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Table 4 - Air Squared expander specifications 4.2.1 Thermodynamic Calculation The heat exchangers were sized using thermodynamic calculations for heat transfer. These calculations used the NTU-effectiveness method where: Parameters Expansion Ratio Max Rotation Speed Max Pressure Displacement Generator 4.1.2 Radial Turbine Value 3.5 3600 RPM 13.8 bar 12 cm3/rev Magnetic Coupling 240 V, 50 Hz ( 3) The University of Canterbury is developing a small radial turbine for use with the ORC-B test bed. Turbines are the most difficult and expensive component to acquire in large ORC systems, and so a method has been developed which allows the turbine wheel of an automotive turbocharger to be used as a radial turbine. The pressure ratio of an automotive turbocharger is considerably less than that experienced during operation of an ORC. Despite this the design is similar and the cost significantly less than other radial turbine technology. This approach will make turbines for small scale ORC systems more affordable. The modification of an automotive turbocharger involves the selection of a turbocharger, evaluation of turbine wheel performance, casing design, development of a lubrication system, and selection of all auxiliary components such as bearings and seals. The proposed design of the ORC turbine, shown in Figure 8, was developed by retrofitting a small turbocharger from a petrol driven vehicle. Figure 8 – Radial turbine using an automotive turbocharger 4.2 Heat Exchangers Two heat exchangers are required within the ORC-B system: an evaporator and condenser. Shell and tube heat exchangers are typically used for full size ORC systems. A scaled down version of these shell and tube heat exchangers is not possible due to manufacturing limitations. Instead plate heat exchangers will be used for both the evaporator and condenser. Plate heat exchangers allow a compact solution for liquid to liquid heat transfer. (see Shah, R. K. &Sekulić, D. P. Fundamentals of heat exchanger design Wiley Online Library, 2007). The Number of Thermal Units (NTU) calculated from Equation 3 allows the heat exchanger effectiveness to be estimated for the experimental counter-flow heat exchanger data from Shah (Shah, Sekulic, 2007) as shown in Figure 9. This method allowed the correct selection of the heat exchanger to match the duty from the thermodynamic model. Figure 9 - Effectiveness vs NTU for a counter-flow heat exchanger ( 4) The process was repeated iteratively to allow the correct model of heat exchanger to be selected that gives the desired transfer of heat. The Kaori brazed plate heat exchangers selected are designed for use as refrigeration evaporators and condensers to allow phase change. They were found to offer a greater selection than competing products and can operate at pressures of up to 45 bar. Figure 10 - Kaori K205 evaporator 35th New Zealand Geothermal Workshop: 2013 Proceedings 17 – 20 November 2013 Rotorua, New ZealandPDF Image | DESIGN AND BUILD OF A 1 KILOWATT ORGANIC RANKINE CYCLE POWER GENERATOR
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