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2nd European Conference on Polygeneration – 30th March -1st April 2011 – Tarragona, Spain Maximum values of 14% to 15% of electric efficiency can be expected between 5.5 MW and 6.3 MW. The design efficiency of the cycle, predicted with 16.37% (at 5.8 MW) by the manufacturer could not be reached [4]. In the low operational range the point form two parallel clouds. These accumulations of states represent winter operation (upper) and summer operation (lower). In the summer mode even lower thermal inputs are recorded as the system is being run including the re-cooling unit which assures safe continuous operation. Discussion As the annual plot of efficiency values shows, heat guided ORCs do not necessarily have a large operational range on a comparably high efficiency level. Various parameters influence the achieved efficiency in a negative way. In theory it may well be that the thermal power input in the system does not affect the degree of efficiency noticeably. Lower loads on the biomass furnace lead to lower feeding temperatures in the thermal oil system. As the characteristic of the evaporator shows this has great influence on the upper system pressure and thus the pressure difference at the turbine. Between the evaporator and the turbine inlet safety and control fittings, for instance cut-off valve, a control valve and a steam filter are situated. Depending on the mass flow in the system and the particles in the filter the pressure losses here are in a range between 0.3 bar and 0.7 bar. The condenser’s behaviour usually is governed by the return temperature of the sink system. In the analysed plant the excess heat rejection unit is situated parallel in a loop with the condenser. The set point temperatures of the network feed is determined by ambient temperature. If this feed temperature level is exceeded the water is cooled down by the heat rejection unit and fed back to the return. The results show that the condensate pressure level is mainly a function of the feeding temperature and the mass flow on the secondary side. Using the vacuum pump to decrease the condenser pressure, besides the removal of gaseous agents, does not make sense in terms of economy. Assuming that the pump can achieve a maximum vacuum of 60 mbar and knowing that a variation between 90 mbar and 140 mbar leads to a rise of efficiency of less than 0.5%, a maximum further increase of 0.3% in electric efficiency is obtained if the pump is fully operating. For a generator with 500 kVA power and 1.1 kVA nominal power of the vacuum pump, the gain of 1.5 kVA stands versus a consumption of 1.1 kVA. Taking into account wear on the vacuum system and the loss of several litres of MDM a day the disadvantage of this strategy is quite obvious. Additionally the pressure difference has to be compensated by the feeding pump. Furthermore the experiences of the year 2010 clearly showed that the excessive usage of the vacuum pump leads to a low filling level of the cycle. The feeding pump is no longer capable of delivering the requested life steam pressure and volume as the hotwell runs dry. This causes unstable (dynamic) operation at a low pressure level. The findings lead to several conclusions for economic operation of ORCs. The heat transfer characteristic of the condenser is mainly governed by the secondary sides temperatures and mass flows. Higher mass flows cause a lower temperature spread and increase turbulences; therefore the heat transfer coefficient rises. To find an overall optimum, the higher consumption of the network pumps has to be taken into consideration as well. In addition the usage of synchronous alternators at a fixed speed leads to a low turbine admission at low silicone oil mass flows and causes stall. Thus lower enthalpy drops have to be expected. The comparably high isentropic efficiencies cannot be put into practice. This leads to part load conditions at the alternator at lower efficiency, which results in even lower yield. Load states with low mass flows of silicone oil should be avoided in terms of efficiency. The results of the OR-cycle show clearly that the operation has not yet been optimal. The designed peak power could not be reached in daily operation. The upper pressure level of the cycle does not meet the specifications. The turbine characteristic appears to differ from the design data. Fast running small asynchronous engines can reach higher isentropic efficiencies in such cases. 9PDF Image | ElectraTherm Green Machine 190 to 240 F
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