Recent developments of control strategies for organic Rankine cycle (ORC) systems

Organic Rankine cycle (ORC) is one of the most rapidly growing approaches to utilizing low grade thermal energy. This paper deals with the main control problems existed in ORC systems and overviews the main approaches presented in literature. The main ORC operating modes are introduced, the control strategies of ORC systems are then surveyed. Thus, this paper presents a comprehensive review of overall control strategies for ORC energy conversion systems and points out research trend on ORC control systems

Evaporator Modeling and an Optimal Control Strategy Development of an Organic Rankine Cycle Waste Heat Recovery System for a Heavy Duty Diesel Engine Application

The Organic Rankine Cycle (ORC) has proven to be a promising technology for Waste Heat Recovery (WHR) systems in heavy duty diesel engine applications. However, due to the highly transient heat source, controlling the working fluid flow through the ORC system and maximizing the heat recovery is a challenge for real time application. To that end, this research resulted in the following main developments. The first new development is in the area of heat exchanger modeling. The heat exchanger is a key component within the WHR system and it governs the dynamics of the complete ORC system. The heat exchanger model is extended using a thermal image data to improve its phase length prediction capability. It’s shown that the new identified empirical equations help improve the phase length estimation by 43% over a set of transient experiments. As a result, the model can be used to develop an improved control oriented moving boundary model and to provide insights into evaporator design. The second new development is the advancement of the control design of an ORC system. With advanced knowledge of the heat source dynamics, there is potential to enhance power optimization from the WHR system through predictive optimal control. The proposed approach in this this dissertation is a look-ahead control strategy where, the future vehicle speed is predicted utilizing road topography and V2V connectivity. The forecasted vehicle speed is utilized to predict the engine speed and torque, which facilitates estimation of the engine exhaust conditions used in the ORC control model. In the simulation study, a reference tracking controller is designed based on the Model Predictive Control (MPC) methodology. Two variants of Non-linear MPC (NMPC) are evaluated: an NMPC with look-ahead exhaust conditions and a baseline NMPC without the knowledge of future exhaust conditions. Simulation results show no particular improvement to working fluid superheat tracking at the evaporator outlet via the look-ahead strategy for a drive cycle. However, the look-ahead control strategy does provide a substantial reduction in system control effort via dampening the heavily transient working fluid pump actuation, enhancing pump longevity, health, and reducing pump power consumption. This reduction in pump actuation helps the NMPC with preview to maintain the superheat lower than the NMPC without this feature for certain frequency of the exhaust conditions. Overall, NMPC with preview feature can help reduce parasitic losses, like pump power and improve power generation. The third development addresses the modeling errors and measurement inaccuracies for NMPC implementation. NMPC is inherently a state feedback system and for that reason an Extended Kalman Filter (EKF) is used to estimate unmeasurable states inside the ORC evaporators based on exhaust gas and working fluid temperatures. Since it is not realistic to expect that the system model will perfectly describe the behavior of the evaporator dynamics in all operating conditions, the estimator is therefore augmented with a disturbance model for offset free MPC tracking. Simulation study shows that the augmented system is perfectly capable of discarding the model errors and rejecting the measurement inaccuracies. Moreover, experimental validation confirms that no steady state error is observed during online implementation of the augmented EKF. Finally, experimental validation of the designed NMPC control strategy was conducted. The performance of the NMPC was evaluated on a heavily transient drive cycle, as well as on a sinusoidal generated heat signals. Both experimental and simulated sinusoidal exhaust condition shows that evaporator under consideration inherently helps attenuate the fluctuating exhaust conditions due to its thermal inertia especially for heat signals of shorter time periods. However for slow changing exhaust conditions, a slower rate of change of working fluid flow helps in inhibiting temperature overshoot at the evaporator outlet

Experimental study of Predictive Control strategies for optimal operation of Organic Rankine Cycle systems

In this paper the performance of Model Predictive Control (MPC) and PID based strategies to optimally recover waste heat using Organic Rankine Cycle (ORC) technology is investigated. First the relationship between the evaporating temperature and the output power is experimentally evaluated, concluding that for some given heat source conditions there exists an optimal evaporating temperature which maximizes the energy production. Three different control strategies MPC and PID based are developed in order not only to maximize energy production but to ensure safety conditions in the machine. For the case of the MPC, the Extended Prediction Self-Adaptive Control (EPSAC) algorithm is considered in this study as it uses input/output models for prediction, avoiding the need of state estimators, making of it a suitable tool for industrial applications. The experimental results obtained on a 11kWe pilot plant show that the constrained EPSAC-MPC outperforms PID based strategies, as it allows to accurately regulate the evaporating temperature with a lower control effort while keeping the superheating in a safer operating range.The Next Generation Organic Rankine Cycle

Dynamic modeling and control strategies of organic Rankine cycle systems: Methods and challenges

Organic Rankine cycle systems are suitable technologies for utilization of low/medium-temperature heat sources, especially for small-scale systems. Waste heat from engines in the transportation sector, solar energy, and intermittent industrial waste heat are by nature transient heat sources, making it a challenging task to design and operate the organic Rankine cycle system safely and efficiently for these heat sources. Therefore, it is of crucial importance to investigate the dynamic behavior of the organic Rankine cycle system and develop suitable control strategies. This paper provides a comprehensive review of the previous studies in the area of dynamic modeling and control of the organic Rankine cycle system. The most common dynamic modeling approaches, typical issues during dynamic simulations, and different control strategies are discussed in detail. The most suitable dynamic modeling approaches of each component, solutions to common problems, and optimal control approaches are identified. Directions for future research are provided. The review indicates that the dynamics of the organic Rankine cycle system is mainly governed by the heat exchangers. Depending on the level of accuracy and computational effort, a moving boundary approach, a finite volume method or a two-volume simplification can be used for the modeling of the heat exchangers. From the control perspective, the model predictive controllers, especially improved model predictive controllers (e.g. the multiple model predictive control, switching model predictive control, and non-linear model predictive control approach), provide excellent control performance compared to conventional control strategies (e.g. proportional–integral controller, proportional–derivative controller, and proportional–integral–derivative controllers). We recommend that future research focuses on the integrated design and optimization, especially considering the design of the heat exchangers, the dynamic response of the system and its controllability

Integración de sistemas basados en ciclos ORC en viviendas

En este documento hablaremos sobre la tecnología de los ciclor ORC en el sector residencial en Sevilla. Para ello se ha realizado un estudio para seleccionar las condiciones del ciclo, los componentes y modos de operación para ayudarnos a conocer cual se adaptaría mejor a Sevilla y a este tipo de clima en general. Además analizaremos parámetros claves en el funcionamiento de este tipo de instalaciones como el grado de satisfacción de la demanda, el funcionamiento a carga parcial y almacenamiento disponible. Posteriormente extrapolaremos nuestras instalaciones a distintos lugares del mediterráneo y Sudamérica para realizar una comparación haciendo especial hincapié en el grado de satisfacción de la demanda y la rentabilidad de la implantación de un sistema ORC en los lugares estudiados.This document will discuss the ORC technology to residential sector in Sevilla. To this end, it has conducted a study to select cycle conditions, the components and operation modes to help us know which would best meet Seville and this kind of weather in general. In addition, we analyze key parameters in the operation of such facilities as the degree of satisfaction of demand, partial load operation and storage available. Then, we extrapolate our facilities to locations around the Mediterranean and South America to make a comparison with particular emphasis on the degree of satisfaction of the demand and profitability of the implementation of an ORC system in the areas studied.Universidad de Sevilla. Grado en Ingeniería de la Energí

Performance evaluation of organic Rankine cycle architectures : application to waste heat valorisation

In our society, there is an ever increasing need for electricity. However, today most of the electricity is generated by burning fossil fuels in a thermal power plant. A proposed alternative is to make use of low temperature heat from renewable sources (geothermal and solar) or waste heat (excess heat that is dumped into the atmosphere) in an organic Rankine cycle (ORC) to generate electricity. The purpose of the presented work is to support further adoption of ORC technology. To achieve this, two main challenges need to be resolved. First, sound criteria should be devised to compare and size ORCs and secondly the performance of the ORC should be increased further. From literature it is clear that novel ORC architectures have the opportunity to increase the performance of the basic subcritical ORC. However these studies are not cross comparable. As such, a new screening approach is created which rigorously compares and quantifies the potential of three different ORC architectures. Secondly, the sizing and the financial appraisal of the ORC is tackled by introducing a multi-objective optimization which combines financial and thermodynamic criteria in the optimization objectives. Finally, experimentally validated part-load models of the ORC were developed. These part-load models are crucial to predict the actual power output of time varying heat sources like waste heat streams. In addition, the models permit to investigate the concept of retrofitting existing subcritical ORCs to work under the more optimal working regime of partial evaporation