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Table 1. Waste heat recovery technologies. Rankine Cycles Organic Turbo-expander Small turbine Size Steam Thermoelectrics Large turbine at No turbine. temperatures <500°C Performance Efficient at source temperature less than 500°C Efficient at source temperatures above 500°C. Current technology has lower efficiencies than Rankine cycles. Maturity Field-proven in waste heat recovery and geothermal applications. Field proven in large combined cycle applications. Field proven in remote (e.g., pipelines) and harsh (e.g., space) applications. Cost Barely cost effective at low source temperature less than 500°C. Cost effective at temperature above 500°C. Current technology is expensive on a per kilowatt basis. Temperature Limitations Organic fluids must be kept below 320°C for thermal stability. Maximum temperature dictated by metallic components, not fluid. Off-the-shelf materials work at <250°C. More exotic compounds work at 1000°C. Technical Challenge Organic fluid stability and flammability require secondary heat transfer loop A compact and efficient small-scale steam turbine. New material breakthrough. 1.2 Project Goals and Objectives The purpose of this project is to develop and demonstrate a Direct Evaporator for an ORC system. The focus of this effort is land-based gas turbines, which are used in a broad range of applications to produce both shaft and electrical power. Most commonly known for generating electricity either as peaking units or as base load units, they are also used to directly drive pumps, compressors, or other machinery requiring shaft power. Simple cycle gas turbines have the advantage of a short startup time relative to coal-fired and nuclear units. However, they incur a significant penalty on their efficiency. Large-frame gas turbines usually are combined with bottoming steam-based Rankine cycles to increase the overall efficiency of the system and thereby improve their cost performance. Small-frame gas turbines with exhaust temperatures around 500°C could, in principle, benefit from steam bottoming cycles, but rarely use them in practice because of the high capital cost of the steam system. Particularly for base-load small-frame gas turbines, akin to those used in pipeline applications, an increase in efficiency is highly desirable. This technology improves cycle efficiency and cost by eliminating the usual secondary heat transfer loop. The project’s technical objective is to eliminate the pumps, heat exchangers, and all other added cost and complexity of the secondary loop by developing an evaporator that resides in the waste heat stream, yet virtually eliminates the risk of a working fluid leakage into the gaseous exhaust stream. The research team comprising INL and GE engineers has leveraged previous research in advanced ORC technology to develop a new direct evaporator design that will reduce the ORC system cost by up to 15%, enabling the rapid adoption of ORCs for waste heat recovery. Currently available technology employs an intermediate heat transfer loop between the hot exhaust stream and the ORC evaporator. This precaution regulates the maximum temperature that the working fluid can reach and prevents accidental leaks of fluid into the exhaust stream. This over-conservative 4PDF Image | Final Report Modifications and Optimization of the Organic Rankine Cycle to Improve the Recovery of Waste Heat
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