02-Orc Vanslambrouck

CHP: Technology Update
The Organic Rankine Cycle (ORC)
ing. Bruno Vanslambrouck, Howest, dept Masters Industrial Sciences Laboratory of Industrial Physics and Applied Mechanics
Contence
The (Organic) Rankine Cycle Working Fluids Relevant applications Conclusions Economic information Our ORC related activities
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The Rankine Cycle

1. 2. 3. 4. Electrofilter Boiler Steam turbine generator 5. 6. 7. Transformer Condensor Cooling tower
Source: Electrabel
Steam turbine installation in a power station

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The Rankine Cycle
E-production from recovered heat of a gasturbine exhaust using a Rankine Cycle Source: Electrabel
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The Rankine Cycle
T-s diagram for a working fluid
Rankine cycle with superheated steam Carnot efficiency:
The Rankine Cycle

Working fluid: usually water Advantages: cheap, widely available non toxic high heat capacity: excellent medium for heat transport chemical stable: less material requirements low viscosity: low friction losses Disadvantages: due to low condensation t very low pressure, high specific volume, big : installations needed (turbine, condensor) high pressure drop to become a high enthalpy drop: expensive multi stage turbines needed expansion has to start in the superheated area to avoid too high moisture content after expansion: need of a high t heat source but very partically use because of this: efficiency loss and limited suitability to waste heat recovery
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The Organic Rankine Cycle

Disavantages water probably to correct using other working fluids, mostly of organic origin: Organic Rankine Cycle Organic medium (ORC) Used are: Toluene, butane, pentane, ammonia, refrigeration fluids, silicone oils
Organic Rankine Cycle in the T-s diagram
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ORC Working Fluids

Wet fluid Dry fluid Isentropic fluid
superheating required remains superheated superheating unnecessary superheating efficiency after expansion of recuperator unnecessary higher vaporization heat at saturated vapor best choice for ORC from lower pressures superheating unnecessary this point of view evaporation requires a lot superheating efficiency of heat or high pressures
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ORC Working Fluids
Relevant applications
1. Power production from industrial waste heat
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Electrical efficiency = ca 16% if waste gases are cooled down to 120 C

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2. Exhaust heat recovery on stationary combustion engines or gas turbines
Ca 10% increase of electrical output without extra fuel Economical attractive on engines using renewable fuels (landfill gas, biogas, vegatable oils) because of governmental support (Green Certificates). Simple PBT of 3 years calculated. Possibility to upgrade old (build before 2002) cogeneration units with respect to CHP certificates by adding an ORC (increase of relative primary energy savings with 5 %). Very short PBT if feasible (1- 2 years). Because of high temperature exhaust gases, a steam turbine can be considered on bigger plants Some ORCs are adapted to use jacket cooling water heat
Ex: 150 kW ORC by Tri-O-Gen (Nl) Electricity 1550 kWe
Exhaust gas (510 C)
Engine cooling Exhaust gas (180 C) (585 kWth, incl losses)
LT heat
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150 kWe
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ORC integration in an (existing) CHP:
Greenhouse CHP
180 C
Boiler Turbine
325 C
Generator Flue gas

T > 350 C 760 kW th
Working fluid: Toluene

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Recuperator
Inverter 165 kWe 400 V Main feed pump Pre-feed pump
50 C 600 kWth 35 C
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ORC on exhaust gases 2 MW Deutz gas engine Roses farm Olij, De Kwakel The Netherlands
Tri-O-Gen B.V. Nieuwenkampsmaten 8 7472 DE Goor Nederland
Range: TG30(+) 30 kW; TG60(+) 60 kW Specific designed to recover biogas engine heat (+ means integrated use of engine jacket cooling). Fits on biogas engines in the range 250-500 kW. Heat source: from 230 (TG30/TG30+) C from 270 (TG60/TG60+) C Cooling source: 30 or up to 80 (CHP-version) C C
Heinrich-Hertz-Str. 18 59423 Unna Germany
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Maxxtec new small series Waste heat source: Thermal need Thermal oil in/out Electricity output Gross Net (appr.) Condensor heat output Condensor circuit in/out Gross Electric Efficiency Net Electric Efficiency
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Model 60 Model 80 Model 120 375 kWth 280/140 C 520 kWth 280/140 C 750 kWth 280/140 C 65 kWe 51 kWe 306 kWth 43/64 C 17,3 % 13,6 % 92 kWe 81 kWe 423 kWth 43/64 C 17,7 % 15,6 % 130 kWe 114 kWe 612 kWth 43/64 C 17,3 % 15,2 %
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ORC with double screw expander
Heavy duty design, derived from screw compressors Not sensitive to fluid drops: can expand both superheated or saturated steam, no damage when fluids drops passes trough (usefull when large process variations are going on). As ORC usable at lower temperatures Adapted to recover jacket water heat
Double srew expander based ORC
ElectraTherm 3208 Goni Road Carson City, Nevada 89706 BEP EUROPE NV Ten Briele 6 B-8200 Brugge
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3. ORC, fed by biomass combustion
Many references in CH, A, D, I (also 1 in NL, 2 planned in Belgium). In concurrence with the steam cycle. Always designed as CHP.
Turboden s.r.l. Viale Cernaia, 10 25124 Brescia - Italy
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Turboden ORC-CHP range:
MIROM Roeselare : 2,5 MWe net by Turboden Heat source: water @180 C 17 % net efficiency
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ORC integration in an (existing) biomass boiler:
Biomass boiler
Greenhouse
4. ORC, fed by geothermal heat sources Many references known, from 250 kW to > 100 MW Source temperatures from 75C up to 300C. Same technology usable to recover waste heat on the same temperature levels.
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Heber Geothermal 52 MWe power station (California)
Geothermal ORC 250 kWe (Ormat) Geothermal fluid temperature in/out: 110/85 C Thermal power in: ~ 2500 kW ORC working fluid: Isopentane
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ORC derived from a centrifugal chiller (reversed)
Cheap, reliable, proven technology
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Pure Cycle 280: 186-257 kWe net

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5. Power generation from thermal solar energy
probably cheaper than photovoltaic solar systems possible to use condensor heat for sanitary heat water huge potential on desalination systems 40 kW solar heat ORC (Turboden, 1984)
Evacuated tube collector fitted to temperatures untill 180-200C
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Solar-biomass hybrid ORC
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Principle design combined solar driven electricity and domnestic hot water production system (final work HOWEST, 2004-2005)
Tests (HOWEST) on a scroll expander (2005) (Sanden scroll car airco compressor TRS-090)
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6. ORC driven domnestic micro-CHP
alternative to gas engine based micro CHP to integrate within a cv-boiler in concurrence with other new technologies as stirling engines, fuel cells
Energetix Group plc Capenhurst Technology Park Chester CH1 6EH UK
Genlec module: 1 kW scroll expander based ORC to integrate in central heating boilers (micro CHP) Example: Boiler manufacturor Daalderop (NL)
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7. ORC driven cooling
Alternative if electrical grid connection big chillers is impossible or not allowed. Been proven having better efficiency (COP) compared to absorption chillers. Solar powering or hybrid with solar heat feasible.
Some Economics
Some budget prices ORC-modules:
Turboden: 500kW: about 1900 /kWe 1000 kW: about 1350 /kWe 2000 kW: about 950 /KWe Pure Cycle 280 (ca 250 kWe) : 335 000 or 1350/kWe Maxxtec/Adoratec: confidential prices, but of the same order of Turboden Also attractive priced new 60, 85 and 120 kW units. Tri-O-Gen: 150 kW unit @ 650 000 ca 4300 /kWe (turn key ?) BEP-Europe: 50 kW unit @ 120 000 (module) or 200 000 (installed) 2400 /kWe 4000 /kWe 250 kW unit: lower price/kWe compared with the 50 kWe unit
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Some Economics
On renewable energy applications, we calculated a simple PBT of 3 year (IRR ca 25%), with the help of green certificates. For industrial waste heat recovery, a PBT of 5 year is realistic when available heat is on high temperature (~300 So the ROI can C). reach 15%, after taxes, what means that the investment can be asked within the benchmarking agreement. This result is strongly related to the electricity prices. Other financing methods (third party) could be considered
Some Conclusions
- ORC is a proven and commercially available technology for applications such as industrial waste heat recovery, ICE heat recovery, biomass burning, use of solar heat, geothermal heat sources - main advantage compared with a steam cycle is the higher thermal efficiency when using heat sources at lower temperatures. The ORC is also less complicated and easier to operate. Occuring pressures are lower. - the classical steam cycle should be considered when sufficient temperature levels are reachable (fuel burning) combined with turbine scale sizes from about 500 kWeto 2,5 MWe (to discuss, no clear answer given when to chose an ORC above a steam cycle) - favorable economical perspectives, especially in relation to green certificates or energy benchmarking. - excellent CHP capability since the condensor heat can be used
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Our ORC related activities

2 master thesises 2003-2005 TETRA project proposal on ORC in 2005. Technically and scientifically approved but not financed, had to be cancelled. New proposal in 2007, focused on renewable energy sources. Accepted, in progress from Oct 1st 2007 till Dec 31th 2009 Second proposal on industrial waste heat accepted (Jan 1st 2010- Dec 31 th 2011 or 2012). European ERA-SME concept with Ghent University and Stuttgart University of Applied Sciences as research partners.
A TETRA project is 92,5 % financed by the Flemisch Government (IWT) and 7,5% by industrial partners (at least 4 SMEs). 2 scientific researchers can work during 2 or 3 years on it. Cofinancing User Group is the preference partner to receive project information during project runtime, at the end publical available (by publications, seminars, website)
2 th ORC Project structure
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Laboratory setup
For research and demonstrational purposes
Laboratory setup
Heat source:
Maxxtec thermal oil heater Max 250 kW @ 340 C Flow: 14 m/h
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10 x 25kW , GC-Heat
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Laboratory setup
Cooling loop:
- water + glycol - max. 20m/h - max. 120 C
3-way valve 3-way valve Circulator Circulator
Cooler Cooler
Flow Flow sensor sensor
Thanks for your attention. Questions ???

ing Bruno Vanslambrouck HOWEST, dept Masters Industrial Sciences
Laboratory of Industrial Physics and Applied Mechanics
Graaf Karel de Goedelaan 5, B-8500 Kortijk Mail: bruno.vanslambrouck@howest.be Tel: +32 56 241211 or +32 56 241227 (dir)
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CHP: Technology Update

The Organic Rankine Cycle (ORC)

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

The Rankine Cycle

Steam turbine installation in a power station

The Rankine Cycle

elcyC eniknaR cinagrO ehT

The Rankine Cycle

T-s diagram for a working fluid

Rankine cycle with superheated steam Carnot efficiency:

The Rankine Cycle

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

The Organic Rankine Cycle

Organic Rankine Cycle in the T-s diagram

The Organic Rankine Cycle

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

The Organic Rankine Cycle

ORC Working Fluids

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

ORC Working Fluids

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

Electrical efficiency = ca 16% if waste gases are cooled down to 120 C

elcyC eniknaR cinagrO ehT

Engine cooling Exhaust gas (180 C) (585 kWth, incl losses)

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

ORC integration in an (existing) CHP:

Generator Flue gas

Working fluid: Toluene

elcyC eniknaR cinagrO ehT

Inverter 165 kWe 400 V Main feed pump Pre-feed pump

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

Turboden s.r.l. Viale Cernaia, 10 25124 Brescia - Italy

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

Pure Cycle 280: 186-257 kWe net

Evacuated tube collector fitted to temperatures untill 180-200C

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT

elcyC eniknaR cinagrO ehT