Good day, folks.
I have a question which stems from claims concerning the efficiency of ORC (Organic Rankine Cycle) vs. its standard saturated steam counterpart.
As I have been given to understand the issue, ORC is oft called upon to scavenge waste heat from more energetic power generation cycles; effectively collecting that which would otherwise be lost. In addition, it has proven useful in low-temperature settings of varied type: Solar trough, geothermal, and other thermodynamically-similar applications have all been successfully paired with ORC to generate power through turbomachinery.
The question which I have surrounds the overall efficiency of the mature ORC apparatuses which are in use by industry vs. that which is typical of conventional steam systems. Here are the particulars which I wish to present as fodder for this discussion:
- In the ORC process, heat is transferred to the working fluid (most commonly R-134a these days) from another medium by a high-efficiency heat exchanger of some sort. I may be in error, but I reckon this transfer to be at least 60% efficient (?)
- From here, the fluid is transferred through a system of conduits and valves; knocking off a percentage of the total energy available to the turbine along the way (down to 50%?).
- At this point, the fluid is run into the turbine for power generation. In one instance, turbine efficiency for ORC is claimed to be unbelievably high; around 85%. Figuring this value to be nearly ideal; we could probably admit 75% as a more realistic value.
- From here, we can conservatively consider the generator to produce actual electrical current at around 80% overall efficiency; inclusive of drivetrain losses.
On the basis of the forgoing assumptions (hopefully all conservative), we wind up with a predicted overall ORC system efficiency of around 30%. On the low side vs. mature steam systems (~45%); but still pretty good.
However, as is cited in one prominent example furnished by The Alaska Energy Authority (amongst several others), 10% overall efficiency is considered to be the norm for ORC systems in practical usage; regardless of scale/setting!
So here's the question: Where is the thermodynamic bottleneck in the conveyance of energy from a selected heat source to the generator in an ORC setting? With all of the supposed thermodynamic advantages of ORC over steam, it would seem that we should be able to match/exceed the 40+% heat-to-electricity conversion efficiency bar which is set by current mature steam Rankine apparatuses in actual practice.
So, assuming that I am in significant error somewhere in my forgoing estimates, am I too high efficiencywise at the
- Heat exchanger level;
- Conduit level; or
- Turbine level?
Thank you for your interest, and have a good day 
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