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Application of Organic Rankine Cycles (ORC)

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Application of Organic Rankine Cycles (ORC) ( application-organic-rankine-cycles-orc )

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1. Introduction to Organic Rankine Cycle In chemical industries as well as in the production of food, paper, cement etc. a lot of thermal energy is needed. During these processes the heat carrier cools down to a temperature level where the residual heat can’t be used for the primary process. If the residual heat cannot be used for subsequent processes like drying granulates, the conversion of the waste heat to electricity may be an option. Organic Rankine Cycle (ORC) is a technology that can convert thermal energy at relative low temperatures in the range of 80 to 350 °C to electricity and can therefore play an important role to improve the energy efficiency of new or existing applications. Beside industrial waste heat alternative heat sources such as solar and geothermal energy as well as biomass can be applied. To better understand the Organic Rankine Cycle the process of a very simple conventional steam power plant (also called Clausius Rankine Cycle) is presented, see Figure 1. In a steam power plant the thermal energy is converted to electricity as water passes through a sequence of state changes. To implement these state changes the components like a turbine with generator, condenser, feed pump and boiler are needed. Figure 1 Left, middle: T,s-Diagram and corresponding schematic of a simple conventional Rankine Cycle; right: Carnot efficiency and electrical efficiency of a Rankine Cycle with various working fluids Superheated steam passes into the turbine with high temperature and pressure (state 1). The turbine converts the thermal energy into mechanical energy, which is converted to electricity by the generator. While the turbine extracts energy from the steam the pressure and temperature decrease. If the expansion exceeds the saturated vapor curve wet steam occurs which may erode the turbine blades due to the impact of water droplets. The cool low pressure steam at turbine exit (state 2) is condensed to liquid water (state 3) and pressurized (state 4) by the feed pump. By adding heat to the water, steam is generated and superheated within the boiler. Now the condition before turbine (state 1) is reestablished and the thermodynamic cycle is closed. The water steam cycle is suitable for turbine inlet temperatures above 350 °C. At lower temperatures the efficiency significantly decreases and the danger of erosion due to droplets increases because the expansion goes deep into the wet steam region, see Figure 2. By decreasing the turbine inlet pressure the steam quality at the end of the expansion can be improved. However, wet steam still exists and the efficiency additionally drops. ORC overcomes these problems by using an organic fluid, e. g. Pentane, instead of water (therefore it’s called Organic Rankine Cycle). Organic fluids have lower boiling temperatures than water which make them suitable to explore heat potential with temperatures below 350 °C. By adoption of the working fluid to an existing waste heat temperature higher efficiencies can be achieved than with a conventional steam cycle. Figure 1 (right) shows the electrical efficiency as a function of the turbine inlet temperature for several working fluids as well as the Carnot efficiency (the theoretical maximum). Many organic working fluids have an “overhanging” saturated vapor curve with the advantage that die expansion always ends within the superheated and therefore dry region, see Figure 2 (right). This way the danger of blade erosion is excluded and a low maintenance operation is assured. In general, the ORC technique is characterized by its robustness, compact design, high ability for automation and the comparatively high efficiency.

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