Small Scale Organic Rankine Cycle (ORC)

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Small Scale Organic Rankine Cycle (ORC) ( small-scale-organic-rankine-cycle-orc )

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Energies 2017, 10, 413 2 of 26 At present, ORC is a mature technology in the MW power range [4]. However, the downsizing of this technology poses challenges that make small-scale ORC still unattractive at the commercial level. In fact, the plant specific cost (e/kW) for small-scale applications is still too high to guarantee a reasonable return on investment. In this work, the specific cost for competitive ORC plants will be quantified as the ratio of ORC unit cost and power output. The ORC market capacity in the range of 1–100 kW is small, with an approximated installed capacity worldwide of 4.95 MW [5]. Despite the large market potential for small-scale ORC, the high specific cost of the technology makes it currently uncompetitive compared to other existing technologies (e.g., wind, solar, etc.). To this end, the efficiency of the ORC components should be improved to maximize the power production of such power plants, whilst keeping their cost as low as possible. A compromise between these two parameters is essential for the future development of ORC for decentralized power production. Several ORC architectures have been presented in the literature with added components to the basic thermodynamic processes with the aim of increasing the performance of the system. However, in small-scale ORCs, a simpler plant schematic is usually preferred, which is mainly driven by its capability of a lower specific cost. The cost of the power plant needs to be low enough to guarantee a decent payback period to the end user. Small power plants are intended to be installed in industrial or civil facilities in which specialized technicians are not available to face system breakdowns. Therefore, low pressure levels, limited turbine rotational speed and non-toxic organic fluids need to be used, thus enforcing the limits to the options generally available in ORC design. The aforementioned limitation on thermodynamic and technical parameters lowers the optimal performance of the cycle. Thermo-economic analysis has been implemented to minimize the cost of ORC systems. However, it is important to mention that the cost engineering techniques often lead to high discrepancy compared to the realistic cost. Lemmens [6] applied cost engineering techniques to estimate the price of an ORC and concluded that the results may diverge by up to +30%. Lecompte et al. [7] proposed a novel framework for the multi-objective thermo-economic optimization of ORC systems. Quoilin et al. [8] show how the optimal working fluid and thermodynamic conditions change when considering as the objective function the minimization of the specific cost of the system rather than the cycle performance. Cavazzini and Dal Toso [9] studied a commercial ORC for small-scale applications to retrofit an internal combustion engine. They stated that the system under investigation was not feasible due to high costs. Whiye and Sayma [10] proposed a method to improve the economies of scale of small-scale ORC systems. They demonstrated that ORC systems can be fitted with a single radial inflow turbine when in the 2–30-kW range of power output. The design of ORC components is widely discussed in the literature. The need for competitive e/kW systems has led to the investigation of low-cost heat exchanger solutions. Lazova et al. [11] proposed an innovative helical coil heat exchanger for supercritical ORC systems that improved the heat transfer coefficient and hence the cycle efficiency. Bari and Hossain [12] adapted a commercial shell and tube heat exchanger to recover heat from the exhaust gas of an internal combustion engine. From the experimental results, the power output of the engine was increased by up to 23.7%. Longo [13] ran experiments on a Brazed Plate Heat Exchanger (BPHE) using R134aas the working fluid. He claimed that the heat transfer coefficient of the super-heated vapour is from 3–8% higher than the one of saturated vapour. Different experimental setups have installed BPHEs because of their wide availability, low cost and size. BPHEs have been the prevailing choice in small-scale ORC systems that are commercially available. The pump absorbs a percentage of the power produced by the expander, which varies depending on the organic fluid considered. Quoilin et al. [14], in their ORC survey, observed that the power consumption of the pump has a non-negligible impact on the net power the system can deliver as opposed to what occurs in the Rankine cycle. They show that the percentage of the power absorption of the pump may exceed 10% of the power produced by the turbine, when considering fluids such as R 1234yf and R 134a.

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