• Energy Research
• Open Access close

Abstract In the present work a novel technology based on a dual injection vane expander has been introduced. The component works on a power unit fed by the exhaust gases of 3L turbocharged diesel engine. The new device was tested in a wide range of operating conditions and its numerical model was validated on the experimental data. The performances of the new machine were compared to those of the original one. The results showed that the dual injection expander provided an increase of the indicated and mechanical power up to 50% and 30%. Mass flow rate can be increased by 30% and this widens the performances of the power unit; this aspect is particularly suitable for a recovery unit fed by the widely changing exhaust gases flow rates in ICEs.

To date, Sliding Vane Pump (SVP) technology is one of the most attractive solution in different technical applications thanks to its reliability and compactness and capability to keep a high efficiency even when it is working far from rated condition. In particular, this feature makes the SVP suitable to be employed for the oil circulation (SVOP) in Internal Combustion Engine (ICE) which is characterized by a wide oil flow rates variation, delivered pressure and temperature variation which causes operating conditions of the pump far from the design point. Flow delivered changes in these machines are produced by varying the eccentricity for a mechanical connection with the engine - or by varying the speed of revolution. The mild hybridization of the powertrains calls for a strong development of electrically assisted engine auxiliaries which undoubtedly makes the flow variations easier to be done, but the presence of an electric motor requires some technological choices not fully assessed, a cost increase and a reliability decrease. The paper presents a mathematical model of a SVOP for oil circulation in ICE, suitably validated by a wide experimental activity. The model integrates a mono and zero-dimensional fluid-dynamic analysis and allows to represent the intimate behaviour of the machine. Moreover, it was employed as virtual platform to discuss pros and cons of different flow rate variation strategies and their effect on the efficiency of the SVOP.

Presently the on-the-road transportation sector is responsible of the 21% of the whole CO2 amount emitted into atmosphere. This pushes the International Governments and Organizations to provide strict limitations in terms of ICEs emissions, also introducing fees payment for the car manufacturers. The vehicle electrification allows certainly to meet these requirements, but the higher cost and the need of a green electricity still limit a widespread diffusion among all social classes. Thus, the technological improvement of internal combustion engine plays a key role in the transition period. Among these technologies, the engine thermal management allows to achieve a good compromise between the CO2 emission reduction and related costs. It was demonstrated that replacing the conventional centrifugal pump of engine cooling system with a sliding vane rotary pump (SVRP), important benefits in terms of CO2 emission reduction can be achieved as centrifugal pump efficiency decreases significantly when the engine works far from the maximum load (i.e. design point of the pump). Nevertheless, the complex thermo-fluid-dynamic phenomena taking place inside a SVRP make its design not immediate, particularly if heavy duty ICE cooling systems are considered. These applications indeed are challenging due to the wide operating range and the huge flow rates which pump must deliver. These operating requirements make difficult the choice of the main design parameters: among the different ones, the pump revolution speed and displaced volume. In the present paper a design strategy is developed for this type of pumps based on a comprehensive mathematical model of the processes occurring, predicting volumetric, indicated and mechanical efficiencies. The model was validated with a wide experimental activity so acting as virtual development platform. The results show how the best global efficiency (0.59) is achieved adopting a dual axial intake port configuration, with a suitable choice result of a trade-off between displaced volume and revolution speed. The analysis also show that the pump keeps its efficiency close to the design one for a wide operating range which is particularly suitable for the cooling of an ICE.

A promising solution for the Combined Heat and Power (CHP) micro production is certainly represented by Organic Rankine Cycle (ORC)-based power units. In the domestic appliances with electrical power range of the units below 1 kW, the reduced dimensions of the components represent a critical aspect as well as the need to guarantee a high reliability. When the hot source is represented by solar energy, the optimization of the electricity production keeping insured the thermal energy availability represents an aspect which invites to a proper management of the unit. Solar-based ORC-recovery units frequently work in off-design conditions due to the variability of the hot source and to the Domestic Hot Water (DHW) requirements. For this reason, the design and the selection of the components should be carefully performed. The expander is commonly retained the key component of the unit being the one that mainly affects the behaviour. For the mentioned power ranges, the volumetric expander is the best technological option and, among those available, Sliding Rotary Vane Expander (SVRE) are gaining a sensible interest. At off design conditions, according to permeability theory, the expander intake pressure linearly varies with mass flow rate of the Working Fluid (WF) which is the most suitable and easiest parameter to be changed. This modifies the performances of the unit, both from a thermodynamic and technological point of view. In this paper, the speed variation of the expander is considered as control parameter to restore design expander intake pressure. In order to assess a strategy for the speed variation of the expander, in this paper a comprehensive model of the SVRE is presented when it operates in a solar-driven ORC-based unit. The model is physically based and recovers and widens the permeability theory developed by the authors in previous works. An experimental ORC-based unit was fully instrumented and operated, coupled with a reservoir, usually present when flat plate solar collectors are used, which store the thermal energy which fulfils thermal energy requests and feeds the generating unit. The model was widely validated with the experimental data properly conceived for the purpose. In the unit the expander speed was varied and, thanks to the permeability theory, the relationships between WF flowrate variations, inlet expander pressure and expander speed variation were investigated. The potentiality of a control strategy of the expander revolution speed of the expander was fixed as well as a deeper understanding of the SVRE behaviour and relationships between operating variables. In particular, it was observed that varying the speed from 1000 RPM up to 2000 RPM, the expander behaviour was optimized ensuring proper working condition matching with a (30–100 g/s) flowrate range.

Abstract The current work presents a thermodynamic analysis of a Trilateral Flash Cycle (TFC) system for low grade heat to power conversion applications. Novel aspects of the research are the usage of rotary positive displacement expanders as prime movers of the TFC system as well as the reference to working fluids and their mixtures at the state of the art. In particular, the role of a correct built-in volume ratio of the expander with respect to the pressure ratio of the thermodynamic cycle is emphasized. In fact, a mismatching of these two quantities would lead to an isochoric expansion process which, in turn, might negatively affect the overall power recovery. With reference to a transcritical CO 2 stream at 100°C as heat source for the TFC system, parametric and screening studies were carried out using different expander built-in volume ratios and working fluids respectively. Among the fluids analyzed, results showed that pure substances such as R1234ze(E) and propane would provide a greater specific work but, on the other hand, would require built-in volume ratios (8 and 14) that are beyond the capabilities of rotary positive displacement expanders (5). The addition of CO 2 to the afore mentioned working fluids would ease the mismatching issue but, at the same time, would reduce the specific power output. Regarding the built-in volume ratio analysis, it was found that optimal values change in accordance to the working fluid and refer to an expansion process with a slight isochoric phase.

Sliding Rotary Vane Expanders (SVRE) are often employed in Organic Rankine Cycle (ORC)-based power units for Waste Heat Recovery (WHR) in Internal Combustion Engine (ICE) due to their operating flexibility, robustness, and low manufacturing cost. In spite of the interest toward these promising machines, in literature, there is a lack of knowledge referable to the design and the optimization of SVRE: these machines are often rearranged reversing the operational behavior when they operate as compressors, resulting in low efficiencies and difficulty to manage off-design conditions, which are typical in ORC-based power units for WHR in ICE. In this paper, the authors presented a new model of the machine, which, thanks to some specific simplifications, can be used recursively to optimize the design. The model was characterized by a good level of physical representation and also by an acceptable computational time. Despite its simplicity, the model integrated a good capability to reproduce volumetric and mechanical efficiencies. The validation of the model was done using a wide experimental campaign conducted on a 1.5 kW SVRE operated on an ORC-based power unit fed by the exhaust gases of a 3 L supercharged diesel engine. Once validated, a design optimization was run, allowing to find the best solution between two “extreme” designs: a “disk-shaped”—increasing the external diameter of the machine and reducing axial length—and by a “finger-shaped” machine. The predictions of this new model were finally compared with a more complex numerical model, showing good agreement and opening the way to its use as a model-based control tool.

ORC power units represent a promising technology for the recovery of waste heat in Internal Combustion Engines (ICEs), allowing to reduce emissions while keeping ICE performance close to expectations. However, the intrinsic transient nature of exhaust gases represents a challenge since it leads ORCs to often work in off-design conditions. It then becomes relevant to study their transient response to optimize performance and prevent main components from operating at inadequate conditions. To assess this aspect, an experimental dynamic analysis was carried out on an ORC-based power unit bottomed to a 3 L Diesel ICE. The adoption of a scroll expander and the control of the pump revolution speed allow a wide operability of the ORC. Indeed, the refrigerant mass flow rate can be adapted according to the exhaust gas thermal power availability in order to increase thermal power recovery from exhaust gases. The experimental data confirmed that when the expander speed is not regulated, it is possible to control the cycle maximum pressure by acting on the refrigerant flow rate. The experimental data have also been used to validate a model developed to extend the analysis beyond the experimental operating limits. It was seen that a 30% mass flow rate increase allowed to raise the plant power from 750 W to 830 W.