Power Production from Low Temperature Heat -...

Lehrstuhl

Energie

Systeme

Prof. Dr.-Ing. H. SpliethoffLehrstuhl

Energie

Systeme

Prof. Dr.-Ing. H. Spliethoff

The Organic Rankine Cycle –Power Production from Low Temperature Heat

Hartmut Spliethoff, Andreas Schuster

Institute for Energy Systems

Technische Universität München

Electricity generation, combined heat and power

Strasbourg, 14 -16 September 2006

Electricity generation, combined heat and powerStrasbourg, 14 -16 September 2006

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Contents

• Introduction

– History…

– Recapitulation Clausius Rankine Cycle

• State of the Art Applications– Biomass Combustion

– Geothermal Power Plants

• Innovative Applications

– Solar Desalination with Organic Rankine Cycle

– Waste-heat recovery from biomass digestion plants

• Conclusion and Outlook


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William John MacquornRankine

* 5th July 1820

† 24th December 1872

• Scottish physicist and

engineer

• one of the founders of

thermodynamics

• important contributions to

the theory of steam

engine

WJM Rankine

Who was the Rankine - cycle’s “father” ?


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Turbine House(steam turbine,

condenser, generator)

Boiler House(steam generator)

Cooling Towers

Coal Stockyard

Flue Gas Cleaning(dust removal, nitric oxide

removal, desulphurization)

Jürgen Karl




Cooling Towers

Coal Stockyard



Jürgen Karl

Assembly of a steam power station




Cooling Towers

Coal Stockyard



Jürgen Karl




Cooling Towers

Coal Stockyard



Jürgen Karl

G

Generator

MMFeed Pump

Boiler Steam

Turbine

Condenser


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Power range and efficiency of common power machines for external combustion

0,01

0,1

1

10

100

1000

0 20 40 60 80

efficiency [%]

po

we

r ra

ng

e [

MW

]

Organic Rankine Cycle

Steam Power Plants

Steam Engine

Stirling EngineJürgen Karl, Dezentrale Energiesysteme

0,01

0,1

1

10

100

1000

0 20 40 60 80

efficiency [%]

po

we

r ra

ng

e [

MW

]


Steam Power Plants

Steam Engine

Stirling Engine

0,01

0,1

1

10

100

1000

0 20 40 60 80

efficiency [%]

po

we

r ra

ng

e [

MW

]


Steam Power Plants

Steam Engine

Stirling EngineJürgen Karl, Dezentrale Energiesysteme


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The Organic Rankine Cycle – an applicationfor small power range

The ORC uses organic

substances instead of water as working fluid

• Silicone Oils

• Hydrocarbons

• Fluorocarbons

water organic fluids

Organic fluids lead to

• higher turbine efficiencies due to the higher mass flow (leakage ↓)

• low maintenance operation

• good part load behavior


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Availaible in a power range up to 1500 MW…(dust removal, nitric oxide

removal, desulphurization)MM

G

Feed Pump

Boiler

Generator

Steam

Turbine

Condenser

(dust removal, nitric oxide

removal, desulphurization)MMMM

GGG

Feed Pump

Boiler

Generator

Steam

Turbine

Condenser01

2

3

4

50

100

200

300

400

500

0,0 2,0 4,0 6,0 8,0 10,0

spezific entropy [kJ/kgK]

tem

pe

ratu

re [

°C]

p=0,05 bar

1 bar

10 bar

100 bar

x=0,2

0,4

0,6

0,81

0

2 3

4

5

0

100

200

300

400

500

0,0 2,0 4,0 6,0 8,0 10,0

spezific entropy [kJ/kgK]

tem

pe

ratu

re [

°C]

p=0,05 bar

1 bar

10 bar

100 bar

x=0,2

0,4

0,6

0,81

0

2 3

4

501

2 3

4

5

Availaible in a power range up to 1500 kW…

The Organic Rankine Cycle – an application for small power range and external heat source

0

50

100

150

200

1,0 1,2 1,4 1,6 1,8 2,0spezific entropy [kJ/kgK]

tem

pe

ratu

re [

°C]

10

2 34

5

6

x=0,

2

0,4

0,6 0,8

p=1 bar

5 bar

10 bar

25 bar

0

50

100

150

200


tem

pe

ratu

re [

°C]

10

2 34

5

6

x=0,

2

0,4

0,6 0,8

p=1 bar

5 bar

10 bar

25 bar

M

G

M

G

Heat

Exchanger

Turbine

Generator

Condenser

Feed Pump

District Heating Network

Cooling Tower

5

432

0

6

4

1

5

32

1

0 6biomass boiler

geothermal heat

waste heat

…


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0

50

100

150

200


tem

pe

ratu

re [

°C]

10

2 34

5

6

x=0,

2

0,4

0,6 0,8

p=1 bar

5 bar

10 bar

25 bar

0

50

100

150

200


tem

pe

ratu

re [

°C]

10

2 34

5

6

x=0,

2

0,4

0,6 0,8

p=1 bar

5 bar

10 bar

25 bar

M

G

M

G

ORC without recuperatorORC with recuperator

M

G

MM

G

• Expansion does end in the area of superheatedsteam

• Sensible Heat of steam ( - ) can be usedfor preheating the liquid working fluid

5

6

5

65

5

6


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State of the Art Applications


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ORC Unit from Turboden, Brescia Italy

• Units from 500 kW up to

1500 kW available

• Standardized Product

Evaporator

RekuperatorCondenser

Turbine

Generator Feed Pump

Evaporator

RekuperatorCondenser

Turbine

Generator Feed Pump

• Units are delivered completely

assembled to installation site


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Biomass Combustion Sauerlach – 700 kWel

Toblach – 1500 kWel

Fußach – 1100 kWel

GG

Thermo oil loop

Organic

Rankine Cycle


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Insertion

• dependency of electric

efficiency of exhaust gas

losses of biomass boiler

• flow temperature / return

temperature thermo oil 270 °C

/ 220 °C

Electric Efficiency

10…12 %

Manufacturer information

of 16…18 % don’t include

the furnace


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Geothermal Power Plants

www.geothermie.de

ww

w.g

eoth

erm

ie.d

e

Altheim 1000 kWel

Neustadt-Glewe 210 kWel

Injection Bore HoleBore Hole

15-110 m³/h

ORC

System

21°C, 120-395 m³/h

Well

Water processing

Return

Cooler

28°C

98°C

Injection Bore HoleBore Hole

15-110 m³/h

ORC

System

21°C, 120-395 m³/h

Well

Water processing

Return

Cooler

28°C

98°C


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Innovative applications


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Innovative stand-alone solar desalination

system with an Organic Rankine Cycle

CollectorLoop

Organic Rankine CycleOsmosis Process


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Design Criteria for ORC with solar heat

4,0

4,2

4,4

4,6

4,8

5,0

5,2

5,4

5,6

50 75 100 125 150

live steam temperature [°C]

cycle

eff

icie

ncy

[%

]

R236fa

R134a

R227 R245fa

• Scroll expander for mechanical power in the

range of 10 kW

• Scroll expander is a positve displacement

expansion machine

• Different working fluids

offer nearly the same

efficieny

• Fluid with efficiency

maximum at the lowest

posssible temperature fits

best


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Status of the project

The research was done in the framework

of the project RO-Solar-Rankine (COOP-

CT-2003-507997) funded by the

European Comission. Therefore the TU

München is much obliged.

• The project is succesfully

finished

• The expander efficiency is

between 60 and 70 % over

a wide operation range

• The cycle efficiency is

around 4 %

• The fresh water production

is approximately 320 l/h

with a thermal input of 35

kW


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Waste-heat recovery from biomass digestion

plants

Organic Waste

Energy Crops

IC engine

Biogas

tankFermenter

Manure

Desulphurization

Biogas

Grid

ORC

System

recovery with low temperature ORC

• Gainful use of the excess heat of

the IC engine is important for the

economic and energetic efficiency

• Only 20…25 % of the waste heat

of the engine is needed for heating

the digester

• The characteristics of heat

demand and the location of the

digestion plants is hindering for

the use of waste heat in district

heating networks

enhanced electricity production

by the application of ORC


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Case Study for biomass digestion plant

IC engine

Thermo oil loop


Test Rig at TUM


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Case Study for biomass digestion plant

• Combustion Engine 555 kW

Deutz TCG 2016 V12

• Electrical Power 537 kWel

• Exhaust gas temperature of ~

490 °C

• Additional Power production of

35 kWel equivalent to an

efficiency gain of 2.6 %

• With an interest rate of 5 % and

7.500 full load hours electricity

production cost of 5.65 €-

Ct/kWh can be reached

5 Ct

6 Ct

7 Ct

8 Ct

9 Ct

O.R.5 C

t

6 Ct

7 Ct

8 Ct

9 Ct

O.R.5 C

t

6 Ct

7 Ct

8 Ct

9 Ct

O.R.


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Conclusions:

• Organic Rankine Cycles are a modification of the well known Clausius Rankine Cycle

• The use of organic fluids offer various advantages

• The ORC technology for electricity production from biomass and geothermal heat is state of the art

• ORCs are also suitable for waste-heat recovery and power production from solarthermal heat – these applications are subject of further research

• ORC linked with Reverse Osmosis is a promising possibility for seawater desalination

Power Production from Low Temperature Heat -...

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