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2.6 Prototype Test 2.6.1 Testbed and Equipment Figure 24. Direct evaporator installed at GE test facility. Figure 24 shows the direct evaporator and supporting equipment installed at the GE test facility. The testbed consisted of a cooling water loop, direct evaporator prototype, hot exhaust gas supply, working fluid loop, compressor, container/trailer, and leak containment. The test and setup were designed to characterize an experimental heat exchanger with the working fluid cyclopentane in the direct path of an exhaust stream to simulate the heat exchanger behind a GE PGT25 gas turbine. The working fluid cycled in a loop consisting of the test heat exchanger, a heat recovery vapor generator (HRVG) (Deltak, Inc.), a condenser (Thermal Products Inc.), and a pump (ChemPump). The pressure in the system was maintained by a rack of hydraulic piston accumulators (Pearse Bertram). The maximum temperature of the vapor exiting the Heat Exchanger (HX) superheater (I-16) is 250°C, and the system pressure was controlled at 508 psia (35 bar) as measured at the inlet to the HX. Prior to entering the pump, fluid is condensed and subcooled to approximately 165°C. This test was run via a remote station equipped with remote monitoring cameras on the heat exchanger and on the inside of the container. After a short performance characterization test, the system was run for >300 hours with periods for ramping and deramping the system with predetermined sampling intervals to measure the degradation products. Prior to starting full-scale tests with flammable cyclopentane, a detailed shakedown plan was drawn up to test various subsystems and procedures with a benign chemical (10% alcohol/water mixture). Performing a full subsystems and procedures shakedown test with the above fluid allowed a further benefit of precleaning the test rig before finally charging with cyclopentane. One of the main features of the protective staging concept was that it mitigated the risk of high wall temperatures in the working fluid loop. Furthermore, variable fin density in each of the three sections of the heat exchanger (economizer, evaporator, and superheater) on the outside of the working fluid tubes was used to control the heat flux into each section. It was generally observed during the experiment that even where the hot exhaust temperature was >400°C, the wall temperature of the finned tubes remained below 300°C. Therefore, the fluid was not exposed to high-risk temperatures, validating the effectiveness of the protective staging concept and the design of the heat exchanger. 24PDF Image | Final Report Modifications and Optimization of the Organic Rankine Cycle to Improve the Recovery of Waste Heat
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