Experimental investigations into power generation with low grade waste heat and R245fa Organic Rankine cycles (ORCs)

In this study, experimental research was conducted to investigate the performance of a small-scale Organic Rankine Cycle (ORC) system utilising low grade heat sources to generate electric power at different operating conditions. The experiment setup consisted of typical ORC system components, such as a turboexpander with high speed generator, finned-tube condenser, ORC pump and plate evaporator. R245fa was selected as a working fluid in the experimental system, considering its appropriate thermosphysical properties for the ORC system and low ozone depletion potential (ODP). At constant heat sink (ambient) parameters, extensive experiments were carried out to examine the effects of various important parameters including heat source temperature and working fluid pump speed etc. on system performance. Results showed that at a fixed working fluid speed, the thermal efficiency of the tested ORC system could be improved with an increased heat source temperature. On the other hand, at a constant heat source temperature, the working fluid pump speed could be optimised to maximise system thermal efficiency. Both the heat source temperature and ORC pump speed were found to be important parameters in determining system thermal efficiency and the component operations. The experimental outcomes can instruct future optimal system design and controls

Thermo-Economic optimization of waste heat recovery Organic Rankine Cycles

The present paper focuses both on the thermodynamic and on the economic optimization of a small scale ORC in waste heat recovery application. A sizing model of the ORC is proposed, capable of predicting the cycle performance with different working fluids and different components sizes. The working fluids considered are R245fa, R123, n-butane, n-pentane and R1234yf and Solkatherm. Results indicate that, for the same fluid, the objective functions (economics profitability, thermodynamic efficiency) lead to different optimal working conditions in terms of evaporating temperature: the operating point for maximum power doesn’t correspond to that of the minimum specific investment cost: The economical optimum is obtained for n-butane with a specific cost of 2136 €/kW, a net output power of 4.2 kW, and an overall efficiency of 4.47%, while the thermodynamic optimum is obtained for the same fluid with an overall efficiency of 5.22%. It is also noted that the two optimizations can even lead to the selection of a different working fluid. This is mainly due to additional fluid properties that are not taken into account in the thermodynamic optimization, such as the fluid density: a lower density leads to the selection of bigger components which increases the cost and decreases the economical profitability

Organic Rankine Cycle system performance targeting and design for multiple heat sources with simultaneous working fluid selection

This work presents a systematic approach toward the design of Organic Rankine Cycles (ORC) for the generation of power from multiple heat sources available at different temperature levels. The design problem is approached in a mixed-integer non-linear programming (MINLP) formulation where an inclusive and flexible ORC model is automatically evolved by a deterministic algorithm for global optimization. The basic building block of the model is the ORC cascade which consists of a heat extraction, a power generation, a condensation and a liquid pressurization section. The aim of the optimization is to determine the optimum number of ORC cascades, the structure of the heat exchanger network shared among different cascades, the operating conditions and the working fluid used in each cascade in order to identify an overall ORC structure that maximizes the power output. The approach is illustrated through a case study which indicates that a system of two waste heat sources is best exploited through two interconnected ORC utilizing different working fluids