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It has been shown by means of experiment that: The temperature of a boiling (and superheating) ORC working fluid can be controlled by using protective staging when the hot resource temperature is significantly higher than the working fluid decomposition temperature. The heat transfer rate into the working fluid can be controlled be using variable fin densities in the evaporator, superheater, and economizer. The working fluid degradation/decomposition after 320 hours of hot run time was 30 ppm—an insignificant amount—suggesting the protective staging and variable finning approach was very effective. The safety hazard of direct exposure of a flammable fluid to a hot combustion gas was effectively mitigated in this experiment. There were no safety incidents involving the flammable fluid throughout this experiment. 2.6.2 Test Results The test was run for over 300 hours at conditions that produced a nominal working fluid temperature of 185°C. Figure 25 shows the variation of nominal working fluid temperature through the heat exchanger. The working fluid temperature was increased to a higher average temperature of 213°C during the last two runs. The test rig was operated for a cumulative time of over 333 hours. Data collected from the test consisted of the following: HX inlet flow profiles to determine flow uniformity at the HX inlet Thermocouple data at various locations in the heat exchanger Mass flow rates and pressure drop for the exhaust gas and working fluid Calorimetric data to measure heat leak from the HX shell to the environment Calorimetric data to measure net heat transfer from hot exhaust gas into the working fluid Wall temperature of the tubes to monitor excursions into high temperatures that risk fluid decomposition Chemical tests of the samples to determine the level of decomposition products Analysis of residuals in the HX tubes to assess fouling. 25PDF Image | Final Report Modifications and Optimization of the Organic Rankine Cycle to Improve the Recovery of Waste Heat
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