The Organic Rankine Cycle (ORC) - Ibge
The Organic Rankine Cycle (ORC) - Ibge
The Organic Rankine Cycle (ORC) - Ibge
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23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
CHP: Technology Update<br />
<strong>The</strong> <strong>Organic</strong> <strong>Rankine</strong> <strong>Cycle</strong> (<strong>ORC</strong>)<br />
ing. Bruno Vanslambrouck,<br />
Howest, dept Masters Industrial Sciences<br />
Laboratory of Industrial Physics and Applied Mechanics<br />
1 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
Contence<br />
• <strong>The</strong> (<strong>Organic</strong>) <strong>Rankine</strong> <strong>Cycle</strong><br />
• Working Fluids<br />
• Relevant applications<br />
• Conclusions<br />
• Economic information<br />
• Our <strong>ORC</strong> related activities<br />
<strong>Organic</strong> <strong>Rankine</strong> <strong>Cycle</strong> 2
23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
<strong>The</strong> <strong>Rankine</strong> <strong>Cycle</strong><br />
<strong>The</strong> <strong>Rankine</strong> <strong>Cycle</strong><br />
1. Electrofilter 5. Transformer<br />
2. Boiler 6. Condensor<br />
3. Steam turbine 7. Cooling tower<br />
4. generator<br />
Source: Electrabel<br />
Steam turbine installation in a power station<br />
3 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
E-production from recovered heat of a gasturbine exhaust<br />
4 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
using a <strong>Rankine</strong> <strong>Cycle</strong><br />
Source: Electrabel
23-02-2010 <strong>The</strong><br />
<strong>The</strong> <strong>Rankine</strong> <strong>Cycle</strong><br />
T-s diagram for a working fluid<br />
23-02-2010 <strong>The</strong><br />
<strong>The</strong> <strong>Rankine</strong> <strong>Cycle</strong><br />
Working fluid: usually water<br />
<strong>Rankine</strong> cycle with superheated steam<br />
5 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
Carnot efficiency:<br />
Advantages:<br />
• cheap, widely available<br />
• non toxic<br />
• high heat capacity: excellent medium for heat transport<br />
• chemical stable: less material requirements<br />
• low viscosity: low friction losses<br />
Disadvantages:<br />
• due to low condensation t°: very low pressure, high specific volume, big<br />
installations needed (turbine, condensor…)<br />
• high pressure drop to become a high enthalpy drop: expensive multi stage<br />
6 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
turbines needed<br />
• expansion has to start in the superheated area to avoid too high moisture<br />
content after expansion: need of a high t°- heat source but very partically use<br />
• because of this: efficiency loss and limited suitability to waste heat recovery
<strong>The</strong> <strong>Organic</strong> <strong>Rankine</strong> <strong>Cycle</strong><br />
Disavantages water probably to correct using other working fluids, mostly of<br />
organic origin: <strong>Organic</strong> <strong>Rankine</strong> <strong>Cycle</strong> <strong>Organic</strong> medium<br />
(<strong>ORC</strong>)<br />
Used are:<br />
Toluene, butane,<br />
pentane, ammonia,<br />
refrigeration fluids,<br />
silicone oils…<br />
<strong>Organic</strong> <strong>Rankine</strong> <strong>Cycle</strong><br />
in the T-s diagram<br />
23-02-2010 <strong>The</strong><br />
<strong>The</strong> <strong>Organic</strong> <strong>Rankine</strong> <strong>Cycle</strong><br />
23-02-2010 <strong>The</strong><br />
7 <strong>Cycle</strong> <strong>Organic</strong><br />
8<br />
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<strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong>
<strong>The</strong> <strong>Organic</strong> <strong>Rankine</strong> <strong>Cycle</strong><br />
23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
<strong>ORC</strong> Working Fluids<br />
Wet fluid Dry fluid<br />
• superheating required<br />
• superheating → efficiency ↑<br />
• higher vaporization heat at<br />
lower pressures →<br />
evaporation requires a lot<br />
of heat or high pressures<br />
• remains superheated<br />
after expansion of<br />
saturated vapor<br />
• superheating unnecessary<br />
• superheating → efficiency ↓<br />
Isentropic fluid<br />
• superheating unnecessary<br />
• recuperator unnecessary<br />
• best choice for <strong>ORC</strong> from<br />
this point of view<br />
9 <strong>Cycle</strong> <strong>Organic</strong><br />
10<br />
<strong>Rankine</strong><br />
<strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong>
23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
<strong>ORC</strong> Working Fluids<br />
Relevant applications<br />
1. Power production from industrial waste heat<br />
11 <strong>Cycle</strong> <strong>Organic</strong><br />
12<br />
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23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Relevant applications<br />
Electrical efficiency = ca 16%<br />
if waste gases are cooled<br />
down to 120°C<br />
13 <strong>Cycle</strong> <strong>Organic</strong><br />
14<br />
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• Because of high temperature exhaust gases, a steam turbine can be<br />
considered on bigger plants<br />
15 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
2. Exhaust heat recovery on stationary combustion<br />
engines or gas turbines<br />
• Ca 10% increase of electrical output without extra fuel<br />
• Economical attractive on engines using renewable fuels (landfill gas,<br />
biogas, vegatable oils…) because of governmental support (Green<br />
Certificates). Simple PBT of 3 years calculated.<br />
• Possibility to upgrade old (build before 2002) cogeneration units with<br />
respect to CHP certificates by adding an <strong>ORC</strong> (increase of relative<br />
primary energy savings with 5 %). Very short PBT if feasible (1- 2 years).<br />
• Some <strong>ORC</strong>’s are adapted to use jacket cooling water heat<br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Ex: 150 kW <strong>ORC</strong> by Tri-O-Gen (Nl)<br />
Engine cooling<br />
LT heat<br />
Exhaust gas (510°C)<br />
Electricity<br />
1550 kWe<br />
Exhaust gas (180°C)<br />
16 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
(585 kWth,<br />
incl losses)<br />
150 kWe
<strong>ORC</strong> integration in an (existing) CHP:<br />
23-02-2010 <strong>The</strong><br />
180 °C<br />
23-02-2010 <strong>The</strong><br />
CHP<br />
Relevant applications<br />
Flue gas<br />
T > 350°C<br />
760 kW th<br />
Boiler<br />
325°C<br />
Generator<br />
Turbine<br />
Greenhouse<br />
17 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
Inverter<br />
Main feed pump<br />
Recuperator<br />
165 kWe<br />
400 V<br />
Pre-feed pump<br />
18 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
Working fluid: Toluene<br />
50°C<br />
600 kWth<br />
35°C
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
<strong>ORC</strong> on exhaust gases 2 MW Deutz gas engine<br />
Roses farm Olij, De Kwakel – <strong>The</strong> Netherlands<br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Range: TG30(+) 30 kW; TG60(+) 60 kW<br />
Specific designed to recover biogas engine heat<br />
(+ means integrated use of engine jacket cooling).<br />
Fits on biogas engines in the range 250-500 kW.<br />
Heat source:<br />
from 230°C (TG30/TG30+)<br />
from 270°C (TG60/TG60+)<br />
Cooling source:<br />
30°C or up to 80°C (CHP-version)<br />
Tri-O-Gen B.V.<br />
Nieuwenkampsmaten 8<br />
7472 DE Goor Nederland<br />
Heinrich-Hertz-Str. 18<br />
59423 Unna<br />
Germany<br />
19 <strong>Cycle</strong> <strong>Organic</strong><br />
20<br />
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<strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong>
23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Relevant applications<br />
Maxxtec new small series Model 60 Model 80 Model 120<br />
Waste heat source:<br />
<strong>The</strong>rmal need 375 kWth 520 kWth 750 kWth<br />
<strong>The</strong>rmal oil in/out 280/140 °C 280/140 °C 280/140 °C<br />
Electricity output<br />
Gross 65 kWe 92 kWe 130 kWe<br />
Net (appr.) 51 kWe 81 kWe 114 kWe<br />
Condensor heat output 306 kWth 423 kWth 612 kWth<br />
Condensor circuit in/out 43/64°C 43/64°C 43/64°C<br />
Gross Electric Efficiency 17,3 % 17,7 % 17,3 %<br />
Net Electric Efficiency 13,6 % 15,6 % 15,2 %<br />
21 <strong>Cycle</strong> <strong>Organic</strong><br />
22<br />
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23-02-2010 <strong>The</strong><br />
Relevant applications<br />
<strong>ORC</strong> with double screw expander<br />
• Heavy duty design, derived from<br />
screw compressors<br />
• Not sensitive to fluid drops: can expand<br />
both superheated or saturated steam,<br />
no damage when fluids drops passes<br />
trough (usefull when large process<br />
variations are going on).<br />
• As <strong>ORC</strong> usable at lower temperatures<br />
• Adapted to recover jacket water heat<br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Double srew expander<br />
based <strong>ORC</strong><br />
Electra<strong>The</strong>rm<br />
3208 Goni Road<br />
Carson City,<br />
Nevada 89706<br />
BEP EUROPE NV<br />
Ten Briele 6<br />
B-8200 Brugge<br />
23 <strong>Cycle</strong> <strong>Organic</strong><br />
24<br />
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<strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong>
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
3. <strong>ORC</strong>, fed by biomass combustion<br />
Many references in CH, A, D, I… (also 1 in NL, 2 planned in Belgium).<br />
In concurrence with the steam cycle.<br />
Always designed as CHP.<br />
Turboden s.r.l.<br />
Viale Cernaia, 10<br />
25124 Brescia - Italy<br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
25 <strong>Cycle</strong> <strong>Organic</strong><br />
26<br />
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23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Turboden <strong>ORC</strong>-CHP range:<br />
Relevant applications<br />
MIROM Roeselare : 2,5 MWe net<br />
by Turboden<br />
Heat source: water @180°C<br />
17 % net efficiency<br />
27 <strong>Cycle</strong> <strong>Organic</strong><br />
28<br />
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<strong>ORC</strong> integration in an (existing) biomass boiler:<br />
23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Biomass boiler<br />
Relevant applications<br />
4. <strong>ORC</strong>, fed by geothermal heat sources<br />
Many references known,<br />
from 250 kW to > 100 MW<br />
Source temperatures from<br />
75°C up to 300°C.<br />
Same technology usable to<br />
recover waste heat on the<br />
same temperature levels.<br />
Greenhouse<br />
29 <strong>Cycle</strong> <strong>Organic</strong><br />
30<br />
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23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Heber Geothermal<br />
52 MWe<br />
power station<br />
(California)<br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Geothermal <strong>ORC</strong> 250 kWe (Ormat)<br />
Geothermal fluid temperature in/out:<br />
110/85°C<br />
<strong>The</strong>rmal power in: ~ 2500 kW<br />
<strong>ORC</strong> working fluid: Isopentane<br />
31 <strong>Cycle</strong> <strong>Organic</strong><br />
32<br />
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23-02-2010 <strong>The</strong><br />
Relevant applications<br />
<strong>ORC</strong> derived from a centrifugal chiller (reversed)<br />
Cheap, reliable, proven technology<br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
33 <strong>Cycle</strong> <strong>Organic</strong><br />
34<br />
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23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Pure <strong>Cycle</strong> 280:<br />
35 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
186-257 kWe net<br />
Relevant applications<br />
5. Power generation from thermal solar energy<br />
• probably cheaper than photovoltaic solar systems<br />
• possible to use condensor heat for sanitary heat water…<br />
• huge potential on desalination systems<br />
Evacuated tube collector<br />
fitted to temperatures<br />
untill 180-200°C<br />
40 kW solar heat <strong>ORC</strong> (Turboden, 1984)<br />
<strong>Organic</strong> <strong>Rankine</strong> <strong>Cycle</strong> 36
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Solar-biomass hybrid <strong>ORC</strong><br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
37 <strong>Cycle</strong> <strong>Organic</strong><br />
38<br />
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23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Principle design<br />
combined solar driven<br />
electricity and domnestic<br />
hot water production<br />
system<br />
(final work HOWEST,<br />
2004-2005)<br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Tests (HOWEST) on a scroll expander (2005)<br />
(Sanden scroll car airco compressor TRS-090)<br />
39 <strong>Cycle</strong> <strong>Organic</strong><br />
40<br />
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23-02-2010 <strong>The</strong><br />
Relevant applications<br />
6. <strong>ORC</strong> driven domnestic micro-CHP<br />
• alternative to gas engine<br />
based micro CHP<br />
• to integrate within a cv-boiler<br />
• in concurrence with other new<br />
technologies as stirling engines,<br />
fuel cells…<br />
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
Energetix Group plc<br />
Capenhurst Technology Park<br />
Chester<br />
CH1 6EH UK<br />
Genlec module: 1 kW scroll expander based <strong>ORC</strong> to<br />
integrate in central heating boilers (micro CHP)<br />
Example: Boiler manufacturor Daalderop (NL)<br />
41 <strong>Cycle</strong> <strong>Organic</strong><br />
42<br />
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<strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong>
23-02-2010 <strong>The</strong><br />
Relevant applications<br />
7. <strong>ORC</strong> driven cooling<br />
Alternative if electrical grid connection big chillers is impossible or not allowed.<br />
Been proven having better efficiency (COP) compared to absorption chillers.<br />
Solar powering or hybrid with solar heat feasible.<br />
23-02-2010 <strong>The</strong><br />
Some Economics<br />
Some budget prices <strong>ORC</strong>-modules:<br />
Turboden: 500kW: about € 1900 /kWe<br />
1000 kW: about € 1350 /kWe<br />
2000 kW: about € 950 /KWe<br />
Pure <strong>Cycle</strong> 280 (ca 250 kWe) : € 335 000 or € 1350/kWe<br />
Maxxtec/Adoratec: confidential prices, but of the same order of Turboden<br />
Also attractive priced new 60, 85 and 120 kW units.<br />
Tri-O-Gen: 150 kW unit @ € 650 000 ca € 4300 /kWe (turn key ?)<br />
BEP-Europe: 50 kW unit @ € 120 000 (module) or € 200 000 (installed)<br />
€ 2400 /kWe € 4000 /kWe<br />
250 kW unit: “lower” price/kWe compared with the 50 kWe unit<br />
43 <strong>Cycle</strong> <strong>Organic</strong><br />
44<br />
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<strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong>
23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
Some Economics<br />
• On renewable energy applications, we calculated a simple PBT of 3<br />
year (IRR ca 25%), with the help of green certificates.<br />
• For industrial waste heat recovery, a PBT of 5 year is realistic when<br />
available heat is on ‘high temperature’ (~300°C). So the ROI can<br />
reach 15%, after taxes, what means that the investment can be<br />
asked within the benchmarking agreement. This result is strongly<br />
related to the electricity prices.<br />
• Other financing methods (third party) could be considered<br />
Some Conclusions<br />
- <strong>ORC</strong> is a proven and commercially available technology for applications<br />
such as industrial waste heat recovery, ICE heat recovery, biomass<br />
burning, use of solar heat, geothermal heat sources…<br />
- main advantage compared with a steam cycle is the higher thermal<br />
efficiency when using heat sources at lower temperatures. <strong>The</strong> <strong>ORC</strong> is<br />
also less complicated and easier to operate. Occuring pressures are lower.<br />
- the classical steam cycle should be considered when sufficient<br />
temperature levels are reachable (fuel burning) combined with turbine<br />
scale sizes from about 500 kWe…to 2,5 MWe (to discuss, no clear answer<br />
given when to chose an <strong>ORC</strong> above a steam cycle)<br />
- favorable economical perspectives, especially in relation to green<br />
certificates or energy benchmarking.<br />
- excellent CHP capability since the condensor heat can be used<br />
45 <strong>Cycle</strong> <strong>Organic</strong><br />
46<br />
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<strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong>
Our <strong>ORC</strong> related activities<br />
• 2 master thesises 2003-2005<br />
• TETRA project proposal on <strong>ORC</strong> in 2005. Technically and scientifically<br />
approved but not financed, had to be cancelled.<br />
• New proposal in 2007, focused on renewable energy sources.<br />
Accepted, in progress from Oct 1st 2007 till Dec 31th 2009<br />
• Second proposal on industrial waste heat accepted (Jan 1st 2010- Dec<br />
31 th 2011 or 2012). European ERA-SME concept with Ghent University<br />
and Stuttgart University of Applied Sciences as research partners.<br />
A TETRA project is 92,5 % financed by the Flemisch Government (IWT)<br />
and 7,5% by industrial partners (at least 4 SME’s).<br />
47 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
2 scientific researchers can work during 2 or 3 years on it.<br />
Cofinancing User Group is the preference partner to receive project<br />
information during project runtime, at the end publical available (by<br />
publications, seminars, website…)<br />
23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
2 th <strong>ORC</strong> Project structure<br />
<strong>Organic</strong> <strong>Rankine</strong> <strong>Cycle</strong> 48
23-02-2010 <strong>The</strong><br />
Laboratory setup<br />
For research and demonstrational purposes<br />
23-02-2010 <strong>The</strong><br />
Laboratory setup<br />
Heat source:<br />
Maxxtec thermal oil heater<br />
Max 250 kW @ 340°C<br />
Flow: 14 m³/h<br />
10 x 25kW , GC-Heat<br />
49 <strong>Cycle</strong> <strong>Organic</strong><br />
50<br />
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Cooling loop:<br />
Circulator<br />
→<br />
←<br />
23-02-2010 <strong>The</strong><br />
23-02-2010 <strong>The</strong><br />
Laboratory setup<br />
- water + glycol<br />
- max. 20m³/h<br />
- max. 120°C<br />
3-way valve<br />
Flow<br />
sensor<br />
Cooler<br />
Flow<br />
51 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
Thanks for your attention.<br />
Questions ???<br />
ing Bruno Vanslambrouck<br />
HOWEST, dept Masters Industrial Sciences<br />
Laboratory of Industrial Physics and Applied Mechanics<br />
Graaf Karel de Goedelaan 5, B-8500 Kortijk<br />
52 <strong>Cycle</strong> <strong>Rankine</strong> <strong>Organic</strong><br />
Mail: bruno.vanslambrouck@howest.be<br />
Tel: +32 56 241211 or +32 56 241227 (dir)