Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Modeling and control of Rankine based waste heat recovery systems for heavy duty trucks Vincent GRELET 1 , 2 , 3 , Thomas REICHE 1 , Madiha NADRI 2 , Pascal DUFOUR 2 and Vincent LEMORT 3 1 Volvo Group Trucks Technology Advanced Technology and Research, 1 avenue Henri Germain, 69800 Saint Priest, France 2 Universit´ e de Lyon, Lyon F-69003, Universit´ e Lyon 1, CNRS UMR 5007, Laboratory of Process Control and Chemical Engineering (LAGEP), Villeurbanne 69100, France 3 LABOTHAP, University of Liege, Campus du Sart Tilman Bat. B49 B4000 Liege, Belgium International Symposium on Advanced Control of Chemical Processes 7-10 June, Whistler, British Columbia, Canada 1/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Table of contents Context and motivations 1 Waste heat recovery Rankine cycle based 2 Studied system 3 Control oriented modeling 4 Model assumptions and governing equations Heat transfer Working fluid properties Discretization Controller development 5 Implementation constraint Model identification State of the art PID controller Nonlinear model inversion Controllers structure Simulation results 6 Conclusion and next steps 7 Contacts and discussion 8 2/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Context and motivations In nowadays heavy duty engines, a major part of the chemical energy contained in the fuel is released to the ambient through heat. 3/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Context and motivations In nowadays heavy duty engines, a major part of the chemical energy contained in the fuel is released to the ambient through heat. Waste heat recovery based on the Rankine cycle is a promising technique to increase fuel efficiency. 3/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Context and motivations In nowadays heavy duty engines, a major part of the chemical energy contained in the fuel is released to the ambient through heat. Waste heat recovery based on the Rankine cycle is a promising technique to increase fuel efficiency. Long and frequent transient behavior of the heat sources makes good control strategies mandatory. 3/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Waste heat recovery Rankine cycle based Rankine cycle is widely known and used for power generation. It is based on four basic transformations: 4/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Waste heat recovery Rankine cycle based Rankine cycle is widely known and used for power generation. It is based on four basic transformations: The liquid is compressed from condensing to evaporating pressure (1 → 2). 4/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Waste heat recovery Rankine cycle based Rankine cycle is widely known and used for power generation. It is based on four basic transformations: The liquid is compressed from condensing to evaporating pressure (1 → 2). It is then pre-heat, vaporize and superheat (2 → 3). 4/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Waste heat recovery Rankine cycle based Rankine cycle is widely known and used for power generation. It is based on four basic transformations: The liquid is compressed from condensing to evaporating pressure (1 → 2). It is then pre-heat, vaporize and superheat (2 → 3). It expands from evaporating to condensing pressure (3 → 4). 4/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Waste heat recovery Rankine cycle based Rankine cycle is widely known and used for power generation. It is based on four basic transformations: The liquid is compressed from condensing to evaporating pressure (1 → 2). It is then pre-heat, vaporize and superheat (2 → 3). It expands from evaporating to condensing pressure (3 → 4). It condenses and goes back to liquid state (4 → 1). 4/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Control oriented modeling Controller development Simulation results Conclusion and next steps Contacts and discussion Studied system 5/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Model assumptions and governing equations Control oriented modeling Heat transfer Controller development Working fluid properties Simulation results Discretization Conclusion and next steps Contacts and discussion Model assumptions and governing equations Model assumptions Governing equation Geometry is reduced to a single pipe Internal fluid in pipe HEX. ∂ρ f h f + ∂ ˙ m f h f A cross , f + ˙ q f , int = 0 . (1) ∂ t ∂ z Secondary (or transfer) fluid always Internal pipe wall in single phase. ∂ m w , int c pw , int T w , int Conduction is neglected. q f , int + ˙ ˙ q g , int = . (2) ∂ t Pressure drops are neglected. External fluid Pressure dynamic is neglected. ∂ ˙ m g c pg T g ∂ ˙ m g c pg T g + + ˙ q g , int + ˙ q g , ext = 0 . ∂ z ∂ t Fluid properties are evaluated at the (3) outlet of each node. External pipe wall Mass flow rates are supposed ∂ m w , ext c pw , ext T w , ext q g , ext + ˙ ˙ q amb , ext = . (4) constant along the HEX. ∂ t 6/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Model assumptions and governing equations Control oriented modeling Heat transfer Controller development Working fluid properties Simulation results Discretization Conclusion and next steps Contacts and discussion Heat transfer Heat transfer coefficients n g = α ref , g ˙ m (5) α g g n f , liq = α ref , f , liq ˙ m (6) α f , liq f = α f , 2 ϕ α f , liq . . . � 0 . 37 � − 2 . 2 � (1 − q ) + 1 . 2 q 0 . 4 ρ f , sat , liq (1 − q ) 0 . 01 + . . . . . . ρ f , sat , vap 0 . 67 �� − 2 � − 0 . 5 � α f , vap � 1 + 8 (1 − q ) 0 . 7 ρ f , sat , liq . . . q 0 . 01 (7) α f , liq ρ f , sat , vap n f , vap = α ref , f , vap ˙ (8) m α f , vap f 7/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Model assumptions and governing equations Control oriented modeling Heat transfer Controller development Working fluid properties Simulation results Discretization Conclusion and next steps Contacts and discussion Heat transfer Heat transfer EGR boiler Heat transfer exhaust boiler 8/21 Grelet et al., ADCHEM 2015 paper 098
Context and motivations Waste heat recovery Rankine cycle based Studied system Model assumptions and governing equations Control oriented modeling Heat transfer Controller development Working fluid properties Simulation results Discretization Conclusion and next steps Contacts and discussion Working fluid properties Working fluid properties models Temperature: a T , liq h 2 f + b T , liq h f + c T , liq if h f ≤ h sat , liq T f = T sat , liq + q ( T sat , vap − T sat , liq ) if h sat , liq ≥ h f ≤ h sat , vap (9) a T , vap h 2 f + b T , vap h f + c T , vap if h f ≥ h sat , vap Density a ρ, liq h 2 f + b ρ, liq h f + c ρ, liq if h f ≤ h sat , liq 1 if h sat , liq ≥ h f ≤ h sat , vap ρ f = (10) a ρ, 2 ϕ h f + b ρ, 2 ϕ a ρ, vap h 2 f + b ρ, vap h f + c ρ, vap if h f ≥ h sat , vap 9/21 Grelet et al., ADCHEM 2015 paper 098
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