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Figure 11 is a photograph of the two-phase impulse wheel and nozzle assembly from a larger refrigeration installation. The nozzles are removable inserts. The turbine wheel, to the right, has blisk construction. Figure 11. Two-phase refrigeration nozzle assembly and rotor. Low Temperature Testing Figure 12 is a photograph of a Variable Phase Turbine system pilot plant. This is the world’s first closed cycle two-phase power plant. The VPT shown in the figure has a vertical axis and oper- ates with flashing refrigerants. Testing with flashing R227ea and R245fa refrigerants at the 7 kW level verified the design codes utilized for predicting performance. R134a has not yet been tested in the pilot plant. Refrigerant temperatures exiting the heater have been tested as high as 250 °F (limited by the heater capacity). In addition to performance testing, the unit has been operated for 150 hours to determine whether incipient erosion or cavitation would occur. The wheel showed no signs of either erosion or cavitation. ORC vs. VPC Pinch Point 220 200 180 160 140 120 100 80 60 Welch and Boyle 2 3 Heat Source ORC ORC Cut-off VPC VPC Cut-off Cooling Water 3 1 b 4 0% 10% 20% 30% 40% 50% 60% Heat Transfer 70% 80% 90% 100% Figure 13. VPC and ORC temperature profile comparison. ture sensible heat recovery4. Liquid working fluid is pressurized and then heated in the heat exchanger with no vaporization. The heated, pressurized liquid leaving the heat exchanger is directly expanded in a two-phase expander. The low pressure fluid is condensed, closing the cycle. Consisting of a pump, liquid heat exchanger, turbine, and condenser the VPC is a simple system with lower cost elements than most ORC systems. A significant advantage of this energy conversion system is the heat exchanger. Instead of a heat recovery boiler (which has a large separator drum and extensive operating and maintenance labor), a counter-current compact liquid heat exchanger is used to recover the geothermal energy. The boiling “pinch point” restriction is eliminated (Figure 13). VARIABLE PHASE TURBINE HEATER CONDENSER In the scenario shown, the ORC only captures 59% of the heat that is extracted by the VPC from the resource. This analy- sis assumed an adiabatic pump efficiency of 77%, an adiabatic turbine efficiency of 85% for the ORC turbine and 80% for the VPC turbine, and a gearbox efficiency of 98% for the ORC. The VPC generated 35% more net electricity than the ORC. Variable Phase Cycle: Analytical Comparison to ORC A study was conducted to com- pare the VPC to the ORC. The fluid chosen for the study was R134a, as its low critical temperature (214 °F) and widespread use are conducive to its use in low temperature geothermal. The component efficiencies were selected by The lack of an efficient, reliable two- phase turbine has prevented prior use of the VPC. REFRIGERANT CONTAINER Figure 12. Variable Phase Turbine operating in pilot plant. Variable Phase Cycle The Variable Phase cycle (VPC), also called the triangular or trilateral cycle, is the ideal thermodynamic cycle for low tempera- an independent party familiar with typical ORC performance (Table 2, overleaf). VPT efficiencies were calculated for the VPC expander model. 769 Results are shown in Figures 14a, 14b, and 14c (overleaf) for 250 °F, 300 °F, and 350 °F geothermal inlet temperature, Temperature (°F)PDF Image | New turbines to Enable Efficient Geothermal Power Plants
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