International Journal of Advances in Science Engineering and Technology, ISSN: 2321-9009, Vol-4, Iss-2, Spl. Issue-2 May.

-2016

THERMAL ANALYSIS OF WASTE HEAT RECOVERY UNIT USING

THE EXHAUST GAS EMITTED FROM INTERNAL COMBUSTION
ENGINE
1
ROHIT KUMAR DAS, 2CHINNASAMY SUBRAMANIAN
1
Department of Mechanical Engineering, Velammal Engineering College, Anna University,
2
Asst. Professor in Mechanical Engineering, Velammal Engineering College, Anna University, Chennai
E-mail: [email protected]

Abstract- The heat is emitted from diesel engine after every cycle. This heat goes into waste into the atmosphere. Many
notable steps have been taken to reduce the wastage of heat. The research paper focuses on the analysis of the amount of heat
dissipated from the experimental setup. So therefore analysis software such as ansys fluent software is used to
pictographically view the process. An experimental shell and tube heat exchanger setup has been arranged so as to utilize the
waste heat. Instead of being wasted by release into the ambient environment sometimes waste heat ( or cold) can be utilized
by another process or a portion of heat that would otherwise be wasted can be reused in the same process if the makeup heat
is added to the system ( as with heat recovery ventilation in a building )

Index Terms- Heat, Thermal Analysis, Waste Heat Recovery, Exhaust gas emission.

I. INTRODUCTION room air or a combustion engine releasing heat into

the environment. The need for many systems to reject
Waste heat recovery is the collection of heat created as heat as a by-product of their operation is fundamental
an undesired by-product of the operation of a piece of to the laws of thermodynamics. Waste heat has lower
equipment or machinery to fill a desired purpose utility (or in thermodynamics lexicon a
elsewhere. lower energy or higher entropy) than the original
Waste heat recouping methods range from the simple energy source. Sources of waste heat include all
to the complex. A common simple example is manner of human activities, natural systems, and all
household water drain heat recovery. In this method, organisms. Rejection of unneeded cold (as from a heat
the heat going down a sink or shower drain is pump) is also a form of waste heat (i.e. the medium
recovered by a copper pipe coiling around the drain has heat, but at a lower temperature than is considered
pipe. The coil is then used to heat water as it passes warm).
through pipes on the way to a hot water heater.
Instead of being wasted by release into the ambient
On the more complex side, heat recovered from liquid environment, sometimes waste heat (or cold) can be
cooling systems in data centers can be used for parts of utilized by another process, or a portion of heat that
the facilities where warmer temperatures are desired. would otherwise be wasted can be reused in the same
Other sources of waste heat that can be recovered for process if make-up heat is added to the system (as
practical uses include car exhaust, industrial exhaust, with heat recovery ventilation in a building).
thermoelectric generation and turbines. Depending on
the application, the heat itself may be the desired Three essential components to waste heat recovery
product or may be subjected to another process to (i) Accessible source of waste heat;
provide clean electricity. (ii) Recovery technology
(iii) Use for the recovered heat. Obstacles to waste
According to the United States Department of Energy, heat recovery high costs, good fit, retrofitting
up to 50 percent of the energy from all fuels burned in etc.
the U.S. ends up in the atmosphere as waste heat.
Research indicates that recovery of the energy waste Reasonable payback for the industry & perceived risks
from industrial facilities could fulfill up to 20 percent are negligible. Implement existing technologies and
of total domestic electricity demand and techniques .Carry out further research to enable heat
simultaneously effect a 20 percent reduction in recovery from new sources and increase end use
greenhouse emissions. options. The biggest opportunity for efficiency in
industry is embedded within the entire industrial
Waste heat is by necessity produced both process and highlights the huge potential for waste
by machines that do work and in other processes that energy recovery systematic energy management
use energy, for example in a refrigerator warming the approach required.

Thermal Analysis Of Waste Heat Recovery Unit Using The Exhaust Gas Emitted From Internal Combustion Engine

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International Journal of Advances in Science Engineering and Technology, ISSN: 2321-9009, Vol-4, Iss-2, Spl. Issue-2 May.-2016

PROBLEM DEFINITION TEST FUEL SPECIFICATIONS

In this process we are analyzing waste heat emitting

from the diesel engine into useful work. This is
achieved by using ansys fluent software. This thesis
can reduce the amount of input energy required. The
thesis charts out the heat dissipated away from the
shell and tube heat exchanger as this might help
increase the efficiency of the heat exchanger. The
charts as streamline, temperature have been displayed
in three dimensional views so as to clearly view the
amount of heat flowing in and out of the system

DESIGN AND DEVELOPMENT

The specifications required for the apparatus is as

follows TECHNICAL SPECIFICATIONS [MULTI
CYLINDER APPARATUS]
DIESEL ENGINE SPECIFICATIONS [SINGLE
CYLINDER]

PROPERTIES OF FUEL USED

PROPOTIONS OF FUEL AND THEIR

ALTERNATIVES:
OTHER TECHNICAL SPECIFICATION

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International Journal of Advances in Science Engineering and Technology, ISSN: 2321-9009, Vol-4, Iss-2, Spl. Issue-2 May.-2016

1.1 COMPONENTS USED: Units or devices that could recover the waste heat and
1.1.1 RECUPERATOR: transform it into electricity are called WHRUs or heat
This name is given to different types of heat to power units. For example, an Organic Rankine
exchanger that the exhaust gases are passed through, cycle unit uses an organic fluid as the working fluid.
consisting of metal tubes that carry the inlet gas and The fluid has a lower boiling point than water to allow
thus preheating the gas before entering the process. it to boil at low temperature, to form a superheated gas
The heat wheel is an example which operates on the that could drive the blade of a turbine and thus a
same principle as a conditioning unit. generator. Thermoelectric (See
beck, Peltier, Thomson effects) units may also be
1.1.2 REGENERATOR: called WHRU, since they use the heat differential
This is an industrial unit that reuses the same stream between two plates to produce DC Power
after processing. In this type of heat recovery, the heat A WHRB is different from a Heat Recovery Steam
is regenerated and reused in the process. Generator (HRSG) in the sense that the heated
medium does not change phase.
1.1.3 HEAT PIPE EXCAHNGER:
Heat pipes are one of the best thermal conductors. 1.2 ABOUT SHELL AND TUBE HEAT
They have the ability to transfer heat hundred times EXCHANGER
more than copper. Heat pipes are mainly known in A shell and tube heat exchanger is a class of heat
renewable energy technology as being used exchanger designs. It is the most common type of heat
in evacuated tube collectors. The heat pipe is mainly exchanger in oil refineries and other large chemical
used in space, process or air heating, in waste heat processes, and is suited for higher-pressure
from a process is being transferred to the surrounding applications. As its name implies, this type of heat
due to its transfer mechanism. exchanger consists of a shell (a large pressure vessel)
with a bundle of tubes inside it. One fluid runs through
1.1.4 THERMAL WHEEL: the tubes, and another fluid flows over the tubes
Thermal wheel or rotary heat exchanger: consists of a (through the shell) to transfer heat between the two
circular honeycomb matrix of heat absorbing material, fluids. The set of tubes is called a tube bundle, and may
which is slowly rotated within the supply and exhaust be composed of several types of tubes: plain,
air streams of an air handling system. longitudinally finned, etc.

1.1.5 ECONOMISER: 1.2.1 THEORY AND APPLICATION

In case of process boilers, waste heat in the exhaust Two fluids, of different starting temperatures, flow
gas is passed along a recuperate that carries the inlet through the heat exchanger. One flows through the
fluid for the boiler and thus decreases thermal energy tubes (the tube side) and the other flows outside the
intake of the inlet fluid. tubes but inside the shell (the shell side). Heat is
transferred from one fluid to the other through the tube
1.1.6 HEAT PUMPS: walls, either from tube side to shell side or vice versa.
Using an organic fluid that boils at a low temperature The fluids can be either liquids or gases on either the
means that energy could be regenerated from waste shell or the tube side. In order to transfer heat
fluids. efficiently, a large heat transfer area should be used,
leading to the use of many tubes. In this way, waste
1.1.7 RUN AROUND COIL: heat can be put to use. This is an efficient way to
It is comprised two or more multi-row finned tube conserve energy.
coils connected to each other by a pumped pipework
circuit. Particulate Filters (DPF) to capture emission Heat exchangers with only one phase (liquid or gas)
by maintaining higher temperatures adjacent to the on each side can be called one-phase or single-phase
converter and tail pipes to reduce the amount of heat exchangers. Two-phase heat exchangers can be
emissions from the exhaust used to heat a liquid to boil it into a gas (vapor),
sometimes called boilers, or cool a vapor to condense
1.1.8 HEAT TO POWER UNIT: it into a liquid (called condensers), with the phase
the majority of energy production from conventional change usually occurring on the shell side. Boilers in
and renewable resources are lost to the atmosphere steam engine locomotives are typically large, usually
due to onsite (equipment inefficiency and losses due to cylindrically-shaped shell-and-tube heat exchangers.
waste heat) and offsite (cable and transformers losses) In large plants with steam-driven turbines,
losses, that sums to be around 66% loss in electricity shell-and-tube surface condensers are used to
value. Waste heat of different degrees could be found condense the exhaust steam exiting the turbine into
in final products of a certain process or as a by-product condensate water which is recycled back to be turned
in industry such as the slag in steelmaking plants. into steam in the steam generator.
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International Journal of Advances in Science Engineering and Technology, ISSN: 2321-9009, Vol-4, Iss-2, Spl. Issue-2 May.-2016

1.2.2 SHELL AND TUBE HEAT EXCHANGER 1.2.5 STRAIGHT TUBE HEAT EXCHANGER
DESIGN [TWO PASS TUBE SIDE]
There can be many variations on the shell and tube There are often baffles directing flow through the
design. Typically, the ends of each tube are connected shell side so the fluid does not take a short cut through
to plenums (sometimes called water boxes) through the shell side leaving ineffective low flow volumes.
holes in tube sheets. The tubes may be straight or bent These are generally attached to the tube bundle rather
in the shape of a U, called U-tubes. than the shell in order that the bundle is still
removable for maintenance.
1.2.3 U TUBE HEAT EXCHANGER Counter current heat exchangers are most efficient
In nuclear power plants called pressurized water because they allow the highest log mean temperature
reactors, large heat exchangers called steam difference between the hot and cold streams. Many
generators are two-phase, shell-and-tube heat companies however do not use single pass heat
exchangers which typically have U-tubes. They are exchangers because they can break easily in addition
used to boil water recycled from a surface condenser to being more expensive to build. Often multiple heat
into steam to drive a turbine to produce power. Most exchangers can be used to simulate the counter current
shell-and-tube heat exchangers are either 1, 2, or 4 flow of a single large exchanger.
pass designs on the tube side. This refers to the
number of times the fluid in the tubes passes through
the fluid in the shell. In a single pass heat exchanger,
the fluid goes in one end of each tube and out the other.

FIG 1.3STRAIGHT TUBE HEAT EXCHANGER [TWO PASS

TUBE SIDE]

FIG.1.1 U TUBE HEAT EXCHANGER

1.2.6 SELECTION OF TUBE MATERIAL
To be able to transfer heat well, the tube material
1.2.4 STRAIGHT TUBE HEAT EXCHANGER [
should have good thermal conductivity. Because heat
ONE PASS TUBE SIDE ]
is transferred from a hot to a cold side through the
Surface condensers in power plants are often 1-pass
tubes, there is a temperature difference through the
straight-tube heat exchangers (see Surface
width of the tubes. Because of the tendency of the tube
condenser for diagram). Two and four pass designs
material to thermally expand differently at various
are common because the fluid can enter and exit onthe
temperatures, thermal stresses occur during
same side. This makes construction much simpler.
operation. This is in addition to any stress from
high pressures from the fluids themselves. The tube
material also should be compatible with both the shell
and tube side fluids for long periods under the
operating conditions (temperatures, pressures, pH,
etc.) to minimize deterioration such as corrosion. All
of these requirements call for careful selection of
strong, thermally-conductive, corrosion-resistant,
high quality tube materials, typically metals,
including copper
alloy, stainless steel, , nonFerrous copperalloy, Incon
el, nickel, Hastelloy and titanium.[ Fluoropolymers s
uch as Perfluoroalkoxy alkane (PFA) and Fluorinated
ethylene propylene (FEP) are also used to produce the
FIG 1.2STRAIGHT TUBE HEAT EXCHANGER ONE PASS tubing material due to their high resistance to extreme
TUBE SIDE temperatures. Poor choice of tube material could
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International Journal of Advances in Science Engineering and Technology, ISSN: 2321-9009, Vol-4, Iss-2, Spl. Issue-2 May.-2016

result in a leak through a tube between the shell and diesel, which produces a peak power output of
tube sides causing fluid cross-contamination and 84.42 MW (113,210 hp) at 102 rpm
possibly loss of pressure.
RESULT AND DISCUSSION
1.2.7 APPLICATION AND USES
The simple design of a shell and tube heat exchanger ADVANTAGES:
makes it an ideal cooling solution for a wide variety of These systems have many benefits which could be
applications. One of the most common applications is direct or indirect
the cooling of hydraulic fluid and oil in engines,
transmissions and hydraulic power packs. With the DIRECT BENEFITS:
right choice of materials they can also be used to cool The recovery process will add to the efficiency
or heat other mediums, such as swimming pool water of the process and thus decrease the costs of
or charge air. One of the big advantages of using a fuel and energy consumption needed for
shell and tube heat exchanger is that they are often that process
easy to service, particularly with models where a
floating tube bundle (where the tube plates are not INDIRECT BENEFITS:
welded to the outer shell) is available. Reduction
in Pollution: Thermal and air pollution will
1.3 DIESEL ENGINE dramatically decrease since less flue gases of
The diesel engine (also known as high temperature are emitted from the plant
a compression-ignition or 'CI' engine) is an internal since most of the energy is recycled
combustion engine in which ignition of the fuel that Reduction in the equipment sizes: As Fuel
has been injected into the combustion chamber is consumption reduces so the control and
initiated by the high temperature which a gas achieves security equipment for handling the fuel
when greatly compressed (adiabatic compression). decreases.
This contrasts with spark-ignition engines such as Also, filtering equipment for the gas is no
a petrol engine (gasoline engine) or gas engine (using longer needed in large sizes.
a gaseous fuel as opposed to petrol), which use a spark Reduction in auxiliary energy consumption:
plug to ignite an air-fuel mixture. Reduction in equipment sizes means another
The diesel engine has the highest thermal reduction in the energy fed to those systems
efficiency (engine efficiency) of any like pumps, filters, fans etc.
practical internal or external combustion engine due
to its very high compression ratio and OTHER BENEFITS:
inherent lean burn which enables heat dissipation by o Waste of the byproduct heat is reduced
the excess air. A small efficiency loss is also avoided o Co-generation system is introduced i.e.
compared to two-stroke non-direct-injection gasoline Combined heat and power system is invoked
engines since un burnt fuel is not present at valve o Effective utilization of small temperature
overlap and therefore no fuel goes directly from the difference to generate other forms of energy
intake/injection to the exhaust. Low-speed diesel o Pre heating of incoming fluid and objects so as
engines (as used in ships and other applications where to economize the input source
overall engine weight is relatively unimportant) can o Electrification of waste heat is enabled
have a thermal efficiency that exceeds 50% o Lower temperature is used to produce
Diesel engines are manufactured electricity
in two-stroke and four-stroke versions. They were
originally used as a more efficient replacement for CONCULSION
stationary steam engines. Since the 1910s they have
been used in submarines and ships. Use in Thus this research shows how thermal energy can be
locomotives, trucks, heavy equipment and electricity utilized for recycling. Although based on second law
generation plants followed later. In the 1930s, they of thermodynamics that the efficiency cannot be one
slowly began to be used in a few automobiles. Since hundred percent but the efficiency can be increased
the 1970s, the use of diesel engines in larger on-road using different material. The virtual visualization has
and off-road vehicles in the USA increased. been achieved using fluent software.
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