Abstract
A 340 kW ORC system was designed and tested for a Low Pressure Saturated Steam (LPSS) heat source which is an abundant industrial waste heat. The thermal design considered four working fluids with R245fa ultimately selected for its high thermal efficiency. Many thermal simulation conclusions from previous researches were evaluated but found to be improper for the present design. Then, the main system components, including a radial turbine, two shell and tube heat exchangers, and a shield pump were designed with other matching components selected based on the thermal design. The effects of the system operating parameters, including the evaporating temperature, condensing temperature, super heating and subcooling were analyzed with the results showing that the thermal optimization must consider the effects of the operating conditions on the component safeties and efficiencies. Finally, the system was constructed and tested near the design condition with the results showing that the maximum generator output power was 302 kW with a thermal efficiency of 9.7%. For these conditions, the isentropic turbine efficiency was 80.7% at 10,389 RPM. Suggestions for LPSS-ORC system designs are given to improve the system safety and component design.
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