Combined Supercritical CO2 Power and Transcritical Refrigeration Cycles by Waste Heat Recovery of Engine
Combined Supercritical CO2 Power and Transcritical Refrigeration Cycles by Waste Heat Recovery of Engine
a r t i c l e i n f o a b s t r a c t
Article history: The majority of the energy in the fuel burned in the internal combustion engines is lost in the form
Received 9 September 2019 of waste heat. To address this issue, waste heat recovery technology has been proposed to increase the
Revised 5 March 2020
overall efficiency of engine. This paper investigates a heat driven cooling system based on a supercritical
Accepted 29 April 2020
CO2 (S-CO2 ) power cycle integrated with a transcritical CO2 (T-CO2 ) refrigeration cycle, aiming to provide
Available online 16 May 2020
an alternative to the absorption cooling system. The combined system is proposed to produce cooling
Keywords: for food preservation on a refrigerated truck by waste heat recovery of engine. In this system, the S-
Refrigerated truck CO2 absorbs heat from the exhaust gas and the generated power in the expander is used to drive the
Supercritical CO2 power cycle compressors in both S-CO2 power cycle and T-CO2 refrigeration cycle. Unlike the bulky absorption cooling
Transcritical CO2 refrigeration cycle system, both power plant and vapour compression refrigerator can be scaled down to a few kilo Watts,
Waste heat recovery opening the possibility for developing small-scale waste heat driven cooling system that can be widely
applied for waste heat recovery from IC engines of truck, ship and train. A new layout sharing a common
cooler is also studied. The results suggest that the concept of S-CO2 /T-CO2 combined cycle sharing a
common cooler has comparable performance and it is thermodynamically feasible. The heat contained in
exhaust gas is sufficient for the S-CO2 /T-CO2 combined system to provide enough cooling for refrigerated
truck cabinet whose surface area is more than 105 m2 .
© 2020 The Author(s). Published by Elsevier Ltd.
This is an open access article under the CC BY license. (http://creativecommons.org/licenses/by/4.0/)
Mots clés: Camion frigorifique; Cycle énergétique au CO2 transcritique; Cycle frigorifique au CO2 transcritique; Récupération de chaleur résiduelle
1. Introduction aboard trucks, only less than 45% of the combustion energy can be
converted to shaft power output, the residential energy is mostly
Refrigerated truck is necessary for maintaining the quality and lost by means of the exhaust gas and jacket water (Dolz et al.
prolonging the shelf-life of fresh, frozen and perishable prod- 2012). Hence, there is a demand of developing concepts for uti-
ucts during transportation. With respect to a typical diesel engine lizing the waste heat to meet the cooling demand.
An ideal solution would be adopting a technology that can con-
vert heat into cooling directly. Thermally powered cooling tech-
∗
Corresponding author: Tel.: +44 (0) 141 330 2530. nologies have been investigated and some effort has been de-
E-mail address: [email protected] (Z. Yu).
https://doi.org/10.1016/j.ijrefrig.2020.04.031
0140-7007/© 2020 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license. (http://creativecommons.org/licenses/by/4.0/)
Y. Liang, Z. Sun and M. Dong et al. / International Journal of Refrigeration 118 (2020) 470–482 471
cycle (ORC) and vapour compression cycle (VCC) was proposed as Song et al. (2018) and Liang et al. (2019) proposed to integrate S-
an alternative refrigeration method by Prigmore and Barber (1975). CO2 with an ORC, which is used as a bottoming cycle for the fur-
Compared to the thermally powered absorption cooling technolo- ther recover the residual heat load.
gies, the ORC-VCC has some potential advantages in terms of per- The concept of CO2 vapor compression refrigeration system was
formance and simplicity. Furthermore, the VCC powered by an ORC first proposed by Alexander Catlin Twining in 1850, but CO2 was
can make use of the heat source throughout the year (Wang et al., first used actually in a vapor compression system to produce ice
2011a) to provide either cooling or electricity when cooling is not by Thaddeus Lowe in 1866 (Ma et al., 2013). However, due to poor
required (Wang et al., 2011b), increasing the operational flexibil- technology at that time, the CO2 refrigeration presents a low re-
ity and improving the economic profitability. Although the ORC- frigeration efficiency and its application was not popular. Interest
VCC is attractive providing cooling by waste heat recovery, there in CO2 -based refrigeration system was renewed in the early 1990s
are still some problems for its practical applications, including the due to the phase-out of ozone depleting refrigerants. In 1987, Mon-
decomposition issue of the organic working fluid in ORC and the treal Protocol and its amendments (Protocol, 1987) gave a deadline
difficulty in finding suitable environmentally friendly refrigerants to the use of chlorofluorocarbon (CFC) and hydrochlorofluorocar-
in VCC (Liang et al., 2018). bon (HCFC) refrigerants, which are being phased out. As a result,
With respect to most diesel engines, the maximum tempera- natural refrigerants, such as carbon dioxide, ammonia and hydro-
ture of the exhaust gas approximately ranges from 720 to 870 carbons, have been found to be attractive refrigerants in refrig-
K (Zheng et al., 2019), while the decomposition temperature of eration system. Amongst the natural refrigerants, carbon dioxide
most working fluids is below 600 K. By considering the decom- seems to be the most promising one, especially as the natural re-
position issue of organic working fluids, ORC application is limited frigerant for automotive air conditioning systems. Other factors like
in the field of engine WHR. Furthermore, the size and weight of safety requirements, extra tax on HFC systems and limitations on
the expander need to be considered for the economic factor. That the maximum amount of HFC charge that can be used on a sin-
is the reason why ORC has not been applied in automobile en- gle system also attribute to CO2 acceptability in commercial re-
gine WHR yet although it has been investigated and tested for a frigeration. For refrigeration purpose, subcritical CO2 or transcrit-
long time. The supercritical carbon dioxide Brayton cycle was pro- ical CO2 (T-CO2 ) refrigeration would be chosen based on the heat
posed by Fether (1968) and Angelino (1968) because carbon diox- sink temperature. One of the first T-CO2 systems was a prototype
ide is a nature refrigerant, which is environmentally friendly, low- automotive air conditioning system built and tested by Lorentzen
cost, non-toxic, non-flammable, non-corrosive and has good chem- and Pettersen (1993), and further reported by Pettersen (1994). The
ical stability. When comparing the operational principles of super- result indicated that transcritical CO2 based automotive air condi-
critical Brayton cycle (SBC) and ORC or steam Rankine technology, tioning has comparable performance with that of a R12 system,
the main difference is that in a SBC the working fluid remains at which encouraged further development of transcritical CO2 system.
supercritical condition through the whole cycle and the fluid is The technical feasibility of using transcritical CO2 refrigeration cy-
compressed with a compressor instead of a pump. The high fluid cle for engine waste heat recovery has been verified and guaran-
density of S-CO2 enables extremely compact turbomachinery de- teed as it has already been used in vehicle air conditioning devices
signs, which is significantly attractive for the practical applications (Kim et al., 2009; Tao et al., 2010).
of waste heat recovery aboard vehicles. As the heat exchangers From the literature review above, there is a possibility to in-
and turbines become more and more efficient, CO2 -based power tegrate a S-CO2 power cycle with a CO2 based refrigeration cy-
cycles, including both supercritical and transcritical cycle, attract cle, which will adopt the similar concept of ORC-VCC consist-
more and more attention in recent years since they are more suit- ing a power cycle and refrigeration cycle. However, due to its
able for high temperature WHR. high operation pressure, the design of expander and compressor
In Combs’s (1977) investigation, the performance of a supercrit- is the main concern for the practical application. Daikin indus-
ical CO2 engine was studied for propulsion power in a naval ship tries Ltd (Ohkawa et al., 2002) developed a swing type compres-
application using basic thermodynamics approach. It is reported sor with high efficiency and reliability for CO2 heat pump wa-
that the supercritical CO2 cycle can achieve higher power and effi- ter heaters. Reducing the ratio of cylinder height to cylinder di-
ciency with significant fuel saving. Recently, Sarkar (2015) and Ahn ameter was introduced to minimize the leakage loss during op-
et al. (2015) reviewed the literature related to the current research eration. To reduce the stress intensity and the leakage caused by
and development of supercritical CO2 cycles. It is recognized that the high operation pressure of CO2 , Dreiman et al. (2004) de-
nuclear, fossil fuel, waste heat and other high temperature heat signed two cylinder rotary hermetic compressors. The test results
source are the potential application areas of S-CO2 . A comprehen- showed that volumetric efficiency ranged between 0.4 and 0.8 and
sive comparison of different S-CO2 Brayton layouts was conducted the compressor efficiency was up to 0.6. In Chinen’s study (2014),
by Wang (2017), in which S-CO2 Brayton cycle is considered to be the COP of a CO2 rotary compressor was enhanced by optimizing
integrated with the molten salt solar power tower systems. A su- the design of the discharge pathway from the compression cham-
percritical carbon dioxide (SC-CO2 ) based regenerative recompres- ber, including the discharge-port diameter, and adjusting the flux
sion Brayton cycle (RRCBC) was proposed for shipboard applica- level of the motor. Stosic et al.(20 02, 20 06) proposed that for the
tions in terms of waste-heat-recovery-system (WHRS) by Sharma twin screw machines, a major problem is that the pressure dif-
(2017). Echogen Power Systems (EPS) company (Persichilli et al., ference between entry and exit creates very large radial and axial
2012; Persichilli et al., 2011) carried out preliminary tests of 250 forces on the rotors whose magnitude and direction is indepen-
kW CO2 heat engine by recovering exhaust gas waste heat, which dent of the direction of rotation. He developed a combined com-
indicates the possibility of recovering the waste heat of engine ex- pressor expander, in which rotor forces created by the compres-
haust gas. It is also reported that the Levelized Cost of Electric- sion and expansion processes can be partially balanced in order
ity (LCOE) is calculated at an average USD $0.025 per kWh for the to eliminate the axial forces and reduce the radial bearing forces.
CO2 -based heat engine. These studies proved the great potential of The development of different type compressors promoted the in-
S-CO2 in the field of waste heat recovery of engine. In the S-CO2 vestigation and development of the CO2 based thermodynamic
cycle, recuperator is typically used to further utilize the energy at cycle.
turbine outlet to increase cycle efficiency. However, the total heat In this paper, an integrated system of S-CO2 and T-CO2 is pro-
load of the hot S-CO2 cannot be recovered entirely by the recu- posed to provide refrigeration by waste heat recovery of refriger-
perator due to the limited heat exchanger effectiveness. Therefore, ated truck engine. In spite of numerous studies on individual S-
Y. Liang, Z. Sun and M. Dong et al. / International Journal of Refrigeration 118 (2020) 470–482 473
Fig. 1. Schematic diagram of the S-CO2 /T-CO2 combined cycle with two separate coolers.
2. System description
Table 2
Expressions for energy balance, exergy destruction and exergy efficiency of components.
Components Energy balance Exergy destruction Exergy efficiency [Sun et al., 2019]
Boiler Qboiler = m f 1 (h4 − h3 )Qboiler = mg (h15 − h16 ) Iboiler = E3 + E15 −E4 − E16 ηex,boiler = E4 −E3
E15 −E16
Table 3
Comparison of the present calculated results with the published literature for T-CO2 .
Parameter Reference (Baheta et al., 2015) Calculated Error Reference (Baheta et al., 2015) Calculated Error
P7 (Mpa) 4 - 4 -
P8 (Mpa) 10 - 10 -
T9 (˚C) 40 - 35 -
Ƞis,com-2 100% - 100% -
COP 3.24 3.2431 0.10% 3.82 3.91 2.36%
Fig. 3. Power output of the expander, power consumed by compressor-1 and the
net power output change with the expander inlet pressure in when the evaporation Fig. 4. Discharge temperature of the compressor in T-CO2 refrigeration cycle.
temperature in refrigeration cycle is -5 ˚C.
Fig. 5. Effect of the expander inlet pressure on the cooling capacity in T-CO2 refrig- Fig. 6. Effect of the expander inlet pressure on the cooling COP in T-CO2 refrigera-
eration cycle. tion cycle.
perature Teva =-5 ˚C and Teva =-10 ˚C, the cooling COP decreases difference between the hot and cold stream. In the cooler-1, the
with the expander inlet pressure. When the evaporation tempera- exergy of working fluid deceases by 4.95 kW, including 3.39 kW
ture decreases below -15 ˚C (included), there is an optimum COP exergy destruction and 1.56 kW exergy loss through ambient air.
value as the expander inlet pressure increases. The variation of the The pump consumes 6.25 kW to enhance the pressure, in which
net power output in Fig. 4 and the variation of cooling capacity in 5.69 kW transits to the working fluid and the other is destroyed
Fig. 6 determine the variation of COP shown in Fig. 6. in terms of exergy destruction. Therefore, the total exergy input of
Fig. 7 shows the exergy efficiency of all the components when 49.98 kW (43.73+6.25), equals to the sum of exergy destruction in
the pressure at the expander inlet is 130 0 0 kPa. It can be learned boiler (5.2 kW), exergy destruction in the expander (2.80 kW), ex-
that the expansion valve in T-CO2 presents the maximum value ergy destruction in the recuperator (14.09 kW), exergy destruction
among all the components, following by two compressors, ex- and exergy loss in cooler-1 (1.87 kW and 3.08 kW respectively) and
pander, and exergy efficiency of all heat exchangers is relatively the exergy destruction in compressor-1 (0.56 kW).In the refrigera-
low due to the temperature difference between the hot stream and tion cycle, the exergy input is provided by the power cycle and
cold stream. the amount is 22.38 kW. The total exergy destruction and loss in
To further assess the performance of the system, Grassmann di- the refrigeration cycle is 16.05 kW. In that case, the final transiting
agram was used to show the exergy flow in terms of exergy and cooling exergy is 6.33 kW.
exergy destruction (Hinderink et al.,1999). Fig. 8 is the Grassmann The variation of exergy efficiency with expander inlet pres-
diagram of the combined system when the expander inlet pres- sure for various evaporator temperatures is shown in Fig. 9. In
sure is 130 0 0 kPa in the power cycle. In the power cycle, it can be this system, the power produced in S-CO2 cycle is consumed by
seen that the exergy input of the exhaust gas through the boiler compressor-1 and compressor-2, rather than supplying mechani-
is 43.73 kW, including 38.53 kW to the CO2 stream and 5.2 kW cal power as output. According to Eq. (9), the output and input
exergy destruction during heat transfer. And then 22.38 kW me- exergy of the proposed system is cooling provided by evaporator
chanical power is generated in the expander and 2.8 kW exergy and the heat energy transferred in boiler respectively. For the same
destroyed during the expansion process. In the recuperator, exergy evaporation temperature, the variation trend of exergy efficiency
destruction can be up to 14.09 kW due to the large temperature in Fig. 9 is similar to that of the cooling capacity in Fig. 6. This is
Fig. 7. Exergy efficiency of components when the pressure at the expander inlet is 130 0 0 kPa.
Y. Liang, Z. Sun and M. Dong et al. / International Journal of Refrigeration 118 (2020) 470–482 477
Fig. 8. Grassmann diagram of the proposed combined cycle when the inlet pressure at the expander inlet is 130 0 0 kPa.
because the exergy output of cooling presents a similar variation Different from the previous layout, the stream exiting recuperator
with cooling capacity. However, the maximum exergy efficiency is (state 6) in S-CO2 and that exiting the compressor (8) in T-CO2 cy-
achieved by the conditions Teva =-25 ˚C for its higher cooling ex- cle both flow into the common cooler and are cooled down by the
ergy output. ambient air. In that case, the exiting temperature of S-CO2 is the
same as that of T-CO2 (as shown in Fig. 8) and the state point 1
and point 9 are coincident. The temperature-entropy diagram of
5.2. The S-CO2 /T-CO2 combined cycle sharing a common cooler
the proposed S-CO2 /T-CO2 combined cycle is shown in the Fig. 9.
The same concept was proposed and studied by Aphornratana
Since both sub-cycles are using carbon dioxide as the working
et al. (2010), Saleh et al. (2016) and Li et al. (2013). Different from
fluid, there is a possibility to share a common cooler to make the
our investigation, the working fluids considered in these reference
freezing system more compact and reduce the size and weight.
478 Y. Liang, Z. Sun and M. Dong et al. / International Journal of Refrigeration 118 (2020) 470–482
Fig. 10. Schematic diagram of the S-CO2 /T-CO2 combined cycle sharing a common cooler.
Y. Liang, Z. Sun and M. Dong et al. / International Journal of Refrigeration 118 (2020) 470–482 479
Fig. 14. Variation of thermal efficiency, expander power, pump work and the net
Fig. 12. Variation of evaporation temperature in T-CO2 and cooling capacity with power output of the S-CO2 power cycle.
the pressure in cooler.
Fig. 13. Contribution of each component on the exergy destruction under different pressures in the cooler.
480 Y. Liang, Z. Sun and M. Dong et al. / International Journal of Refrigeration 118 (2020) 470–482
Table 4
Comparison between two layouts under optimal condition (maximum cooling capacity), the ambient temperature
T0 =25 ˚C and the evaporation temperature Teva =-15 ˚C.
parameters System with two separate coolers System sharing a common cooler
kW, which is comparable with that of the first layout that uses two
separate coolers for S-CO2 and T-CO2 (shown in Fig. 6). It can be
concluded that the S-CO2 /T-CO2 combined cycle sharing a common
cooler has greater potential in practical application for its compact-
ness.
The variation of exergy efficiency of the combined cycle shown
in Fig. 17 is similar to that of the cooling capacity shown in
Fig. 16 The exergy efficiency is raised dramatically with the dis-
charge pressure ranging from 7400 kPa to 7600 kPa. When the
discharge pressure is higher above 7600 kPa, the effect of the dis-
charge pressure on the exergy efficiency is minor and it is around
9%.
In order to compare the performance, the evaporation temper-
ature in these two layouts is set to be the same. In that case,
it can be taken as the optimal condition when the cooling ca-
pacity reaches the peak value. The results shown in Table 4 are
operated when the maximum cooling capacity is obtained. From
the comparison in table 4, the S-CO2 /T-CO2 combined system with
Fig. 16. Cooling coefficient of performance and cooling capacity in T-CO2 . two separate coolers shows a cooling capacity 8% higher than with
that sharing a common cooler. However, the system with only one
cooler has advantage in the size and weight for the practical ap-
sure keep increasing, the effect of discharge pressure on the irre- plication. Technical-economic evaluation is required in the further
versibility becomes minor. investigation before the system designs.
Fig. 16 shows the variation of cooling coefficient performance
and cooling capacity with the increasing discharge pressure in 6. Conclusions
the T-CO2 . The COP and cooling capacity show a similar variation
trend, which increases first and then decreases slightly. The varia- This paper proposes a refrigeration system that essentially in-
tion of the discharge pressure has minor effect on cooling capac- tegrates a S-CO2 power cycle and a T-CO2 refrigeration combined
ity and COP when it is higher than 7600 kPa. In the T-CO2 refrig- cycle by waste heat recovery of engine. The heat energy of the ex-
eration cycle, as the discharge pressure increases, the power con- haust gas is recovered by a S-CO2 power cycle, in which the pro-
sumed by compressor increases. Furthermore, when the discharge duced power is use to power two compressors. Cooling is supplied
pressure is higher than 7600 kPa, the cooling capacity is about 37.5 to the cabinet by T-CO2 refrigeration cycle. Furthermore, two dif-
Y. Liang, Z. Sun and M. Dong et al. / International Journal of Refrigeration 118 (2020) 470–482 481
ferent layout are analysed and compared. The analyses led to the Li, H., Bu, X., Wang, L., Long, Z., Lian, Y., 2013. Hydrocarbon working fluids for a
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Declaration of interests and refrigeration cycles. Energy 55, 156–172.
Manente, G., Lazzaretto, A., 2014. Innovative biomass to power conversion systems
based on cascaded supercritical CO2 Brayton cycles. Biomass And Bioenergy. 69,
The authors declare that they have no known competing finan- 155–168.
cial interests or personal relationships that could have appeared to Manzela, A.A., Hanriot, S.M., Cabezas-Gómez, L., Sodré, J.R., 2010. Using engine ex-
influence the work reported in this paper. haust gas as energy source for an absorption refrigeration system. Appl. Energy.
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Ohkawa, T., Kumakura, E., Higashi, H., Sakitani, K., Higuchi, M., Taniwa, H.,
Acknowledgment Ozawa, H., 2002. Development of Hermetic Swing Compressors For CO2 Re-
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conference. Purdue.
This research is funded by EPSRC (EP/N020472/1, Persichilli, M., Held, T., Hostler, S., Zdankiewicz, E., Klapp, D., 2011. Transforming
EP/N0 05228/1, EP/R0 03122/1, and EP/P028829/1) in the United waste heat to power through development of a CO2 -based-power cycle. Electric
Power Expo 10–12.
Kingdom. Persichilli, M., Kacludis, A., Zdankiewicz, E. and Held, T., 2012. Supercritical CO2
power cycle developments and commercialization: why sCO2 can displace
steam ste. Power-Gen India & Central Asia.
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