Organic Rankine cycle macro power plant

(An institute of national importance)

Major project on ORGANIC RANKINE CYCLE POWER PLANT FOR RENEWABLE ENERGY RESOURCES

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE DEGREE OF BACHELORS OF TECHNOLOGY IN PRODUCTION AND INDUSTRIAL ENGINEERING

Guided by

Asst Prof: Alok singh(Mechanical Engg. Dept.)

Submitted by

Sh. Anandkumar singh 091116257

B.TechProduction and industrial engineering

VII Sem to VIII Sem

Introduction

Organic Rankine cycle is a thermodynamic cycle which convert thermal energy into mechanical energy ORC technology is similar to a traditional steam turbine, but important difference.

vaporizes a high-molecular-mass organic fluid butane, pentane etc.

excellent performance and several key advantages: slower turbine rotation, lower pressure, and no erosion of metallic parts and blades.

water vapor, as a working fluid

Biomass

Geothermal

Industrial waste heat Renewable energy sources

Solar energy

Heat

sou

rces

Power Plants based on the Organic Rankine Cycle (ORC) have been increasingly employed over the last 10 years to produce power from clean energy renewable sources. The cycle is well adapted to low moderate temperature heat sources and is widely used for producing small scale to moderate power production (200KW to 10MW). These plants are environmentally friendly.

Power range and efficiency of common power plant

pow

er

ran

ge [

MW

]

efficiency [%]

Link : [2]

The aim of this work is the study and the modeling of an Organic Rankine Cycle power plant for small scale purpose.

Finally three prospective studies are propose

Solar ORC

Biomass ORC

Industrial Waste heat

ORC

And study of different working fluids selection criteria.

The Rankine CycleThe Rankine cycle is a cycle that converts heat into work. The heat is supplied externally to a closed loop. This cycle generates about 90% of all electric power used throughout the world The Rankine cycle is the fundamental thermodynamic underpinning of the steam engine and thermal power plant

There are four processes in the Rankine cycle. These states are identified by numbers in the above Ts diagram.

Boiler

Condenser

Steam turbine

Link : [3]

Rankine cycle

Advantages: cheap, widely available non toxic high heat capacity: excellent medium for heat transport chemical stable: less material requirements low viscosity: low friction lossesDisadvantages: due to low condensation t°: very low pressure, high specific

volume, big installations needed (turbine, condenser ) high pressure drop to become a high enthalpy drop: expensive

multi stage turbines needed expansion has to start in the superheated area to avoid too high

moisture content after expansion: need of a high t°- heat source but very practically use because of this: efficiency loss and limited suitability to waste heat recovery

Working fluid: usually water

The Organic Rankine Cycle

Organic Rankine Cycle working fluids are:TolueneButanePentane AmmoniaRefrigeration fluidsSilicone oils

Disadvantages of water probably to correct using other working fluids, The ORC uses organic substances instead of water as working fluid :

Thermodynamic Process behindthe Organic Rankine Cycle

and is then condensed in the condenser and cooled by the cooling circuit (6,1).

The ORC Turbogenerator uses medium-to-high-temperature thermal oil to preheat and vaporize a suitable organic working fluid in the evaporator (7,4).The organic fluid vapor rotates the turbine (4,5), which is directly coupled to the electric generator, resulting in clean, reliable electric power.

The exhaust vapor flows through the regenerator (5-6), where it heats

the organic liquid (2,7)

The organic working fluid is then pumped (1,2) into the regenerator and evaporator, thus completing the closed-cycle operation.

Organic Rankine Cycle in the T-s diagram

Link : [4]

Working Fluids

Small, fast-moving MoleculesErosion of blades and metal partssuperheated water vapor steam requiredMultistage turbine andhigh mechanical stress

Organic fluids lead to• higher turbine efficiencies due to the higher mass flow (leakage ↓)• low maintenance operation• good part load behavior

• Silicone Oils• Hydrocarbons• Fluorocarbons

Rankine cycle

ORC

Water

Lower boiling temperature Very large flow rateNo wear of bladesand metal parts

RegeneratorCondenser

Turbine Generat

or Feed Pump

Evaporator

ORC Main Components

ORC Unit from Turboden, Brescia Italy

Org

an

ic

flu

id

Cooling water

Thermo oil heat input

Link : [7]

ORC units

Applications:

Solar

Energy

•Concentrating solar power systems with ORC units allow conversion of heat harnessed by solar collectors into electricity through an efficient thermodynamic cycle.

Biomass

•simple and efficient generation of electric power and heat from biomass

Geothermal

•electricity from geothermal resources with medium-to-low-temperatures, generally ranging between (90° C - 180° C).

Waste

heat

•by recovering heat from sources such as industrial processes,

ORC unit

Advantage of ORC

Technical Advantages

High cycle efficiencyVery high turbine efficiencyLow turbine mechanical stress due to low peripheral speedLow turbine rpm, allowing the direct drive of the electric generator without gear reduction in many applicationsNo erosion of blades, thanks to the absence of moisture in the vapor nozzles

Operational Advantages

Simple start-stop proceduresAutomatic and continuous operationNo operator attendance neededQuiet operationHigh availability (typically 98%)High efficiency at partial loadLower maintenance costLong life

Appendix - 1

by taking R-123 as working fluid (2,2dichloro-1,1,1 trifluroethane)

Physical propertiesMolecular weight 152.93Boiling point 27.85 CAt 1 atm Critical temp 183.6CPressure 3668.0 kpadensity 550.0 kg/m3

Non inflammableExposure time is longer easily available at Market

We are taking max pressure at 1.2Mpa and heating the fluid upto 120C and minimum pressure 0.101Mpa (atm) and temp 28C (normal boiling) as a operating condition for ease of calculation. And mass flow rate at 0.2kg/s since our plant is for small kw of output

Data Link [5]

Why? R-123

model no. F.D 3.0-300-72/144Rated output 3kwMax output 7.5kwMin RPM 300Max RPM 10000Starting torque 1.8NMEffi. 80 %Wt. 85Kg

model No. SP2402A01-01 240wattInlet dia 63mmOutlet dia 63mmMax head 9mWorking voltage 110v-220vACRPM 300-3300Wt.3.4Kg

Specification

AC generator Suction pump

Appendix - 2

Link : Dong Guan Youthen Metal Co., Ltd.

Appendix - 3

B= boilerP= feed pumpT= turbineC= condenser

From the steam table of R-123

Data Link [5]

Calculation

Turbine work output Wt = m* . (H1 - H2)m* = 0.2kg Wt = 0.2 (448.6 – 395.096)Wt = 10.708 kw

From steam table 2 at temp 120C and 1.2Mpaenthalpy H1= 448.6kj/kgEntropy S=1.6896 kj/kgKSpecific volume V= 0.0136 m3/kgSpecific heat Cp= 0.9393

From steam table 1 temp 28C and 0.10192MpaEnthalpy of fusion Hf=226.4Kj/kgEnthalpy of vaporization Hg= 396.8kj/kgLatent enthalpy Hfg= 170.4kJ/kg

Enthalpy at turbine outlet H2= Hf + x(Hg-Hf)x= 0.99 (properties of R-123)H2 = 226.4 + 0.99(396.8 – 226.4)H2 = 395.096kj/kg

Again taking the efficiency of steam expander (Turbine ) = 90%Power of shaft = 0.9 X 10.708 = 9.637kw

Form our Ac generator efficiency = 80%Electrical power output = 0.8 X 9.637 = 7.7096 kw

Appendix - 4

Plan of the project

Prototype ORC Unit

This prototype is going to compete with photovoltaic cell.

References 1. Angelino, G. Invernizzi and Molteni, : The potential role of organic bottoming

rankine cycle power station 1999 . Vol 231(A): page No. 75-91

2. Liu, B.T, chien K.H and Wang, : effect of working fluid on organic rankine cycle for waste heat recovery , 2004 vol 29 page No. 1207-1217.

3. ing. Bruno Vanslambrouck, Howest, dept Masters Industrial Sciences Laboratory of Industrial Physics and Applied Mechanics

4. Prof. Dr.-Ing. H. Spliethoff Technische Universität München : The Organic Rankine Cycle Power Production from Low Temperature Heat Institute for Energy Systems.

5. Experimental Study and Modeling of a Low Temperature Rankine Cycle for Small Scale Cogeneration. By Sylvain Quoilin may- 2007

6. ORGANIC RANKINE CYCLE POWER PLANT FOR WASTE HEAT RECOVERY by Lucien Y. Bronicki, Chairman ORMAT International Inc. 980 Greg St., Sparks, Nevada 89431-6039 – USA Tel: +1 775 356 9029, Fax: +1 775 9039 email:[email protected]

7. Pratt & Whitney Power Systems www.pw.utc.com www.turboden.com http://www.youtube.com/watch?v=jU2AlRRlQDc

Thank You