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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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Table 3 - Refrigerant Selection 3.3.3 Thermodynamic Modeling A thermodynamic model of the conceptual design shown in Figure 6 was developed in Engineering Equation Solver (EES) and validated against experimental data from Quoilin (Quoilin, Lemort, & Lebrun, 2010). The model was then adapted to use both the available resource temperatures and expected performance characteristics of the system components. Estimates could then be made for the duty of each of the four major components within the system. The thermodynamic cycle simulated by this model is shown in Figure 4. Working System Fluid Efficiency R-134a 5.0 % R-245fa 5.7% R-365mfc 5.5% HFC-M1 Blend 5.7% (50/50) n-Pentane 5.9% R-141b 6.0% Advantages Readily available, Handling safety Good performance Handling safety Good performance, Available in New Zealand Excellent performance Excellent performance Disadvantages Poor performance, High pressure Not readily available in New Zealand Not readily available in New Zealand Thermodynamic properties are not well documented Flammability risk Ozone depleting The ORC-A system used R-134a as the working fluid as it is readily available, low cost and widely used in the refrigeration industry. The thermodynamic performance of R-134a at temperatures exceeding 50°C was found to be incredibly poor. Higher operating pressures also decreased the safety factor of experimental components. For these reasons it was decided that a more efficient refrigerant should be chosen. A refrigerant mix known as HFC-M1 was selected for use with the ORC test bed. HFC-M1 is a mix of 50% R-245fa and 50% R-365mfc. This mix of refrigerants is more readily available in New Zealand than its virgin constituents as it is used as a blowing agent by the polymer industry. A boiling temperature of 30°C at atmospheric conditions also increases the ease of handling of this refrigerant. The refrigerant offers several benefits over water, such as the lower boiling temperature and dry saturation curve. This is beneficial to the system performance as it means the vapour flowing through the turbine is not a wet mixture. 3.3.2 Heat Extraction Loop A thermal oil extraction loop will be used to transport the thermal energy between the Capstone exhaust and the ORC system evaporator. This provides many benefits to the system design, such as: preventing degradation of the refrigerant due to high film temperatures, additional safety as the oil is non-flammable, as well as making the system easier to control in a laboratory environment. It also allows the ORC system to be designed around a liquid heat source which is more relevant for geothermal applications. The addition of a thermal extraction loop adds extra complexity to the cycle; an additional heat exchanger is required as well as an oil pump, which reduces the overall electrical output of the system. This is not necessary for future geothermal plants. The thermal oil selected from Petro-Canada is known as Calflo HTF. The oil was selected as it is readily available, operates at the required temperature range and has a reasonably low viscosity. A reduced viscosity is desirable as it minimizes the required pump work and increases the heat transfer. Figure 4 - Thermodynamic T-s diagram of conceptual design The duty of each component and proposed operating conditions are shown in Figure 5. Pevap = 695.8 [kPa] Tevap,sh = 80 [C] refrigerant$= r245fa Tdelta,superheat = 5 [C] Evaporator Tevap,sat = 75 [C] 20207 [W] Turbine Wexp = 1204 [W] Wgen = 1084 Vratio,exp = 3.432 [-] 56.03 [C] 211 [kPa] Condenser Tcond,sat = 35 [C] 19055 [W] Tdelta,subcool = 5 [C] Tcond,out = 30 [C] thermal = 0.05703 pump,isen=0.65 [-] m=0.09 [kg/s] Figure 5 - Steady state model of conceptual design 3.2.3 System Efficiency The system efficiency for an ORC system is a key performance parameter and is defined as: ( 1) The thermal efficiency estimated for this design is 5.7%. The efficiency of an ORC system is typically very low due to the low resource temperatures which they utilize. The 35th New Zealand Geothermal Workshop: 2013 Proceedings 17 – 20 November 2013 Rotorua, New Zealand

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