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Waste Heat Recovery Project

This project investigates the recovery of waste heat from diesel generators using a simple Rankine cycle to enhance energy efficiency and reduce emissions. The thermodynamic analysis indicates a potential improvement in system efficiency by up to 6%, with significant environmental and economic benefits. The findings suggest that implementing such systems can lead to substantial cost savings and a quick payback period.

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6 views9 pages

Waste Heat Recovery Project

This project investigates the recovery of waste heat from diesel generators using a simple Rankine cycle to enhance energy efficiency and reduce emissions. The thermodynamic analysis indicates a potential improvement in system efficiency by up to 6%, with significant environmental and economic benefits. The findings suggest that implementing such systems can lead to substantial cost savings and a quick payback period.

Uploaded by

abashosam18
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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MEP 216

THERMODYNAMICS
spring 2025
Major Task, assignment (project)
Industry-Based Seminar on
Thermodynamics Applications
Prepared by: Hosam Mohamed 20P7985 &
ahmed Mohamed abdou 20P5430

Submitted to: Dr. ahmed taher Alaa-eldin &


DR. walid aboelsoud abdelhady
• Role Statement
Ahmed: Responsible for thermodynamic analysis, methodology, and
drafting of results. Hosam: Responsible for literature review, system
design proposal, and environmental/economic analysis.

• Plagiarism Statement
"I certify that this report is original and has not been submitted for the
assessment of another course. I certify that I have not copied in part or
whole or otherwise plagiarized the work of other students or persons."
Signed: ___________________ (Ahmed)
Signed: ___________________ (Hosam)

• Abstract
This project explores the potential of recovering waste heat from
internal combustion engines (ICEs), specifically a diesel generator, for
electric power generation. A simple Rankine cycle is proposed as the
recovery system. Thermodynamic analysis is conducted to evaluate
available waste heat, estimate power output, and assess improvements
in system efficiency. The environmental and economic implications are
also discussed. The findings support the feasibility of using waste heat
recovery to enhance energy efficiency and reduce emissions in
industrial applications.
1. Introduction:
Internal combustion engines (ICEs) are widely used in power
generation, particularly in remote areas and industrial sites due to their
reliability and relatively low installation cost. However, these engines
are thermodynamically inefficient, with nearly 60–70% of the energy
from fuel being lost as waste heat through exhaust gases and cooling
systems.
Recovering this waste heat can significantly improve overall system
efficiency, reduce fuel consumption, and minimize environmental
impact. This project investigates the application of a waste heat
recovery (WHR) system to a diesel-powered generator, focusing on
converting exhaust heat into electricity using a simple Rankine cycle.

2. Literature Review:
Several studies have highlighted the benefits of utilizing waste heat
recovery systems in ICEs. The Rankine cycle, widely adopted in steam
power plants, has proven effective in converting low-grade heat into
mechanical or electrical energy. Research by X. Li et al. (2018)
demonstrated a 10–15% improvement in overall efficiency in diesel
generators integrated with WHR systems.
Technologies such as Organic Rankine Cycle (ORC) and
Thermoelectric Generators (TEG) have also been explored, though the
classic water-based Rankine cycle remains cost-effective and
mechanically simple for medium-to-high temperature exhaust
applications.
3. Methodology:
3.1 Selected System:
The system under study is a diesel generator with a nominal capacity of
500 kW. This engine typically loses around 30–35% of the fuel energy
through exhaust gases.

3.2 Waste Heat Recovery Design:


A simple Rankine cycle is selected for recovering waste heat from the
engine’s exhaust. The key components include:
• Exhaust Gas Heat Exchanger (Boiler): Captures thermal
energy from exhaust to convert water into steam.
• Steam Turbine: Converts steam pressure into mechanical
work.
• Condenser: Cools the steam and returns it to liquid form.
• Pump: Circulates water back to the boiler.
4. Thermodynamic Analysis

4.1 Assumptions:
• The diesel engine operates at steady state and delivers 500
kW of electrical power.
• Approximately 30% of the input fuel energy is lost as
exhaust heat.
• Working fluid: Water.
• Boiler (Heat Exchanger) pressure: 10 bar.
• Condenser pressure: 0.1 bar.
• No pressure loss in piping or heat exchanger.
• Turbine and pump efficiencies:
• Turbine isentropic efficiency: 80%.
• Pump isentropic efficiency: 85%.

4.2 Energy Balance:


1. Fuel Energy Input (Estimated):

To produce 500 kW electrical output with 35% efficiency (typical


diesel generator):
2. Waste Heat Available:
Assume 70% of this can be recovered in the heat exchanger:

4.3. Thermodynamic State Points Table:


State Description P(bar) T(°C) h(KJ/Kg) s(KJ/Kg.K)
1 Pump inlet 0.1 45 H1=191.81 S1=0.6492
(Saturated
Liquid)
2s Isentropic 10 - H2s=195.92 S2s=s1
pump outlet
2 Real pump 10 - H2=196.82
outlet -
(η=85%)

3 Boiler outlet 10 179.9 H3=2776.2 S3=6.5861


(Saturated
Vapor)
4s Isentropic 0.1 - H4s=2060.3 S4s=s3
turbine outlet

4 Real turbine 0.1 - H4=2182.8 -


outlet
(η=80%)
4.4. Net Work Output:
• Turbine work: Wt=h3-h4=2776.2-2182.8=593.3 KJ/Kg
• Pump work: Wp=h2-h1=196.82-191.81=5.01 KJ/Kg
• Net work: Wnet=Wt-Wp=588.39 KJ/Kg
4.5. Mass Flow Rate of Steam:

• Given heat input available = 300 kW:


M=Qboiler/h3-h2= 300/2776.2-196.82=0.1163
4.6. Net Power Generated by Recovery System:

• Wnet=m x Wnet= 0.1163 x 588.39=68.4Kw

5. Design and Optimization


• Heat Exchanger: Shell-and-tube with steel tubing, designed
for 400 kW capacity.

• Turbine: Single-stage, small-scale unit rated for 80 kW.


• Working Fluid: Water due to safety, cost, and compatibility.
• Optimization: Increase boiler pressure and ensure high
exhaust temperature. Avoiding condensation before turbine inlet
is key.
6. Environmental and Economic Impact
• Environmental: Reducing fuel consumption by 75 kW saves
~18 kg of CO2/hour (based on diesel emission factor ~0.24 kg
CO2/kWh).

• Economic: Savings = 75 kW x 8000 hr/year x $0.15/kWh =


$90,000/year
• Estimated cost of system = $120,000 → Payback period < 2
years

7. Case Study Example


A CHP system by Caterpillar Inc. using waste heat from diesel gensets
has been shown to achieve over 45% system efficiency. Our model’s
results are consistent with such implementations.

8. Conclusion and Recommendations


The proposed Rankine-based waste heat recovery system demonstrates
potential for improving ICE system efficiency by up to 6%.
Environmental benefits and economic viability make it suitable for
industrial adoption. Further improvement can be achieved by using
organic Rankine cycles (ORC) or integrating hybrid systems.
References
1. Razmara, M. et al. (2016). "Optimal exergy-based control of
internal combustion engines." Applied Energy, 183, 1389–1403.
2. Çengel, Y. A., & Boles, M. A. (2017). Thermodynamics: An
Engineering Approach (6th ed.).
3. Caterpillar Inc. Combined Heat and Power Applications.

Appendices
• Thermodynamic tables
• Sample calculations
• Efficiency graphs
(End of Document)

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