Antti Uusitalo

Organic Rankine Cycle Power Systems: From the Concept to Current Technology, Applications, and an Outlook to the Future

The cumulative global capacity of organic Rankine cycle (ORC) power systems for the conversion of renewable and waste thermal energy is undergoing a rapid growth and is estimated to be approx. 2000 MWe considering only installations that went into operation after 1995. The potential for the conversion of the thermal power coming from liquid-dominated geothermal reservoirs, waste heat from primary engines or industrial processes, biomass combustion, and concentrated solar radiation into electricity is arguably enormous. ORC technology is possibly the most flexible in terms of capacity and temperature level and is currently often the only applicable technology for the conversion of external thermal energy sources. In addition, ORC power systems are suitable for the cogeneration of heating and/or cooling, another advantage in the framework of distributed power generation. Related research and development is therefore very lively. These considerations motivated the effort documented in this article, aimed at providing consistent information about the evolution, state, and future of this power conversion technology. First, basic theoretical elements on the thermodynamic cycle, working fluid, and design aspects are illustrated, together with an evaluation of the advantages and disadvantages in comparison to competing technologies. An overview of the long history of the development of ORC power systems follows, in order to place the more recent evolution into perspective. Then, a compendium of the many aspects of the state of the art is illustrated: the solutions currently adopted in commercial plants and the main-stream applications, including information about exemplary installations. A classification and terminology for ORC power plants are proposed. An outlook on the many research and development activities is provided, whereby information on new high-impact applications, such as automotive heat recovery is included. Possible directions of future developments are highlighted, ranging from efforts targeting volume-produced stationary and mobile mini-ORC systems with a power output of few kWe, up to large MWe base-load ORC plants.

Siloxanes as Working Fluids for Mini-ORC Systems Based on High-Speed Turbogenerator Technology

This paper presents a study aimed at evaluating the use of siloxanes as the working fluid of a small-capacity (≈10kWe) ORC turbogenerator based on the “high-speed technology” concept, combining the turbine, the pump, and the electrical generator on one shaft, whereby the whole assembly is hermetically sealed, and the bearings are lubricated by the working fluid. The effects of adopting different siloxane working fluids on the thermodynamic cycle configuration, power output, and on the turbine and component design are studied by means of simulations. Toluene is included into the analysis as a reference fluid in order to make comparisons between siloxanes and a suitable low molecular weight hydrocarbon. The most influential working fluid parameters are the critical temperature and pressure, molecular complexity and weight, and, related to them, the condensation pressure, density and specific enthalpy over the expansion, which affect the optimal design of the turbine. The fluid thermal stability is also extremely relevant in the considered applications. Exhaust gas heat recovery from a 120 kW diesel engine is considered in this study. The highest power output, 13.1 kW, is achieved with toluene as the working fluid, while, among siloxanes, D4 provides the best simulated performance, namely 10.9 kW. The high molecular weight of siloxanes is beneficial in low power capacity applications, because it leads to larger turbines with larger blade heights at the turbine rotor outlet, and lower rotational speed if compares, for instance, to toluene.

Design and Flow Analysis of a Supersonic Small Scale ORC Turbine Stator With High Molecular Complexity Working Fluid

In small scale and low temperature waste heat recovery systems, Organic Rankine Cycle (ORC) technology can be identified as a promising solution in converting low-grade heat into electricity. The principle of ORC is based on a conventional Rankine process but an organic working fluid is adopted instead of steam. The use of high molecular complexity working fluids enables the design of high efficiency ORCs and are characterized by dry expansion and high pressure ratios over the turbine, as well as low speed of sound, which typically leads to highly supersonic flows in the ORC turbine stator.In order to design supersonic ORC turbines, the geometry of the turbine stator has to be based on design methods that accurately take into account the real gas effects of the working fluid during the expansion. In this study, a highly supersonic small scale ORC turbine stator using siloxane MDM as working fluid, is studied. The accurate real gas model was implemented in a CFD-flow solver in order to predict the flow field in the stator in design and in off-design conditions. The results of this study gives valuable information on realising small capacity ORC turbomachinery, characterized by highly supersonic stators, and on the off-design performance of supersonic radial turbine stator that has not been documented or discussed in the previous studies.Copyright

Design and testing of high temperature micro-ORC test stand using Siloxane as working fluid

Organic Rankine Cycle is a mature technology for many applications e.g. biomass power plants, waste heat recovery and geothermal power for larger power capacity. Recently more attention is paid on an ORC utilizing high temperature heat with relatively low power. One of the attractive applications of such ORCs would be utilization of waste heat of exhaust gas of combustion engines in stationary and mobile applications. In this paper, a design procedure of the ORC process is described and discussed. The analysis of the major components of the process, namely the evaporator, recuperator, and turbogenerator is done. Also preliminary experimental results of an ORC process utilizing high temperature exhaust gas heat and using siloxane MDM as a working fluid are presented and discussed. The turbine type utilized in the turbogenerator is a radial inflow turbine and the turbogenerator consists of the turbine, the electric motor and the feed pump. Based on the results, it was identified that the studied system is capable to generate electricity from the waste heat of exhaust gases and it is shown that high molecular weight and high critical temperature fluids as the working fluids can be utilized in high-temperature small-scale ORC applications. 5.1 kW of electric power was generated by the turbogenerator.

Loss generation in radial outflow steam turbine cascades

Due to the fact that noise emitted by aero engines became a very important issue especially during the last few years, acoustic measurements were carried out downstream of the low-pressure turbine in a two-stage two-spool test turbine. The aim of these analyses was to determine the influence of small geometry changes in the flow path of the rig under engine-relevant conditions, which usually occur during the operation of an engine. These geometry changes include steps in the flow path and different rotor tip gaps, both generated by a non-uniform warming of different parts of the engine. In order to evaluate the noise emissions, the outflow duct downstream of the second rotor was instrumented with an acoustic measurement section, which uses a circumferentially traversable microphone array located at the outer endwall. The acoustic field is characterized by azimuthal modes gained by traversing the microphone array over 360 degrees. Therefore, the spectra and emitted sound pressure levels are compared regarding different geometry changes.

Design of a 400 KW Gas Turbine Prototype

Decentralized power and heat generation is a growing trend throughout the world. In smaller applications, electrical power output less than few megawatts, reciprocating engines have dominated the market. In recent years, small sized gas turbines have emerged as challengers for the reciprocating engines. The small gas turbines have a growing share of the decentralized energy market, which itself is rapidly growing. Hence, improvements in small gas turbine efficiency have a significant impact from the economic and environmental perspective.In this paper, the design of a high efficiency 400 kW gas turbine prototype is described and discussed. The prototype is a two-spool, recuperated and intercooled gas turbine where both spools comprise of a radial compressor and turbine, a permanent magnet electric generator, an axial and two radial active magnetic bearings and two safety bearings.The prototype design was divided into five categories and each of the categories are discussed. The categories were: the process design, the turbomachinery design, the generator and electrical design, bearing design and rotor dynamic analysis, and mechanical design. The design of recuperator, intercooler, and combustion chamber were outsourced. Hence, they are not discussed in this paper.The prototype design process showed the readiness of the chosen technological selections, as well it showed that the type of machine under discussion can be designed and manufactured.© 2016 ASME

Design and Performance Measurements of a 6 kW High-Speed Micro Gas Turbine Prototype

Small portable electricity generating systems are suitable in remote locations where the access by vehicles is restricted or not even possible. These kind of places include for example catastrophic areas after earthquakes or tropical cyclones. Such machines can also be used as auxiliary power units in motor or sail boats. Gas turbine based electricity generation systems offer a good alternative for typical engine-generator units which are characterized by lower specific powers. It is suggested that the power to weight ratio of a 6 kW micro gas turbine can be more than eight times higher than that of the corresponding engine-generator unit. The biggest drawback is the higher specific fuel consumption; however, by introducing a recuperator, the specific fuel consumption can be improved.In this article, the design process and experiments of a 6 kW micro gas turbine prototype are described and discussed in detail. The built non-recuperated prototype is based on a commercial, small jet engine originally designed to give thrust to radio controlled model airplanes. The jet nozzle of the jet engine was replaced by an axial power turbine which was directly connected to a small, high speed permanent magnet generator. The experiments showed the potential of the prototype.Copyright