ORGANIC RANKINE SYSTEM(ORC)
Waste heat to power technology
What is an Organic Rankine Cycle (ORC)?
The Organic Rankine Cycle is a fundamental thermodynamic cycle used to convert heat into mechanical work. This cycle operates in a closed loop, typically using water as the working fluid. In this process, heat is supplied to water, transforming it into steam, which then drives a turbine to generate mechanical work. The steam is subsequently condensed back into water to repeat the cycle. The Rankine Cycle based on water accounts for approximately 85% of the world's electricity production, underscoring its significance in global power generation.
Heat Addition (Evaporator)
Heat is added to a heat exchanger called the evaporator. This heat increases the temperature of an organic working fluid with a low boiling point, which is non-toxic, non-flammable, and ozone-friendly. The heated fluid expands into a high- pressure dry gas.
Energy Generation (Turbine)
The high-pressure gas spins a turbine, generating mechanical energy. This mechanical energy is converted into electricity by a direct-drive generator attached to the turbine. The generated electricity can be used on-site or supplied to the grid.
Heat Rejection (Condenser)
After passing through the turbine, the gas enters a second heat exchanger called the condenser. In the condenser, the gas releases its excess heat, condensing back into a liquid.
Fluid Circulation (Pump)
The liquid working fluid is then pumped back into the evaporator by a specific pump , completing the closed ORC loop.
Waste Heat Recovery
Waste heat recovery is a critical development area for the Organic Rankine Cycle (ORC) technology. ORC can be applied to various heat and power plants, including small-scale cogeneration plants on domestic water heaters, as well as industrial and agricultural processes. Examples include organic product fermentation, hot exhausts from ovens or furnaces (such as lime and cement kilns), flue-gas condensation, exhaust gases from vehicles, intercooling of compressors, and condensers in power cycles.
Biomass
Biomass is widely available globally and can be utilized to produce electricity in small to medium-sized power plants. The challenge of high specific investment costs for machinery, such as steam boilers, is mitigated by the low working pressures in ORC power plants. Additionally, the ORC technology ensures a long operational life for the machinery due to the properties of the working fluid, which, unlike steam, is non-eroding and non-corroding for valve seat tubing and turbine blades. The ORC process is also well-suited for regions with limited biomass resources, as it enables efficient power generation even in smaller plants.
| Data Point | 20-KW | 50-KW | 100-KW | 550-KW |
|---|---|---|---|---|
| Description | Alternator 3-Phase brushless | Alternator 3-Phase brushless | Alternator 3-Phase 415 Volt Induction | Alternator 3-Phase 415 Volt Induction |
| Turbine | Multi stage EnerTek radial expander turbine | Multi stage EnerTek radial expander turbine | Multi stage EnerTek radial expander turbine | Multi stage EnerTek radial expander turbine |
| Bearings | Sealed Tapered | Sealed Tapered | Sealed Tapered | Sealed Tapered |
| Working Fluid | N Pentane (Solvent) | N Pentane (Solvent) | N Pentane | N Pentane |
| Controls | PLC based | PLC based | PLC based | PLC based |
| Remote Monitoring | Web-based gateway | Web-based gateway | Web-based gateway | Web-based gateway |
| Electrical Output (Gross) | 20 kW | 50 kW | 120 kW | 600 kW |
| Evaporation Temp | 225ºF, 124ºC | 225ºF, 124ºC | 225ºF, 124ºC | 225ºF, 124ºC |
| Input Energy Design Standards | 360,000 KJ/Hr, 8612 Kcal/Hr | 360,000 KJ/Hr, 8612 Kcal/Hr | 342,8500 KJ/Hr, 816300 Kcal/Hr | 188,57100 KJ/Hr, 448,9795 Kcal/Hr |
| Mounting | Skid Mounting | Skid Mounting | Skid Mounting | Skid Mounting |
| Temperature Input | 392ºF, 200ºC | 392ºF, 200ºC | 320ºF, 160ºC | 392ºF, 160ºC |
| Temperature Output | 284ºF, 140ºC | 284ºF, 140ºC | 176ºF, 80ºC | 176ºF, 80ºC |
| Oil Flow Rate | 0.8 Kg / Sec, 1.76 lb / Sec | 0.8 Kg / Sec, 1.76 lb / Sec | 5.41 Kg / Sec, 11.9 lb / Sec | 29.76 Kg / Sec, 65.47 lb / Sec |
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