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Task 4: First Prototype Direct Evaporator Evaluation GE GRC-Niskayuna commissioned a heat exchanger vendor to manufacture a Direct Evaporator prototype. This task culminated in a test of the prototype Direct Evaporator. The results of the test were documented in Milestone Report 5, “Test Bed and Fouling Tests.” 2. RESULTS AND DISCUSSION 2.1 Working Fluid Selection 2.1.1 Performance ORC systems offer a wide range of parameters for optimization, with the most obvious being the selection of working fluid. The working fluid selection dictates the operating pressures on the condenser and evaporator side, expander design, need for a recuperator, etc. The operating pressures are strongly dependent upon the available heat source and sink temperatures. For different combinations of heat source temperature range and heat sink temperature range, there would likely be a different optimal fluid. To simplify the optimization process, the initial down-selection process focuses on cycle performance, with other considerations introduced later in the process. The selection of the optimal working fluid is the result of a systematic comparison of over 40 different fluids on the basis of their suitability for use in an ORC cycle. Fluids were compared on the basis of chemical stability, flammability, toxicity, performance under the boundary conditions of the gas turbine exhaust application, and environmental risk in the event of a leak. Other considerations that factor into working fluid selection include corrosiveness and tendency to foul. When selecting a fluid, cost was not considered a factor since the pressure level, component selection, operating temperature, and other attributes—independent from fluid choice—most influence cost. The candidate fluids fall under five broad chemical groups: 1. Simple aliphatic hydrocarbons, such as butane, pentane, and hexane, are attractive because their near-ambient boiling points enable condensation near atmospheric pressure 2. Fluorinated (or otherwise halogenated) hydrocarbons (including most refrigerants), are attractive because of their efficient expansion behavior and lack of need for a recuperator 3. Aldehydes and ketones are variations on simple hydrocarbons that can be chosen so as to combine the benefits of hydrocarbons and refrigerants 4. Silicones with extremely high chemical stability at elevated temperatures to guarantee continued performance over the lifetime of the machinery 5. Aromatic hydrocarbons that combine high stability with good expansion properties, but generally boiling well above ambient temperatures. Perfluorocarbons, chlorofluorocarbons, and hydrochlorofluorocarbons have very attractive properties for the ORC, but unfortunately have an extremely high greenhouse warming potential, and therefore were not considered. The down selection of working fluids was based primarily on performance in an ORC subject to the constraints identified above. Further selection was guided by consideration of the stability of the chemical at high temperature, health hazards, and potential to cause environmental harm. Important characteristics that govern working fluid performance are as follows: A high stability and critical point such that the fluid may be boiled at a relatively high temperature, allowing the recovery as work of a relatively high fraction of the embodied heat energy (enthalpy) of the fluid. The use of fluid blends versus a single fluid presents concerns over unmixing. 8PDF Image | Final Report Modifications and Optimization of the Organic Rankine Cycle to Improve the Recovery of Waste Heat
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