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The steps taken to achieve improved bearing life in the organic Rankine cycle (ORC) engine being developed for use on solar parabolic dishes are presented. A summary of test results is given. Dynamic tests on the machine shaft and rotors of the ORC engine are also discussed.
An organic Rankine-cycle (ORC) power module was developed for use in a multimodule solar power plant to be built and operated in a small community. Many successful components and subsystems, including the reciever, power conversion subsystem, energy transport subsystem, and control subsystem, were tested. Tests were performed on a complete power module using a test bed concentrator in place of the proposed concentrator. All major single-module program functional objectives were met and the multimodule operation presented no apparent problems. The hermetically sealed, self-contained, ORC power conversion unit subsequently successfully completed a 300-hour endurance run with no evidence of wear or operating problems.
The organic Rankine-cycle (ORC) power conversion assembly was tested. Qualification testing of the electrical transport subsystem was also completed. Test objectives were to verify compatibility of all system elements with emphasis on control of the power conversion assembly, to evaluate the performance and efficiency of the components, and to validate operating procedures. After 34 hours of power generation under a wide range of conditions, the net module efficiency exceeded 18% after accounting for all parasitic losses.
The Organic Rankine Cycle (ORC) Solar Dynamic Power System (SDPS) is one of the candidates for Space Station prime power application. In the low Earth orbit of the Space Station approximately 34 minutes of the 94-minute orbital period is spent in eclipse with no solar energy input to the power system. For this period the SDPS will use thermal energy storage (TES) material to provide a constant power output. An integrated heat-pipe thermal storage receiver system is being developed as part of the ORC-SDPS solar receiver. This system incorporates potassium heat pipe elements to absorb and transfer the solar energy within the receiver cavity. The heat pipes contain the TES canisters within the potassium vapor space with the toluene heater tube used as the condenser region of the heat pipe. During the insolation period of the Earth orbit, solar energy is delivered to the heat pipe in the ORC-SDPS receiver cavity. The heat pipe transforms the non-uniform solar flux incident in the heat pipe surface within the receiver cavity to an essentially uniform flux at the potassium vapor condensation interface in the heat pipe. During solar insolation, part of the thermal energy is delivered to the heater tube and the balance is stored in the TES units. During the eclipse period of the orbit, the balance stored in the TES units is transferred by the potassium vapor to the toluene heater tube.
The use of a rotary fluid management device (RFMD) and shear flow condenser for two-phase fluid management in microgravity organic Rankine cycle (ORC) applications is examined. A prototype of the proposed Space Station ORC heat rejection system was constructed to evaluate the performance of the inventory control method. The design and operation of the RFMD, shear flow condenser, and inventory control fluid accumulator are described. A schematic diagram of the ORC, RFMD, and condenser, and a functional diagram of the heat rejection system for the ORC are presented.
The global geothermal electricity market has significantly grown over the last decade and is expected to reach a total installed capacity of 18.4 GWe in 2021 (GEA, 2016). Currently, geothermal project developers customize the size of the power plant to fit the resource being developed. In particular, the turbine is designed and sized to optimize efficiency and resource utilization for electricity production; most often, other power plant components are then chosen to complement the turbine design. These custom turbine designs demand one-off manufacturing processes, which result in higher manufacturing setup costs, longer lead-times, and higher capital costs overall in comparison to larger-volume line manufacturing processes. In contrast, turbines produced in standard increments, manufactured in larger volumes, could result in lower costs per turbine. This study focuses on analysis of the global supply chain and manufacturing costs for Organic Rankine Cycle (ORC) turboexpanders and steam turbines used in geothermal power plants. In this study, we developed a manufacturing cost model to identify requirements for equipment, facilities, raw materials, and labor. We analyzed three different cases 1) 1 MWe geothermal ORC turboexpander 2) 5 MWe ORC turboexpander and 3) 20 MWe geothermal steam turbine, and calculated the cost of manufacturing the major components, such as the impellers/blades, shaft/rotor, nozzles, inlet guide lanes, disks, and casings. Then we used discounted cash flow (DCF) analysis to calculate the minimum sustainable price (MSP). MSP is the minimum price that a company must sell its product for in order to pay back the capital and operating expenses during the plant lifetime (CEMAC, 2017). The results showed that MSP could highly vary between 893 dollar/kW and 30 dollar/kW based on turbine size, standardization and volume of manufacturing. The analysis also showed that the economy of scale applies both to the size of the turbine and the number manufactured in a single run. Sensitivity analysis indicated these savings come largely from reduced labor costs for design and engineering and manufacturing setup.
The present disclosure is directed to heat recovery systems that employ two or more organic Rankine cycle (ORC) units disposed in series. According to certain embodiments, each ORC unit includes an evaporator that heats an organic working fluid, a turbine generator set that expands the working fluid to generate electricity, a condenser that cools the working fluid, and a pump that returns the working fluid to the evaporator. The heating fluid is directed through each evaporator to heat the working fluid circulating within each ORC unit, and the cooling fluid is directed through each condenser to cool the working fluid circulating within each ORC unit. The heating fluid and the cooling fluid flow through the ORC units in series in the same or opposite directions.
The global geothermal electricity market has significantly grown over the last decade and is expected to reach a total installed capacity of 18.4 GWe in 2021 (GEA, 2016). Currently, geothermal project developers customize the size of the power plant to fit the resource being developed. In particular, the turbine is designed and sized to optimize efficiency and resource utilization for electricity production; most often, other power plant components are then chosen to complement the turbine design. These custom turbine designs demand one-off manufacturing processes, which result in higher manufacturing setup costs, longer lead-times, and higher capital costs overall in comparison to larger-volume line manufacturing processes. In contrast, turbines produced in standard increments, manufactured in larger volumes, could result in lower costs per turbine. This study focuses on analysis of the global supply chain and manufacturing costs for Organic Rankine Cycle (ORC) turboexpanders and steam turbines used in geothermal power plants. In this study, we developed a manufacturing cost model to identify requirements for equipment, facilities, raw materials, and labor. We analyzed three different cases 1) 1 MWe geothermal ORC turboexpander 2) 5 MWe ORC turboexpander and 3) 20 MWe geothermal steam turbine, and calculated the cost of manufacturing the major components, such as the impellers/blades, shaft/rotor, nozzles, inlet guide lanes, disks, and casings. Then we used discounted cash flow (DCF) analysis to calculate the minimum sustainable price (MSP). MSP is the minimum price that a company must sell its product for in order to pay back the capital and operating expenses during the plant lifetime (CEMAC, 2017). The results showed that MSP could highly vary between 893 dollar/kW and 30 dollar/kW based on turbine size, standardization and volume of manufacturing. The analysis also showed that the economy of scale applies both to the size of the turbine and the number manufactured in a single run. Sensitivity analysis indicated these savings come largely from reduced labor costs for design and engineering and manufacturing setup.
This binary plant is the first high-output refrigeration based waste heat recovery cycle in the industry. Its working fluid is environmentally friendly and as such, the permits that would be required with a butane based cycle are not necessary. The unit is modularized, meaning that the unit’s individual skids were assembled in another location and were shipped via truck to the plant site. This project proves the technical feasibility of using low temperature brine. The development of the unit led to the realization of low temperature, high output, and environmentally friendly heat recovery systems through domestic research and engineering. The project generates additional renewable energy for Nevada, resulting in cleaner air and reduced carbon dioxide emissions. Royalty and tax payments to governmental agencies will increase, resulting in reduced financial pressure on local entities. The major components of the unit were sourced from American companies, resulting in increased economic activity throughout the country.
The heavy truck diesel engine rejects a significant fraction of its fuel energy in the form of waste heat. Historically, the Department of Energy has supported technology efforts for utilization of the diesel exhaust heat. Specifically, the Turbocompound and the Organic Rankine Cycle System (ORCS) have demonstrated that meaningful improvements in highway fuel economy can be realized through waste heat utilization. For heat recovery from the high temperature exhaust of future adiabatic diesel engines, the DOE/NASA are investigating a variety of alternatives based on the Rankine, Brayton, and Stirling power cycles. Initial screening results indicate that systems of this type offer a fuel savings advantage over the turbocompound system. Capital and maintenance cost projections, however, indicate that the alternative power cycles are not competitive on an economic payback basis. Plans call for continued analysis in an attempt to identify a cost effective configuration with adequate fuel savings potential.
A thermo-economic model has been built and validated for prediction of project economics of Enhanced Geothermal Projects. The thermo-economic model calculates and iteratively optimizes the LCOE (levelized cost of electricity) for a prospective EGS (Enhanced Geothermal) site. It takes into account the local subsurface temperature gradient, the cost of drilling and reservoir creation, stimulation and power plant configuration. It calculates and optimizes the power plant configuration vs. well depth. Thus outputs from the model include optimal well depth and power plant configuration for the lowest LCOE.
United Technologies Research Center (UTRC), in collaboration with the Georgia Institute of Technology and the National Institute of Standards and Technology will evaluate and develop fundamental and component level models, conduct experiments and generate data to support the use of mixed or enhanced working fluids for geothermal power generation applications.
A new power generation thermodynamic cycle is described that eliminates need for bulk liquid condensation and vaporization steps required in conventional ORC power systems. An exemplary harmonic adsorption recuperative power cycle system offers more efficient power generation as compared with conventional ORC systems. A multibed adsorption system is used to provide thermal compression for the cycle. An adsorption compressor contains a sorbent with strong adsorption affinity for the working fluid in the pores while well outside the P-T conditions needed to condense the liquid phase, allowing the adsorption compressor to reduce operating pressure exiting the expander.
The Stillwater Power Plant is the first hybrid plant in the world able to bring together a medium-enthalpy geothermal unit with solar thermal and solar photovoltaic systems. Solar field and power plant models have been developed to predict the performance of the Stillwater geothermal / solar-thermal hybrid power plant. The models have been validated using operational data from the Stillwater plant. A preliminary effort to optimize performance of the Stillwater hybrid plant using optical characterization of the solar field has been completed. The Stillwater solar field optical characterization involved measurement of mirror reflectance, mirror slope error, and receiver position error. The measurements indicate that the solar field may generate 9% less energy than the design value if an appropriate tracking offset is not employed. A perfect tracking offset algorithm may be able to boost the solar field performance by about 15%. The validated Stillwater hybrid plant models were used to evaluate hybrid plant operating strategies including turbine IGV position optimization, ACC fan speed and turbine IGV position optimization, turbine inlet entropy control using optimization of multiple process variables, and mixed working fluid substitution. The hybrid plant models predict that each of these operating strategies could increase net power generation relative to the baseline Stillwater hybrid plant operations.
Microreactors can be used to provide electrical power up to 10 MWe for emergency situations, remote areas, or military applications. Combined cycles comprised of an air Brayton topping cycle and an Organic Rankine bottoming cycle were evaluated in HYSYS using different working fluids in the bottoming cycle and in different ambient environments. The results suggest that a bottoming ORC can increase the thermal efficiency of the air Brayton cycle up to 40.22%. Exergy analysis was also performed on the combined cycle along with a simple validation of HYSYS on the bottoming cycle. The exergy analysis shows that of available work, most is lost at the reactor or turned into work at the topping cycle. A rudimentary capital cost estimate showed that adding a bottoming cycle is not prohibitively expensive.
Employing innovative product developments to demonstrate financial and technical viability of producing electricity from low temperature geothermal fluids, coproduced in a mining operation, by employing ElectraTherm's modular and mobile heat-to-power "micro geothermal" power plant with output capacity expected in the 30-70kWe range. The Green Machine is an Organic Rankine Cycle power plant. The Florida Canyon machine is powered by geothermal brine with air cooled condensing. The data provided is an hourly summary from May 2013
Employing innovative product developments to demonstrate financial and technical viability of producing electricity from low temperature geothermal fluids, coproduced in a mining operation, by employing ElectraTherm's modular and mobile heat-to-power "micro geothermal" power plant with output capacity expected in the 30-70kWe range. The Green Machine is an Organic Rankine Cycle power plant. The Florida Canyon machine is powered by geothermal brine with air cooled condensing. The data provided is an hourly summary from 8/1/13 to 8/31/13.
Employing innovative product developments to demonstrate financial and technical viability of producing electricity from low temperature geothermal fluids, coproduced in a mining operation, by employing ElectraTherm's modular and mobile heat-to-power "micro geothermal" power plant with output capacity expected in the 30-70kWe range. The Green Machine is an Organic Rankine Cycle power plant. The Florida Canyon machine is powered by geothermal brine with air cooled condensing. The data provided is an hourly summary from 7/1/13 to 7/31/13.