Description
Limits of efficiencies cause immense amounts of thermal energy in the form of waste heat to be vented to the atmosphere. Up to 60% of unrecovered waste heat is classified as low or ultra-low quality, making recovery difficult or inefficient. The organic Rankine cycle can be used to generate mechanical power and electricity from these low temperatures where other thermal cycles are impractical. A variety of organic working fluids are available to optimize the ORC for any target temperature range. San Diego State University has one such experimental ORC using R245fa, and has been experimenting with multiple expanders. One limitation of recovering waste heat is the sporadic or cyclical nature common to its production. This inconsistency makes sizing heat recovery ORC systems difficult for a variety of reasons including off-design-point efficiency loss, increased attrition from varying loads, unreliable outputs, and overall system costs. Thermal energy storage systems can address all of these issues by smoothing the thermal input to a constant and reliable level and providing back-up capacity for times when the thermal input is deactivated. Multiple types of thermal energy storage have been explored including sensible, latent, and thermochemical. Latent heat storage involves storing thermal energy in the reversible phase change of a phase change material, or PCM, and can have several advantages over other modalities including energy storage density, cost, simplicity, reliability, relatively constant temperature output, and temperature customizability. The largest obstacles to using latent heat storage include heat transfer rates, thermal cycling stability, and potentially corrosive PCMs. Targeting 86°C, the operating temperature of SDSU's experimental ORC, multiple potential materials were explored and tested as potential PCMs including Magnesium Chloride Hexahydrate (MgCl_× 6H_O), Magnesium Nitrate Hexahydrate (Mg(NO_)_× 6H_O), montan wax, and carnauba wax. The addition of graphite to augment heat transfer rates was also tested. Melting and solidification temperatures largely matched predictions. The magnesium salts were found to be less stable under thermal cycling than the waxes. Graphite was only soluble in the waxes. Mixtures of magnesium salts and waxes yielded a layered composite with the less dense waxes creating a sealing layer over the salt layer that significantly increased the stability of the magnesium salts. Research into optimum heat exchangers and storage vessels for these applications indicates that horizontally oriented aluminum pipes with vertically oriented aluminum fins would be the best method of storing and retrieving energy. Fin spacing can be predicted by an equation based on target temperatures and PCM characteristics.
