recovery via thermoelectric materials may be an interesting alternative to the currently used technologies. In particular, due to their material characteristics, conducting polymers may be competitive when compared with the power machinery and equipment. These materials can be used in a wide range of the geometries e.g. the bulk products, thin films, pristine form or composites and the others. In this article, the authors present selected issues related to the mathematical and thermodynamic description of the heat transfer processes in the thermoelectric materials dedicated for the waste heat recovery. The link of these models with electrical properties of the material and a material solution based on a conducting polymer have also been presented in this paper.