WASTED HEAT RECOVERY SYSTEM: HOW TO GAIN ENERGY ABDUL MUHAIMIN BIN MOHD SHAFIE UNIVERSITI TEKNIKAL MALAYSIA MELAKA

WASTED HEAT RECOVERY SYSTEM: HOW TO GAIN ENERGY ABDUL MUHAIMIN BIN MOHD SHAFIE UNIVERSITI TEKNIKAL MALAYSIA MELAKA

SUPERVISOR DECLARATION I hereby declare that I have read this thesis and in my opinion this report in sufficient in terms of scope and quality for the award of the degree of Bachelor of Mechanical Engineering (Automotive). Signature :.. Supervisor :DR. MUSTHAFAH BIN MOHD TAHIR Date :..

WASTED HEAT RECOVERY SYSTEM: HOW TO GAIN ENERGY ABDUL MUHAIMIN BIN MOHD SHAFIE This report is submitted in partial fulfillment of the requirements for the award of a Bachelor of Mechanical Engineering (Automotive) Faculty of Mechanical Engineeing Universiti Teknikal Malaysia Melaka JUNE 2013

ii DECLARATION I hereby declare that the work in this report is my own except for the summaries and quotations which have been duly acknowledge. Signature Author Date :.. :ABDUL MUHAIMIN B. MOHD SHAFIE :...

iii Special for Father and mother Family Lecture and friends

iv ACKNOWLEDGEMENT I would like to express my deepest appreciation to all of those who provided me the possibility to complete this final year project report. A special gratitude I give to my final year project super visor, Dr. Musthafah bin Mohd Tahir, whose contribution in stimulating suggestion and encouragement, helped me to coordinate my project especially in my writing this report. Furthermore, I would like to acknowledge with much appreciation to my institution, staff, and my faculty members who helped me a lot during my project progress. I also extend my heartfelt thanks to my family and well-wishers.

v ABSTRACT Waste heat is one of the sources that can produce energy. Furthermore, waste energy produces no emission to the environment. In this study, a waste heat recovery system is build up and an experiment is conducted to the system. An Organic Rankine cycle is selected among the other Rankine cycle due to its characteristics. This report also discussing about the component that is used in the waste heat recovery system and their specification. Furthermore, an experiment has been done in order to find the highest power gained and what is the different in temperature when the power at peak. The working fluid used in the waste heat recovery system is refrigerant R-134a as it is the most suitable to apply in the system. The heat is gained from the engine before it is cooled at the radiator. In order to transfer the heat from one working to other working fluid, heat exchanger is used. The graphs of power and different in temperature versus time are used to analyze the result. The maximum power gained from the experiment is 37.84 Watt. That value stated means that the power that should be transfer from the radiator coolant to the heat recovery system.

vi ABSTRAK Haba buangan adalah salah satu sumber tenaga yang dapat menghasilkan tenaga.selain itu, haba buangan juga tidak menghasilkan produk yang mencemarkan alam sekitar. Kajian ini, sistem pemulihan haba buangan akan dibina dan akan dilakukan eksperimen ke atasnya. Sistem kitaran Organik Rankine telah dipilih dari kitaran Rankine yang lain diatas faktor-faktor yang tertentu. Laporan ini juga membincangkan tentang komponen yang digunakan didalam sistem pemulihan haba buangan dan juga spesifikasinya.tambahan pula, satu eksperimen telah dijalankan untuk mencari nilai kuasa yang tertinggi diperolehi dan aoa perbezaan di antara suhu apabila berada pada puncak. Bendalir kerja yang digunakan di dalam sistem pemulihan haba adalah penyejuk R-134a kerana ia paling sesuai untuk sistem tersebut. Haba yang diperolehi dari enjin sebelum ia disejukkan oleh radiator. Untuk memindahkan haba dari satu cacair kerja kepada cecair kerja lain, plat penukar haba digunakan.graf kuasa dan perbezaan suhu berlawanan masa digunakan untuk dianalisis.keputusan menunjukkan kuasa maksimum yang diperolehi dari eksperimen adalah 37.84 Watt.Nilai yang dinyatakan bermaksud kuasa yang sepatutnya dipindahkan dari cecair penyejuk kedalam sistem pemulihan haba.

vii TABLE OF CONTENT CHAPTER TITLE PAGES DECLARATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENT LIST OF TABLE LIST OF FIGURE LIST OF SYMBOLS LIST OF APPENDIX ii iv v vi vii x xi xiii xiv CHAPTER 1 INTRODUCTION 1 1.1 Overview 1 1.2 Problem Statement 2 1.3 Objective 3 1.4 Scope 3 1.5 Thesis Overview 4 CHAPTER 2 LITERATURE REVIEW 6 2.1 Theory of An Organic Rankine Cycle 6 2.1.1 Rankine Cycle System 6 2.1.2 Organic Rankine Cycle 9 2.2 Theoretical Equation For Organic Rankine Cycle 10 2.3 Waste Heat 13

viii CHAPTER 3 METHODOLOGY 15 3.1 Overview. 15 3.2 Project Requirement 15 3.3 Project Flow Chart 16 3.4 Heat Recovery System 17 3.4.1 Schematic Diagram For Heat Recovery System 17 3.4.2 Components Justification System 18 a) Engine 18 b) Pump 19 c) Air Motor 21 d) Heat Exchanger 22 e) NIST Reference Fluid Thermodynamic and Transport Properties (REFPROP) 23 f) Working Fluid 25 g) Sensors and Wiring 29 h) WINDAQ Software 31 i) Reservoir tank 33 j) Hose 35 3.4.3 System Installation 36 3.4.4 Procedure To Retrieve The Data 38 CHAPTER 4 RESULTS AND DISCUSSION 40 4.1 One Minutes After The Engine Started 42 4.2 5 Minutes After Engine Started 43 4.3 5 Minutes After The Engine Started With Fan Off 44 4.4 10 Minutes After The Engine Started With Fan Off 45 4.5 20 Minutes After The Engine Started 46 4.6 Important Findings 47 CHAPTER 5 CONCLUSION AND RECOMMENDATION 48 5.1 Conclusion 48 5.2 Recommendation 49

ix REFERENCE 50 APPENDIX A 52 APPENDIX B 53 APPENDIX C 54

x LIST OF TABLE NO TITLE PAGES 2.1 Table 2.1 : Wasted heat streams classified by temperature (Neeharika, 2012). 7 3.1 Table 3.1 : Critical pressure and boiling point of working fluid. 25 4.1 Table 4.1 : Comparison between the graphs 47

xi LIST OF FIGURE NO TITLE PAGES 2.1 Figure 2.1 : Simple ideal Rankine cycle(power cycle, n.d). 9 2.2 Figure 2.2 : Schematic diagram for Rankine cycle (Geothermal power, n.d). 10 2.3 Figure 2.3 : Pressure versus Enthalpy of a closed Rankine cycle (Power cycle, n.d). 11 3.1 Figure 3.1 : Project flow chart 16 3.2 Figure 3.2 : Schematic diagram for heat recovery system 17 3.3 Figure 3.3: Engine used for this experiment 18 3.4 Figure 3.4:Illustration of the heat in the cooling system (Fauzan, n.d). 19 3.5 Figure 3.5: Pump used 20 3.6 Figure 3.6: Pump specification 21 3.7 Figure 3.7 : Air motor 22 3.8 Figure 3.8 : Heat exchanger (Brazed plate heat exchanger) 23 3.9 Figure 3.9 : Heat exchanger used in the experiment 23 3.10 Figure 3.10 : Initial display of REFPROP 24 3.11 Figure 3.11 : REFPROP used to find Enthalpy 25 3.12 Figure 3.12: Graph of pressure versus enthalpy for R-134a 28 3.13 Figure 3.13 : Graph of temperature versus Entropy for R-134a 28 3.14 Figure 3.14 : Sensors attach to the piping 29 3.15 Figure 3.15 : Wiring for Data logger 31 3.16 Figure 3.16 : Selecting the channel 32 3.17 Figure 3.17 : Calibration box 32 3.18 Figure 3.18 : Appearance of WINDAQ 33 3.19 Figure 3.19 : Changing the sample rate. 33 3.20 Figure 3.20: Reservoir tank used 34 3.21 Figure 3.21 : Installation of refrigerant 35 3.22 Figure 3.22 : Hose used 36

xii 3.23 Figure 3.23 : Installation of the system. 38 4.1 Figure 4.1 : Heat recovery system 40 4.2 Figure 4.2 : Leaking at the reservoir tank 41 4.3 Figure 4.3 : Graph after 1 minute 42 4.4 Figure 4.4 : Graph after 5 minutes 43 4.5 Figure 4.5 : Graph after 5 minutes engine started with fan off 44 4.6 Figure 4.6 : 10 minutes after engine started with fan off 45 4.7 Figure 4.7 : Graph after 20 minutes engine started with fan operate 46

xiii LIST OF SYMBOLS C Degree Celsius W Watt (Power) F Degree Fahrenheit q in q out w turb, out w pump, in h heat in heat out Work Turbine out Work pump in enthalpy KJ/Kg Kilojoule per kilogram MPa Psi _ rpm kg/m 3 K W Mega Pascal Per square inch Flow rate Thermal efficiency Revolution per minute Density Kelvin Work

xiv LIST OF APPENDIX NO TITLE PAGES A Gantt chart 52 B Drawing 53 C Piping 54

CHAPTER 1 INTRODUCTION 1.1 OVERVIEW Recently, the development of a country used a lot of energy consumption. Industrial development, increasing in number of the vehicles in the road, and domestic equipments used a large scale of energy to operate. There are many sources that can convert into electric energy such as, fuel, hydro, wind, and others. Over the time, crude oil and petroleum product will become limited, costly to find and produce. At the same time, the demand for these sources is high. Moreover, environmental problems also need to be considering in the development. Green house effect and pollution are an example of the environmental problem recently. An alternative ways to gain energy is required in order not only to reduce the energy consumption but also to reduce the environmental problem. A low-grade heat source is one of the sources that can be considered as a new energy sources. The study of an interest for a low grade heat recovery has grown dramatically in recently years. Usually, low-grade heat is a by-product of a system and these heats usually wasted through a cooler which act to cool down the system. There are many sources of low-grade heat that can be recovering such as biological waste heat, engine exhaust gases, domestic boilers, solar thermal, power plant, and heat from vehicle s engine.

2 Low-grade heat can produce an electric which can be used for another system. In a cement power plant that is currently located in Switzerland, they use wasted heat from the suspension preheated gas and clinker cooler waste air and convert them into a clean electrical energy (Borrnet, 2011). These processes not only make the efficiency of the power plant increase, but also reduce the production of the CO 2 emission. Twenty percent of the consumption of the cement power plant also can be save using low-grade wasted heat sources(borrnet, 2011). Recovering wasted heat can reduce the dependence on the crude oil, produce no additional risky emission such as carbon and reduce the operating cost. 1.2 PROBLEM STATEMENT Since a few years ago, development of a world s economy leads to produce a by-product commonly carbon dioxide which a sources of the green house effect. Moreover, the usage of raw fuel seems to be increase over the time. People cannot depend only on a raw fuel that will decrease slowly. They need to find new sources that may reduce the usage of a raw fuel. Waste heat is one of the sources that can produce energy without adding the carbon emission to the environment. Plus, waste heat is one of the ways to reduce the dependence on the foreign oil. Internal combustion engine (ICE) operates by converting chemical energy which is fuel into kinetic energy. This process occurs when the engine operate passing a spark into a compressed cylinder that contain a mixture of fuel and oxygen gas. During the combustion process, cylinder temperature often reaches quite high value. Overheating of the head cylinder may cause to overheated spark plug electrodes causing pre-ignition that leads to power lost of the engine. Temperature reach often affect the performance of the engine, and to reduce the engine s temperature to a desire temperature, radiator is used to remove the heat from the engine into a surrounding. The fuel efficiency of the ICE is around 25 to 35% (Ganesan, 2007). This means that only 25 to 35% of the fuel is used to drive the vehicle. Another 65 to 75% is lost in term of heat, dissipated through exhaust, and

3 friction. 30 to 35% of the total heat supplied by the fuel is removed through cooling medium which is radiator by carried away the lubricating oil and heat to the radiator(ganesan, 2007). Waste heat from the radiator can be used as new sources of energy by converting the heat energy into an electrical energy. This can be done by building a heat recovery system for a vehicle that can be used in the future. The usage of the clean sources leads to produce a health environment. 1.3 OBJECTIVE Main objective in this project is to build up a waste heat recovery system and obtain energy form the wasted heat in this system. This study also will prove that the theory that wasted heat can be recovered by heat recovery system. Moreover, the ancillary objective in this study is to analyse the different of heat in the radiator that will produce a high energy for the recovery system. 1.4 SCOPE Heat from the vehicle s radiator (60 C- 80 C in this study) is use as a waste heat for the waste heat recovery system. In this study, the experimental equipment is build up and the equipment is setup from the beginning by repairing the engine. Air motor will use as the turbine in this experiment to shows that he energy is recover.

4 1.5 THESIS OVERVIEW These reports consist of 5 main chapters which are: CHAPTER 1 - INTRODUCTION Introducing the readers to the general background of the case study, the objective of the project, scope of the project, and the problem statement that leads to this study. CHAPTER 2 - LITERITURE REVIEW In this chapter, it consists of a study about this project about their theory. This study are referred from the books, journals, thesis and internet. CHAPTER 3 - METHODOLOGY This chapter mainly about the progress of the project. This is shown using a flow chart. In this chapter also including the process of collecting the data and information from the previous study, collecting of data, drawing the system, process and analyse the data to obtain the final result. CHAPTER 4 - DISCUSSION In this chapter, it consist of the discussion from the result obtain in the previous chapter. It also has the result, graph and dimension of the system.

5 CHAPTER 5 - CONCLUSION This chapter will show the conclusion about the study and the recommendation for the future improvements. CHAPTER 6 - REFERENCE All of the reference used in this report will be located in this chapter. This chapter will include the references from the book, journals, internet, and others

CHAPTER 2 LITERATURE REVIEW 2.1 THEORY OF AN ORGANIC RANKINE CYCLE In this chapter, Organic Rankine cycle (ORC), Wasted heat recovery system, the component involved in the ORC will be introduced. All of the information stated in this chapter is through a study that has been done for this project. 2.1.1 RANKINE CYCLE SYSTEM There are three types of Rankine power cycle, which is Stream Rankine Cycle (SRC), Organic Rankine cycle (ORC), and Kalina cycle (KC). Table 2.1 shows the waste heat stream that is classified by temperature. In this table, the cycle that needs to use as a reference for a system can be determine. For the Internal Combustion Engine, the radiators usually produce the heat at range 60 to 80 C. This type of ICE will use temperature that is classified as low temperature. For a low temperature classification, there are two type of waste heat to power the technologies, which is Organic Rankine Cycle and Kalina cycle. For this study, Organic Rankine cycle is used to refer to the actual cycle. Kalina is not suitable for this project because Kalina use a mixture of water and ammonias the

7 working fluid (Neeharika, 2012). Although Kalina cycle is more efficient energy extraction from the heat source and have an efficiency 15 to 25 percent more efficient thanorc, Kalina is dangerous if the system installed in the vehicle when an accident occurs. Table 2.1 : Wasted heat streams classified by temperature (Neeharika, 2012). Temperature Classification Waste Heat Source Characteristics Commercial Waste Heat to Power Technologies High (>927 C) Furnaces - steel electric arc -steel heating High quality heat High heat transfer High power-generation Wasted heat boilers and steam turbines -basic oxygen - glass melting Coke ovens Fume incinerators Hydrogen plants efficiencies Chemical and mechanical contaminants Medium (227-927 C) Prime mover exhaust streams - gas turbine - reciprocating engine Heat-treating furnace Ovens - Cement kilns Medium powergeneration efficiencies Chemical and mechanical contaminants (some streams such as cement kilns) Waste heat boilers and stream turbine (> 227 C) Organic Rankine cycle (< 527 C) Kalian cycle (< 727 C) Low Boilers Energy contained in Organic Rankine (<227 C) Ethylene furnace numerous small source cycle (> 27 C Steam condensate Low power-generation gaseous streams, > Cooling water efficiencies -98 C liquid - furnace doors Recovery of combustion streams) - annealing furnace streams limited due to Kalian cycle (> - - air compressors acid concentration if 73 C) - IC engines temperature reduce

8 Low-temperature ovens below -23 C Many of impracticalities associated with the carnot cycle can be eliminated bysuperheating the steam in the boiler and condensing it completely in the condenser, as shown in Figure 2.1, a schematically on a T-s diagram (Cengal and Boles, 2011, p.551). Rankine cycle is the result of this case, which is the ideal cycle for the vapor power plants. Heat is converted into a work or energy by Rankine cycle (RC). The working fluid in the Rankine cycle is usually water or steam. The heat is supplied into a Rankine cycle which is in close loop in order to operate. 90% of the electric power generated in this world are comes from Rankine cycle(wiser Wendell H.,2000). Commonly, biomass, coal, solar thermal, and nuclear power plants used Rankine cycle to regenerate the heat lost. For an ideal Rankine cycle, internal irreversibility does not involve and consists of the following process:- 1 2 Isentropic compression in pump 2 3 Constant pressure heat addition in boiler 3 4 Isentropic expansion in turbine 4 1 Constant pressure heat rejection in a condenser