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Organic Rankine Cycle Diesel engines lose about 30-40% of the input energy in the exhaust. Organic Rankine Cycles (ORC) look to take this low temperature heat source and improve the overall efficiency of the engine or produce electricity directly. Some estimate the efficiency of an ORC unit to be about 10-20%, which would improve the overall engine efficiency by about 3-5%. An ORC unit works very much like that of a traditional steam Rankine Cycle: a working fluid is pumped through a heat exchanger where it is vaporized and passed through a turbine and then re-condensed, and then the process is repeated. The big difference is in that of the working fluid. The traditional Rankine Cycle uses H2O as its working fluid with has a high boiling point. Since the waste heat from the engine is a low temperature source H2O will not work. So an ORC unit uses some organic fluid as its working fluid. Choice of the working fluid will depend on the heat source and some companies have their own special blend that allows them to capture heat at low temperatures. ORC units have been installed in various places. Ormat, a leader in the ORC technology, has units in North America, Europe and Asia1. These units, however, are being installed on an industrial scale, ranging from 200 kW to 22 MW. For use on a diesel generator one would be looking for a unit less than 100 kW for the most part. Not many units have been built at this size, although there are companies with them in the works. In order to get a better grasp of the state of this technology it is will be helpful to look at these companies individually. Editorial comments will be left out as much as possible with the hope that the facts gleaned from the companies websites and through personal contact will be enough to show how close we are to seeing an ORC unit installed with a diesel generator as a way to capture waste heat. ORC Companies After a thorough web search, seven companies were found that use ORC technology in their products. Some of these companies specifically targeted the waste heat from diesel engines while others were broader in their application. The companies looked at were Global Energy, Barber-Nichols, ElectraTherm, TransPacific Energy, Deluge Inc., Ormat, Turboden, UTC Power and GMK. Each company will be looked at in turn. Global Energy Global Energy, a Madison, WI company under the leadership of Greg Giese, has developed the Infinity Turbine ®. This is an ORC turbine built for waste heat and geothermal applications. While there are potentially numerous uses for this turbine one that is specifically being targeted is the diesel engine exhaust. According to the website, the Infinity Turbine consists of a single skid-mounted assemble that fits in the standard 20 or 40 foot ISO standard shipping container. All the equipment required for the power 65PDF Image | Optimizing Heat Recovery Systems for Power Generation in Rural AK
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