DESIGN AND BUILD OF A 1 KILOWATT ORGANIC RANKINE CYCLE POWER GENERATOR

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DESIGN AND BUILD OF A 1 KILOWATT ORGANIC RANKINE CYCLE POWER GENERATOR ( design-and-build-1-kilowatt-organic-rankine-cycle-power-gene )

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PROSPECT • Analyse Possible Resources • Conceptual Design Modelling • Feasibility Analysis Design and Simulation • Component Selection • Fabrication • Build and Commission The extractable heat resource is limited in order to meet the requirements outlined in Table 1. A limit of 30 kW is set to ensure the extracting heat exchanger causes minimal pressure drop and is compact. The limit also prevents the exhaust temperature dropping below 100°C. Preliminary calculations show that a fin and tube heat exchanger will be capable of extracting up to 30 kW without exceeding the tolerable pressure drop. 3.2 Cooling Resource The primary cooling options available on-site were: air cooling, water cooling or air cooling using a water tower. Due to the small scale of this system it was determined that water cooling would be the easiest option. The estimated water wastage of 100 tons/year was deemed to be acceptable. A cooling tower would be recommended for a larger system to reduce wastage. Figure 2 - ORC design guideline This design guideline was used where applicable throughout the design of the ORC-A system. The feasibility analysis completed was brief for this system as it was pre- determined that a test bed would be designed. All of the steps are linked as this is a highly iterative process: any changes require reconsideration of the previous steps. 3. PROSPECTING The preliminary phase of ORC design requires the prospective heat resource to be assessed for use with an ORC system. This involves visiting the site and collecting any important information regarding the potential resource. It is important to fully understand the resource before commencing the design of the ORC as typical waste heat and geothermal resources have limiting factors or special requirements, such as reinjection or minimizing effect on the resource. The details of water or air cooling also need to be considered as these will affect the size and efficiency of the plant. 3.1 Capstone Gas Turbine The selected heat resource for the ORC-B is the waste heat produced by the exhaust of a 30 kW Capstone Diesel Turbine. This heat resource is easily assessed as the waste heat specifications are well documented. There are minimal special requirements for this heat resource, as the heat would otherwise be vented to atmosphere. Table 1 - Capstone turbine waste heat resource parameters Table2 - Water cooling parameters Parameter Water Temperature Water Flow Rate 3.3 Conceptual Design Value 15°C 0.5 kg/s Parameter Resource Type Temperature Mass Flow Total Waste Heat 1. 2. 3. Specification Hot exhaust gases. Clean gas. 220°C 0.3 kg/s 90 kW Exit temperature must remain greater than 100°C for the gas to leave the exhaust flue. Heat exchanger back pressure must be less than 1kPa to prevent reduction in the Capstone efficiency. System safety is paramount as the location is accessible by students. 30 kW of thermal energy. The data from the initial prospecting allows the conceptual design of an ORC system that will meet the required specifications. An ORC system coupled with a thermal oil extraction loop is proposed. The thermal oil extraction loop allows greater controllability of the system and allows the ORC system to be located further from the Capstone turbine. Figure 3 - Conceptual design of the ORC unit 3.3.1 Working Fluid To further develop the conceptual design of the ORC system the potential working fluids need to be determined. The working fluid is a limiting factor in ORC design as it affects the thermodynamic design and performance of all components within the system. The refrigerant also influences the required pressure rating and material type of all components in the system. Common refrigerants used for ORC systems were analysed and are summarized in Table 3. 35th New Zealand Geothermal Workshop: 2013 Proceedings 17 – 20 November 2013 Rotorua, New Zealand Limiting Factors Extractable Resource FEASIBILITY • System DESIGN • Detailed CONSTRUCTION

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