Experimental Investigation and CFD Analysis of Pressure Drop in an ORC Boiler for a WHRS Implementation

Waste heat dissipated in the exhaust system of a combustion engine represents a major source of energy to be recovered and converted into useful work. The Waste Heat Recovery System (WHRS) based in an Organic Rankine Cycle (ORC) is an approach for recovering energy from heat sources, achieving a significant reduction in fuel consumption and, as a result, exhaust emissions. This paper studies pressure drop in an ORC shell-and-tubes boiler for a WHRS implementation experimentally and with computational simulations based on a 1-dimensional heat transfer model coupled with 3D calculations. An experimental database is developed, using ethanol in a pressure range of 10-15 absolute bar as working fluid, with mass fluxes inside the tubes in the range of 349.31 kg/s-m² and 523.97 kg/s-m², and inlet temperatures in the range of 60 °C and 80 °C. Thus, the friction factor of different regions of the boiler were estimated using both CFD simulations, experimental data, and bibliographic correlations. Simulations of operating points and the results of the experimental test bench showed good agreement in pressure drop results, with a mean absolute error of 15.47%, without a significant increment in the computational cost.