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13 ORC speed In order to keep ORC small in size, safe in operation and efficient, right speed for ORC shall be selected. In some cases the turbine, pump and generator are on the same shaft and they rotate in same speed. In this case, ORC speed means pump, turbine and generator rotational speed. Not optimizing the speed in an ORC may lead to damages to seals of turbine, limitations for usage of hermetic type of expanders and necessity for gear boxes. This will all add to maintenance cost and complexity of the system. Depending on application, there will be an optimum power to achieve smaller sizes and cost for ORC. Square root of this optimum power is proportional to inverse of speed. As an example, for a 250 kW ORC, speed of 400 round per second would be the option. This can help to choose speed for other powers as well. Selecting right power and speed will cause good efficiencies and low cost for both mechanical and electrical equipment. Using optimum speeds in ORC will omit the necessity to use vacuum and oil pumps, shaft seals and gear box which will make the system so cost effective. It should be noted that working at not optimum speeds will necessitate usage of gear box. Gear boxes cannot be lubricated with low viscosity lubricants like working mediums, hence, optimum speed will help in removing the gear box and its lubrication consequently. Since removing oil can help the shaft seals to work properly; systems with no shaft outlets or hermetic design will be an appropriate option to achieve best component performance with usage of optimum speed. In order to easily compensate the thrust load on thrust bearings via pressure distribution, and to have minimum starting torque on radial bearings, vertical shafts for rotors can be selected. The bearings can be lubricated with fluid in liquid or vapor states. This will help in more compact designs for ORC unit if right speed has also been chosen and no gear box is needed. Applying the hermetic design will only needs a few labyrinth seals and the leakages will pass to condenser, while shaft outlets are removed and no tight sealing, lubrication or vacuum pumps are necessary. This makes the system so low maintenance. All in all, choosing the right speed for ORC will reduce the size of unit, complexity and cost of the system. A study47 suggests that most efficient high speed ORC units are 250kW ones. Since they are modular units, they can be combined to produce more powers efficiently. 47 J. Larjola, Electricity from industrial waste heat using high‐speed organic Rankine cycle (ORC), Int. J. Production Economic 1995; 41: 227‐235. 55PDF Image | Exergy
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