02-Orc Vanslambrouck PDF

CHP: Technology Update
The Organic Rankine Cycle (ORC)
ing. Bruno Vanslambrouck,

Howest, dept Masters Industrial Sciences
Laboratory of Industrial Physics and Applied Mechanics
23-02-2010
The Organic Rankine Cycle
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:
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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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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
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1. Power production from industrial waste heat
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Electrical efficiency = ca 16%

if waste gases are cooled
down to 120C
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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
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Ex: 150 kW ORC by Tri-O-Gen (Nl)
Electricity
1550 kWe
Exhaust gas (510C)
150 kWe
Engine cooling
Exhaust gas (180C)
LT heat
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(585 kWth,
incl losses)
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ORC integration in an (existing) CHP:
Greenhouse
CHP
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17
Recuperator
180 C
Boiler
Turbine
325C
50C
Inverter
Generator
Flue gas
T > 350C
760 kW th
35C
Main feed pump

Working fluid: Toluene
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600 kWth
165 kWe
400 V
Pre-feed pump
18
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
19
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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.
Heinrich-Hertz-Str. 18
59423 Unna
Germany
Heat source:
from 230C (TG30/TG30+)
from 270C (TG60/TG60+)
Cooling source:
30C or up to 80C (CHP-version)
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Maxxtec new small series
Model 60
Model 80
Model 120
Waste heat source:

Thermal need
375 kWth
520 kWth
750 kWth
280/140 C
280/140 C
280/140 C
Gross
65 kWe
92 kWe
130 kWe
Net (appr.)
51 kWe
81 kWe
114 kWe
Condensor heat output
306 kWth
423 kWth
612 kWth
Condensor circuit in/out
43/64C
43/64C
43/64C
Gross Electric Efficiency
17,3 %
17,7 %
17,3 %
Net Electric Efficiency
13,6 %
15,6 %
15,2 %
Thermal oil in/out

Electricity output
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22
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
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23
Double srew expander
based ORC
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ElectraTherm
3208 Goni Road
Carson City,
Nevada 89706
BEP EUROPE NV
Ten Briele 6
B-8200 Brugge
24
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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25
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26
Turboden ORC-CHP range:
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MIROM Roeselare : 2,5 MWe net
by Turboden
Heat source: water @180C
17 % net efficiency
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28
ORC integration in an (existing) biomass boiler:
Biomass boiler
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Greenhouse
29
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)
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Geothermal ORC 250 kWe (Ormat)
Geothermal fluid temperature in/out:
110/85C
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
Evacuated tube collector

fitted to temperatures
untill 180-200C
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40 kW solar heat ORC (Turboden, 1984)
36
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)
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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
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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.
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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 (~300C). So the ROI can
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
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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)
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2 th ORC Project structure
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Laboratory setup
For research and demonstrational purposes
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Laboratory setup
Heat source:
Maxxtec thermal oil heater
Max 250 kW @ 340C
Flow: 14 m/h
10 x 25kW , GC-Heat
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Laboratory setup
Cooling loop:
- water + glycol
- max. 20m/h
- max. 120C
3-way
3-way valve
valve
Cooler
Cooler
Circulator
Circulator
Flow
Flow
sensor
sensor
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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)
23-02-2010
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CHP: Technology Update

The Organic Rankine Cycle (ORC)

ing. Bruno Vanslambrouck,

The Organic Rankine Cycle

The (Organic) Rankine Cycle

The Organic Rankine Cycle

The Rankine Cycle

Steam turbine installation in a power station

The Organic Rankine Cycle

The Rankine Cycle

E-production from recovered heat of a gasturbine exhaust

The Organic Rankine Cycle

The Rankine Cycle

T-s diagram for a working fluid

Rankine cycle with superheated steam

The Organic Rankine Cycle

The Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

ORC Working Fluids

The Organic Rankine Cycle

ORC Working Fluids

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

Electrical efficiency = ca 16%

The Organic Rankine Cycle

Ca 10% increase of electrical output without extra fuel

Economical attractive on engines using renewable fuels (landfill gas,

Possibility to upgrade old (build before 2002) cogeneration units with

Because of high temperature exhaust gases, a steam turbine can be

Some ORCs are adapted to use jacket cooling water heat

The Organic Rankine Cycle

The Organic Rankine Cycle

ORC integration in an (existing) CHP:

The Organic Rankine Cycle

Main feed pump

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

Maxxtec new small series

Waste heat source:

Condensor heat output

Condensor circuit in/out

Gross Electric Efficiency

Net Electric Efficiency

Thermal oil in/out

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle

The Organic Rankine Cycle