Small Organic Rankine Cycle System Research Articles

A Recent Advance on Partial Evaporating Organic Rankine Cycle: Experimental Results on an Axial Turbine

The organic Rankine cycle (ORC) technology is an efficient way to convert low-grade heat from renewable sources or waste heat for power generation. The partial evaporating organic Rankine cycle (PEORC) can be considered as a promising alternative as it can offer a higher utilization of the heat source. An experimental investigation of a small ORC system used in full or partial evaporation mode is performed. First characterized in superheated mode, which corresponds to standard ORC behavior, a semi-empirical correlative approach involving traditional non-dimensional turbomachinery parameters (specific speed, pressure ratio) can accurately describe one-phase turbine performance. In a second step, two-phase behavior is experimentally investigated. The efficiency loss caused by the two-phase inlet condition is quantified and considered acceptable. The turbine two-phase operation allows for an increase in the amount of recovered heat source. The ability to operate in two phases provides a new degree of flexibility when designing a PEORC. The semi-empirical correlative approach is then completed to take into account the partially evaporated turbine inlet condition. The qualitative description and the quantitative correlations in the one-phase and two-phase modes were applied to different pure working fluids (Novec649TM, HFE7000 and HFE7100) as well as to a zeotropic mixture (Novec649TM/HFE7000).

Preliminary Design of an Axial-Flow Turbine for Small-Scale Supercritical Organic Rankine Cycle

A small-scale organic Rankine cycle (ORC) with kW-class power output has a wide application prospect in industrial low-grade energy utilization. Increasing the expansion pressure ratio of small-scale ORC is an effective approach to improve the energy efficiency. However, there is a lack of suitable expander for small-scale ORC that can operate with a high efficiency under the condition of large expansion pressure ratio and small mass flow rate. Aiming at the design of high-efficiency axial-flow turbine in small ORC system, this paper investigates the performance of a kW-class axial-flow turbine and proposes a method for efficiency improvement. First, the preliminary design of an axial-flow turbine is conducted to optimize the geometric parameters and aerodynamic parameters. Then, the effects of tip clearance and trailing edge thickness on turbine performance are analyzed under design and off-design conditions. The results show that the efficiency of the two-stage or three-stage turbine is evidently better than that of the single-stage one. The output power and efficiency of the three-stage turbine are close to that of the two-stage turbine while the speed is lower. Meanwhile, the trailing edge loss and leakage loss can be significantly reduced via reducing the trailing edge thickness and tip clearance, and thus the turbine efficiency can be improved significantly. The estimated efficiency arrives at 0.82, which is 33% higher than that of the conventional turbine. Considering the limitation of turbine speed, three-stage axial-flow turbine is a feasible choice to improve turbine efficiency in a small-scale ORC.

Carnot cycle in practice: compensating inefficiencies of ORC expanders through thermal regeneration

The Organic Rankine Cycle (ORC) is a thermodynamic cycle that can operate with a hot source over a wide range of temperatures, especially with low-grade heat (below 200°C). One of the main limitations for the success of small-scale ORC cycles (few to 100 kWe) is the relatively low isentropic efficiency of the typically used turbomachinery. Low turbine efficiency leads to low ORC cycle performance. To increase the performance of the cycle, the turbine efficiency must be increase, however, this significantly increases the cost of the machinery, making the cycle less profitable. In this work, the performance evaluation of low-temperature ORC cycles (100-150°C) with heat extraction along the expansion process is investigated, in an attempt to overcome this limitation. The studied cycle works in the same way as a conventional ORC, except that during the expansion process, heat is extracted. This heat is re-used later in the cycle, just before the hot source, allowing to reduce its load. The different cycles presented in this paper, using pentane as working fluid, are compared based on their exergetic and energetic efficiencies. The influence of three parameters on the cycle performance is studied: the regeneration ratio, the maximum temperature of the cycle and the turbine isentropic efficiency. In the case of a cycle using pentane with a maximum temperature of 150 °C and an turbine isentropic efficiency of 65%, the energy efficiency increases from 6.2% to 16.3% when going from no regeneration to full regeneration, and the exergy efficiency increases from 21.1 to 45.8%.. Secondly, the influence of the maximum temperature of the cycle is studied. Using pentane as the working fluid, the higher the maximum temperature is, the larger the benefits of heat extraction. However, this temperature cannot exceed the critical temperature of the organic fluid to stay in the case of a subcritical cycle. Finally, considering the turbine isentropic efficiency, it is possible to demonstrate that using a less efficient turbine, for example in small ORC systems, the performance of a cycle with an ideal turbine isentropic efficiency (100%) can be achieved compensating at cycle level the turbine losses with the heat extraction along the expansion process.

Improving the economy-of-scale of small organic rankine cycle systems through appropriate working fluid selection

Organic Rankine cycles (ORC) are becoming a major research area within the field of sustainable energy systems. However, a major challenge facing the widespread implementation of small and mini-scale ORC systems is the economy-of-scale. To overcome this challenge requires single components that can be manufactured in large volumes and then implemented into a wide variety of different applications where the heat source conditions may vary. The aim of this paper is to investigate whether working fluid selection can improve the current economy-of-scale by enabling the same system components to be used in multiple ORC systems. This is done through coupling analysis and optimisation of the energy process, with a performance map for a small-scale ORC radial turbine. The performance map, obtained using CFD, is adapted to account for additional loss mechanisms not accounted for in the original CFD simulation before being non-dimensionalised using a modified similitude theory developed for subsonic ORC turbines. The updated performance map is then implemented into a thermodynamic model, enabling the construction of a single performance contour that displays the range of heat source conditions that can be accommodated by the existing turbine whilst using a particular working fluid. Constructing this performance map for a range of working fluids, this paper demonstrates that through selecting a suitable working fluid, the same turbine can efficiently utilise heat sources between 360 and 400K, with mass flow rates ranging between 0.5 and 2.75kg/s respectively. This corresponds to using the same turbine in ORC applications where the heat available ranges between 50 and 380kWth, with the resulting net power produced by the ORC system ranging between 2 and 30kW. Further investigations also suggest that the same pump could also be used; however, the heat exchanger area scales directly with increasing heat input. Overall, this paper demonstrates that through the optimal selection of the working fluid, the same turbomachinery components (i.e. pump and turbine) can be used in multiple ORC systems. This offers an opportunity to improve the current economy-of-scale of small ORC systems, ultimately leading to more economical systems for the utilisation of low temperature sustainable heat sources.

Geometry Analysis and Effect of Turbulence Model on the Radial Rotor Turbo-Expander Design for Small Organic Rankine Cycle System

Organic Rankine Cycle (ORC) is one of the most promising technology for small electric power generations. The geometry analysis and the effect of turbulence model on the radial turbo-expanders design for small ORC power generation systems were discussed in this paper. The rotor blades and performance were calculated using several working fluids such as R134a, R143a, R245fa, n-Pentane, and R123. Subsequently, a numerical study was carried out in the fluid flow area with R134a and R123 as the working fluids. Analyses were performed using Computational Fluid Dynamics (CFD) ANSYS Multiphysics on two real gas models, with the k-epsilon and SST (shear stress transport) turbulence models. The result shows the distribution of Mach number, pressure, velocity and temperature along the rotor blade of the radial turbo-expanders and estimation of performance at various operating conditions. The operating conditions are as follow: 250,000 grid mesh flow area, real gas model SST at steady state condition, 0.4 kg/s of mass flow rate, 15,000 rpm rotor speed, 5 bar inlet pressure, and 373K inlet temperature. By using those conditions, CFD analysis shows that the turbo-expander able to produce 6.7 kW and 5.5 kW of power when using R134a and R123, respectively.

Design of Radial Turbo-Expanders for Small Organic Rankine Cycle System

This paper discusses the design of radial turbo-expanders for ORC systems. Firstly, the rotor blades were design and the geometry and the perfromance were calculated using several working fluid such as R134a, R143a, R245fa, n-Pentane, and R123. Then, a numerical study was carried out in the fluid flow area with R134a and R123 as the working fluid. Analyses were performed using Computational Fluid Dynamics (CFD) ANSYS CFX on two real gas models, with the k-epsilon and SST (shear stress transport) turbulence models. The results analysis shows the distribution of Mach number, pressure, velocity and temperature along the rotor blade of the radial turbo-expanders and estimation of performance at various operating conditions. CFD analysis show that if the flow area divided into 250,000 grid mesh, and using real gas model SST at steady state condition, 0.4 kg/s of mass flow rate, 15,000 rpm rotor speed, 5 bar inlet pressure, and 373K inlet temperature, the turbo expander produces 6.7 kW, and 5.5 kW of power when using R134a and R123 respectively.

Performance of an organic Rankine cycle with multicomponent mixtures

There is a renewed interest in ORC (organic Rankine cycle) systems for power generation using solar thermal energy. Many authors have studied the performance of ORC with different pure fluids as well as binary zeotropic mixtures in order to improve the thermal efficiency. It has not been well appreciated that zeotropic mixtures can also be used to reduce the size and cost of an ORC system. The main objective of this paper is to present mixtures that help reduce the cost while maintaining high thermal efficiency. The proposed method also allows us to design an optimum mixture for a given expander. This new approach is particularly beneficial for designing mixtures for small ORC systems operating with solar thermal energy. A number of examples are presented to demonstrate this concept.

Process Manufacture Rotor Radial Turbo-expander for Small Scale Organic Rankine Cycles Using Selective Laser Melting Machine

Abstract This paper discusses the manufacturing process of rotor radial turbo-expanders for small Organic Rankine Cycle systems using additive manufacturing machine Selective Laser Melting (SLM) machine. The process manufacturing consists of data preparation, build job process, and process finishing product. Data preparations are include material preparations, build data preparation using software 3D design Solidworks, support management with software magics and additive manufacturing software with Autofab for build job process on SLM machine. The results shows rotor with material Aluminum Silicon Powder (AlSi) can be made with either the appropriate geometry design within 5 hours with total cost for the whole processing is up to 11 milion IDR.

Preliminary Design and Simulation of a Turbo Expander for Small Rated Power Organic Rankine Cycle (ORC)

Nowadays, the Organic Rankine Cycle (ORC) system, which operates with organic fluids, is one of the leading technologies for “waste energy recovery”. It works as a conventional Rankine Cycle but, as mentioned, instead of steam/water, an organic fluid is used. This change allows it to convert low temperature heat into electric energy where required. Large numbers of studies have been carried out to identify the most suitable fluids, system parameters and the various configurations. In the present market, most ORC systems are designed and manufactured for the recovery of thermal energy from various sources operating at “large power rating” (exhaust gas turbines, internal combustion engines, geothermal sources, large melting furnaces, biomass, solar, etc.); from which it is possible to produce a large amount of electric energy (30 kW ÷ 300 kW). Such applications for small nominal power sources, as well as the exhaust gases of internal combustion engines (car sedan or town, ships, etc.) or small heat exchangers, are very limited. The few systems that have been designed and built for small scale applications, have, on the other hand, different types of expander (screw, scroll, etc.). These devices are not adapted for placement in small and restricted places like the interior of a conventional car. The aim of this work is to perform the preliminary design of a turbo-expander that meets diverse system requirements such as low pressure, small size and low mass flow rates. The expander must be adaptable to a small ORC system utilizing gas of a diesel engine or small gas turbine as thermal source to produce 2–10 kW of electricity. The temperature and pressure of the exhaust gases, in this case study (400–600 °C and a pressure of 2 bar), imposes a limit on the use of an organic fluid and on the net power that can be produced. In addition to water, fluids such as CO2, R134a and R245fa have been considered. Once the operating fluids has been chosen, the turbine characteristics (dimensions, input and output temperature, pressure ratio, etc.) have been calculated and an attempt to find the “nearly-optimal” combination has been carried out. The detailed design of a radial expander is presented and discussed. A thermo-mechanical performance study was carry out to verify structural tension and possible displacement. On the other hand, preliminary CFD analyses have been performed to verify the effectiveness of the design procedure.

Characteristics of Small ORC System for Low Temperature Waste Heat Recovery

This paper describes fundamental characteristics of a small organic Rankine cycle (ORC) system to be used for power generation from low temperature heat sources such as waste heat and solar energy. The aim of the study was to develop an ORC system with a small power output of less than 1 kW with a hot source with temperature ranging from 60 to 100°C and a cold source with temperature ranging from 10 to 30°C. An ORC system with a potential to produce a turbine/expander power of 250 W was built and its fundamental characteristics were elucidated. A turbine/expander was not actually installed but was simulated by controlling two expansion valves. First, steady-state energy balance of the system was examined and the required turbine/expander efficiency was estimated in consideration of pump power of the working fluid. Then, the relationship between the expansion ratio and thermal efficiency was elucidated. The most important result of the study was that for maintaining high thermal efficiency in the case that the temperature difference between hot and cold sources varies during operation, it is indispensable to employ a variable expansion mechanism by which the expansion ratio of the turbine/expander can be adjusted to fit the optimal ratio at the operating temperature level.