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For this project, the installation and instrumentation (steam loop, hot water loop, cold water loop, electrical circuit, signal/monitoring/control circuits, data acquisition system) process is very smooth. FINDINGS OF THE GM INFORMATION During the commissioning, a couple of design issues have been discussed: 1. The selected low temperature ORC heat engine (or GM) may be easily converted from a 50kW capacity into a 65kW capacity. 2. A system computer program imperfection to cause emergency shutdown of the ORC system resulted from starting the system under undesired heating flow condition (i.e. high temperature) is not expected. It may not cause any damage to the system but is undesirable. This can be easily overcome by following correct starting procedure or adding control capability into the installed heating loop. Some of the System Limitations: 1. GM has a maximum power output of 50kW so it has a limitation on the conversion of heat into power. Excessive heat may become waste. 2. GM may shut down if the voltage and frequency fluctuations are high for the location where it is installed (Voltage fluctuations greater than ±5V and frequency fluctuations greater than 10%). 3. GM starts only when the temperature difference between hot and cold side is greater than preset value. The pre set value can be changed between 50oF to 80oF. 4. GM initial (i.e. when we start the machine) power output is set by a predefined equation which is a function of temperature difference between hot and cold side (ΔTH-C). If the initial temperature difference (ΔTH-C) is greater than 170oF then the starting power output of GM is greater than 50kW and the machine over speeds and shutdowns. So the initial ΔTH-C should not be too high for the machine to start smoothly. 5. The GM has a hot water supply temperature limitation of 245oF. If the temperature is above this value, GM shutdowns. 6. GM has a minimum net power output limit of 5kW. 7. The components of this ORC system are capable to stand for 65kW output. The system can be modified to increase its power capacity from 50kW to 65kW without too much of work. The system efficiency varies not much across a wide range of input heat. The performance is better than expected and may make the system applicable to a wide range of size of engines. (Examples: At 627kW and 225oF heat source, the engine operates with rated outputs of 50kW and the system efficiency is 8.2%. At 257kW heat source and 155oF, system efficiency is 5.6%.) At a given heat source temperature, the system efficiency varies not much against flow rate. This performance is also better than expected. This may make the system more suitable for engines at different loads. (Example: With the heating source at 86oC, the efficiencies of the system are around 7.52%, 7.53%, and 7.43% for the respective flow rates of about 120gpm, 200gpm, and 300gpm.). The reduced efficiency at 300gpm is resulted from the increased parasitic power of the working fluid pump. 56PDF Image | Optimizing Heat Recovery Systems for Power Generation in Rural AK
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