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ADVANCED MANUFACTURING OFFICE Barriers Accomplishments • Most commercial ORC systems use a flammable hydrocarbon working fluid. If the evaporator were to develop a leak, the flam- mable working fluid would leak into the hot exhaust stream and create a potential fire hazard. Additionally, an evaporator placed directly in the exhaust stream poses the risk of heating up the working fluid to the point that it rapidly decomposes, forming decomposition byproducts. This can reduce cycle efficiency and cause potential fouling of the heat exchanger tubing. • It is common for ORC systems to cost $2,500/kW and above. At this cost, most of the available waste heat recovery opportuni- ties are not economically viable. Pathways To eliminate the limitations caused by the secondary heat transfer loop, researchers developed an advanced ORC system by using a novel direct evaporator approach, which was based on conceptual designs that had been developed by GE. This research effort accelerated the development of the technology through research in flammability, two-phase heat transfer, and experimental validation. Milestones This project started in 2008 and concluded in 2013. • Detailed design and modeling of evaporator • Design and construction of partial prototype test facility • Working fluid decomposition chemical analyses • Test-bed heat transfer evaluation • Design, build, and test prototype evaporator in ORC cycle • A prototype ORC system using direct evaporation technology was fabricated and tested • A process to evaluate and select an optimal ORC working fluid was developed • Safety risks associated with the direct evaporator design were evaluated and mitigation strategies developed Commercialization GE will initially focus on pairing the developed direct evaporator ORC technology with existing GE turbines and engines; specifi- cally the small-frame gas turbines offered by GE Oil and Gas operations, and the natural gas reciprocating engines offered by its Jenbacher operations. After GE has evaluated and proven the reliability of its ORC cycle in a sizable installed base of GE engines and gas turbines, it will then be able to adapt this ORC technology to a broader range of applications, especially those utilizing industrial sources of heat. Project Partners Idaho National Laboratory Idaho Falls, ID Principal Investigator: Donna Post Guillen E-mail: Donna.Guillen@inl.gov General Electric Corporation, Global Research Center Niskayuna, NY For additional information, please contact Bob Gemmer Technology Manager U.S. Department of Energy Advanced Manufacturing Office Phone: (202) 586-5885 E-mail: Bob.Gemmer@ee.doe.gov Project final report available at www.osti.gov/scitech: OSTI Identifier 1116747 For more information, visit: manufacturing.energy.gov DOE/EE-0484 • Updated June 2017 Concept schematic of a direct evaporator for an Organic Rankine Cycle system. Illustration courtesy of Idaho National Laboratory. For more information, visit: manufacturing.energy.gov DOE/EE-0463 • Updated June 2017PDF Image | Improving Recovery of Waste Heat in Industrial Processes
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