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Commentator

Join Date: Feb 2009
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Organic Rankine vs. Steam Rankine Cycle Efficiency

02/18/2009 2:45 PM

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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Anonymous Poster
#1

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

02/18/2009 2:51 PM

I sugegst that you contact ORMAT TURBINES which is the leader in this type of technology.

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Power-User

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#2

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

02/18/2009 3:21 PM

The "thermodynamic bottleneck" is the temperature of heat rejection (condensation) - most commonly ambient air/water. Please review "Carnot Efficiency".

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Commentator

Join Date: Feb 2009
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#3

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

02/18/2009 4:43 PM

Thanks for the input, folks.

Looking at the problem from the standpoint of Carnot efficiency resolves the issue for all low-temp differential applications (steam or otherwise); and apparently resolves the whole matter without further discussion.

On this basis, most ORC systems would seem to be pegged for generally lower efficiency by nature; as Carnot resolves that efficiency is pinned to the overall cycle's temperature differential: A relatively small difference in Tin - Tout = a small capacity to transform that available heat into work.

Correct?

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#4
In reply to #3

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

02/18/2009 5:30 PM

Correct.

And please keep in mind three things:

  1. Carnot efficiency must be calculated with absolute temperatures.
  2. The process efficiency is further exasberated because, in order to get any practical heat transfer in the evaporator or condenser - the working fluid temperature has to be appreciably lower or higher than the sink/source temperatures.
  3. Lowering the temperature of the cold reservoir will have more effect on the ceiling efficiency of a heat engine than raising the temperature of the hot reservoir by the same amount (1-Tc/Th); but this is usually limited to ambient conditions.
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Commentator

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#5
In reply to #4

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

02/18/2009 5:47 PM

On the basis of simple Carnot efficiency (1-Tc/Th) taken from Rankine values (Tc & Th), it's a real "read 'em and weep" scenario for most practical heat engine efficiencies in general: The picture becomes clear.

There has to be a better way out there somewhere . . .

Thanks for the information; and cheers!

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#6
In reply to #5

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

02/18/2009 11:03 PM

I might have missed it in the thread, but the Rankine cycle as normally used in plants and ships, including nuclear boilers, most often includes a vacuum at the condensor end, so that more energy may be derived from the working fluid, with normal sea temperatures. This also prevents the after part of the turbine from being impinged by saturated steam causing blade erosion. The overall efficiency of the system is increased by using the saturated steam in other parts of the system, such as evaporators, eductors to create vacuum, steam heating in the living spaces, preheating incoming boiler water or bunker fuel, etc.

I liked working on a steamship like the Del Orleans (as the Training Ship Golden Bear), because it was a working thermodynamics lab.

Heat Recovery Steam Generators are also used on the exhaust of diesel and gas turbine plants for the equivalent reasons.

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Anonymous Poster
#8
In reply to #5

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

01/30/2011 11:10 AM

Insatiable said... "On the basis of simple Carnot efficiency (1-Tc/Th) taken from Rankine values (Tc & Th), it's a real "read 'em and weep" scenario for most practical heat engine efficiencies in general: The picture becomes clear.

There has to be a better way out there somewhere . . ."

Have you had any success in finding a "better way?"

I'm interested because there are a number of processes out there (Focardi & Rossi & Black Light Power as two examples) where the enthalpies are greater than those associated with "normal" chemical reactions.

Black Light has a hydrino theory; Focardi says "cold fusion" but without a sensible theory.

These appear to be reproducible processes, but the Heat generated is relatively low temperature -- 100C or a bit more at or near atmospheric pressure.

Thermal efficiency (heat energy in vs heat energy out) is around 3:1 up to maybe 10:1. Complicating the situation is the fact that a percentage of the output energy must be fed back to sustain the reaction.

With ORC efficiencies of 10%, there simply isn't enough energy to keep the whole process running AND get energy out.

None of my searches shows any way out, but I just started looking. You've had 2 years! :-)

Hence the question.

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Anonymous Poster
#9
In reply to #8

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

01/30/2011 7:29 PM

For anyone who might be interested:

http://www.cbsnews.com/video/watch/?id=4955212n

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Power-User

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#7

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

02/19/2009 9:06 AM

And where does "latent heat of vaporization" come in? Since the exhaust has to be a gas, the heat of vaporization is lost for power generation, though it can be used for heating, etc. Wouldn't an organic fluid which vaporized easily, compared with water, and behaved more like an ideal gas, lead to greater efficiency?

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#10

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

02/20/2011 11:36 PM

Why the concern over "efficiency"? If you are capturing waste heat from other processes, even 10% is a gain over what would normally go up the stack. The question really should not be efficiency, but whether the limited wasted energy can be recovered cost-effectively. If it takes 50 years to recover the investment with a piece of equipment with a 40 year life expectancy, obviously this is not a good investment...

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Participant

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#11
In reply to #10

Re: Organic Rankine vs. Steam Rankine Cycle Efficiency

08/22/2011 11:00 AM

Ah! since you are talking about cost-efficiency, Power plants are talking about waste heat recovery because the cost of making their own electricity and maybe get renewable certificates is lesser than buying electricity from the grid.

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