Analysis of optimal expansion dynamics in a reciprocating drive for a micro-CAES production system

This paper presents the unique design and processing conditions of a micro-CAES device that generates, stores and delivers electrical energy with highly efficient total energy conversion. The micro-CAES installation is divided into six parts, where air, the energy carrier, is compressed, stored, heated and expanded in appropriate sections. We focus mainly on the post-preparation section, where the air mass flow is pulse heated and controlled by Pulse Width Modulation (PWM), and the expansion section, where multiple piston drives are used to achieve maximum energy conversion efficiency or the required amount of electricity to be fed into the grid. We discover that the controllability of expansion process performance is improved by exploiting the inertia of the following elements in multiple reciprocating engines: piston, piston rod, connecting rod, crank, and crankshaft, connected with air injection dynamics and pulse heating by Thermal Energy Storage (TES). Furthermore, we investigate the efficiency using our own zero-dimensional mathematical model illustrating the complex dynamics of air processing. The mathematical model was compared with experimental data for the single-drive air expander, showing qualitatively and quantitatively satisfying model reliability. Moreover, we performed a sensitivity analysis to determine the best number of reciprocating drives involved in the expansion section and the best operating conditions. The use of the PWM function of mass flow of air supplied the expander with an index of 0.5 together with pulsating air heating in the expander installation, including three- reciprocating drives, allows a maximum total energy conversion efficiency of 81%. The presented piston drive expander seems to be a promising solution for micro-CAES in residential and industrial applications, especially where additional low-temperature waste heat is available, and an intermittent control strategy is implemented. [Display omitted] •Original construction of the air expander includes multi-piston-drives.•The micro-CAES with air preheat and PWM control strategy ware implemented.•Obtained maximum efficiency of piston-drive micro-CAES is 81%.•Generated electrical power could be control with overall efficiency change up to 10%.