WORKING FLUID SELECTION AND DESIGN OF SMALL-SCALE WASTE HEAT RECOVERY SYSTEMS BASED ON ORGANIC RANKINE CYCLES

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WORKING FLUID SELECTION AND DESIGN OF SMALL-SCALE WASTE HEAT RECOVERY SYSTEMS BASED ON ORGANIC RANKINE CYCLES ( working-fluid-selection-and-design-small-scale-waste-heat-re )

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4 Study on dry ORC working fluids The objective of this chapter is to perform a preliminary evaluation of suitable working fluid candidates for small-scale ORC systems adopting high-speed turbines. First, a ther- modynamic analysis was carried out to highlight and discuss the special features related to the use of working fluids from different fluid groups, as well as to study the dependence of the critical temperature and molecular weight of the fluid on the most important pro- cess parameters. All the selected working fluids have a dry expansion to prevent droplets occurring in the turbine. In addition, the use of dry working fluids enables the use of a recuperator in the cycle. Second, a preliminary radial turbine design was carried out for several working fluids to evaluate and compare the availability for designing small-scale turbines with different fluids, as well as to investigate the main turbine dimensions and rotational speeds as a function of turbine power output. The selected turbine power output range is from 10 kW to 200 kW. 4.1 Thermodynamic analysis A thermodynamic analysis of subcritical processes adopting evaporation pressure slightly lower than the critical pressure of the fluid were carried out with two different condensing temperatures of 50 oC and 100 oC. The results were obtained by using the evaporation pressure of pev/pcr=0.9 for each fluid, in order to study processes having the evaporation pressure close to the critical pressure of the fluid and thus representing cycle efficiencies relatively close to the maximum efficiency that can be obtained with a subcritical process. It should be noted that this kind of approach was evaluated being suitable in the prelim- inary evaluation and in the comparison of working fluids, but in a more detailed design of ORC systems, the evaporation pressure of each fluid is highly dependent on the heat source temperature level as well as on the process optimization method. A more detailed thermodynamic analysis taking into account the temperature profiles in the heat exchang- ers is presented later in Chapter 5 and Chapter 7 for the studied applications. The vapor was superheated by 10 oC with all the fluids because a flow through type of evaporator was considered, which requires a superheating in the process (Talonpoika, 1996). Recuperator effectiveness of 0.6 was used which, enables the use of a recuperator, where the flow arrangement can also differ from the pure countercurrent flow configu- ration; and a feed pump efficiency of 60 % was used in the simulations. The turbine isentropic efficiency of 75 % was used in the simulations, which was evaluated as a real- istic value for the turbine efficiency when considering small-scale ORC turbines (Verneau, 1987; van Buijtenen et al., 2003; Kang, 2012). The thermodynamic analysis is structured as follows. First, the relation between the molecular weight and the critical temperature and the critical pressure is studied. Sec- ond, the relation between the cycle efficiency and the critical temperature is studied and discussed. Third, the relation between the critical temperature and the condensing pres- sure, the expansion ratio, and the enthalpy drop over the turbine are studied and discussed. 47

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