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1 s2.0 S1364032113000592 Main PDF
1 s2.0 S1364032113000592 Main PDF
a r t i c l e i n f o a b s t r a c t
Article history: New heat conversion technologies need to be developed and improved to take advantage of the
Received 3 July 2012 necessary increase in the supply of renewable energy. The Organic Rankine Cycle is well suited for these
Received in revised form applications, mainly because of its ability to recover low-grade heat and the possibility to be
10 January 2013
implemented in decentralized lower-capacity power plants.
Accepted 14 January 2013
In this paper, an overview of the different ORC applications is presented. A market review is
proposed including cost gures for several commercial ORC modules and manufacturers. An in-depth
Keywords: analysis of the technical challenges related to the technology, such as working uid selection and
Organic Rankine Cycle expansion machine issues is then reported. Technological constraints and optimization methods are
ORC
extensively described and discussed. Finally, the current trends in research and development for the
Waste heat recovery
next generation of Organic Rankine Cycles are presented.
Binary cycle
Biomass & 2013 Elsevier Ltd. All rights reserved.
Combined heat and power
Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2. ORC technology and applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.1. Biomass combined heat and power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.2. Geothermal energy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.3. Solar power plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.4. Waste heat recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.4.1. Heat recovery on mechanical equipment and industrial processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.4.2. Heat recovery on internal combustion engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3. ORC manufacturer and market evolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4. Comparison with the steam Rankine cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
5. Working uid selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6. Expansion machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.1. Turbomachines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.2. Positive displacement expanders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
6.2.1. Performance indicators for positive-displacement expanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.2.2. Reported performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7. Heat exchangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8. Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8.1. Controllability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8.2. Efciency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
8.3. Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
8.4. Low net pressure suction head (NPSH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
8.4.1. Pre-feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
8.4.2. Gravity fed working uid pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
n
Corresponding author. Tel.: 32 4 366 48 22; fax: 32 4 366 48 12.
E-mail address: squoilin@ulg.ac.be (S. Quoilin).
1364-0321/$ - see front matter & 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.rser.2013.01.028
S. Quoilin et al. / Renewable and Sustainable Energy Reviews 22 (2013) 168186 169
Nomenclature cd condenser
el electrical
D diameter (m) em eletromechanical
h specic enthalpy (J/(kg K)) ev evaporator
M_ mass ow rate (kg/s) ex exhaust
N rotating speed (Hz) exp expander
p pressure (Pa) in internal
pinch pinch point value (K) mech mechanical
Q_ heat power (W) ncg non-condensing gases
r ratio () pp pump
rv,in internal built-in volume ratio () sc subcooling
T temperature (1C) su supply
U peripheral speed (m/s) tp two-phase
V velocity (m/s) tot total
v specic volume (m3/kg)
W_ electrical or mechanical power (W) Acronyms
this layout can also be used to produce heat with a COP41 if the electricity through a thermodynamic cycle. The cost of biomass
ORC is coupled to a heat pump [3]. is signicantly lower than that of fossil fuels. Yet, the investment
necessary to achieve clean biomass combustion is more impor-
For an overview of these more innovative and prospective tant than for classic boilers. For small decentralized units, the
applications, the interested reader can refer to [2,3]. generation cost of electricity is not competitive and combined
heat and power generation is required to ensure the protability
2.1. Biomass combined heat and power of the investment. Therefore, in order to achieve high energy
conversion efciency, biomass CHP plants are usually driven by
Biomass is widely available in a number of agricultural or the heat demand rather than by the electricity demand [4].
industrial processes such as wood industry or agricultural waste. The possibility to use heat as a by-product is an important
Among other means, it can be converted into electricity by asset of biomass ORCs, highlighting the importance of a local heat
combustion to obtain heat, which is in turn converted into demand, which can be fullled e.g. by industrial processes (such
Fig. 1. Schematic view of an ORC with (right) and without (left) recuperator.
S. Quoilin et al. / Renewable and Sustainable Energy Reviews 22 (2013) 168186 171
as wood drying) or space heating (usually district heating) [5]. technological lower bound for power generation is about 80 1C:
Since heat is relatively difcult to transport across long distances, below this temperature the conversion efciency becomes too
biomass CHP plants are most of the time limited to 610 MW small and geothermal plants are not economical. Table 1 indicates
thermal power, corresponding to 12 MW electrical power. This the potential for geothermal energy in Europe and shows that this
excludes traditional steam cycles that are not cost-effective in this potential is very high for low temperature sources.
power range (this particular point will be further developed in To recover heat at an acceptable temperature, boreholes must
Section 4). generally be drilled in the ground, for the production well and for
Simplied diagrams of such cogeneration systems are pro- the injection well (cfr. Fig. 4). The hot brine is pumped from the
posed in Figs. 2 and 3: heat from the combustion is transferred former and injected into the latter at a lower temperature.
from the ue gases to the heat transfer uid (thermal oil) in two Depending on the geological formation, boreholes can be several
heat exchangers, at a temperature varying between 150 and thousand meters deep, requiring several months of continuous
320 1C. The heat transfer uid is then directed to the ORC loop
to evaporate the working uid, at a temperature slightly lower
than 300 1C. Next, the evaporated uid is expanded, passes
through a recuperator to preheat the liquid and is nally con-
densed at a temperature around 90 1C. The condenser is used for
hot water generation.
For the particular example of Fig. 2, although the electrical
efciency of the CHP system is limited (18%), the overall efciency
of the system is 88%, which is much higher than that of centralized
power plants, in which most of the residual heat is lost.
To reduce heat losses in the ue gases, these gases must be
cooled down to the lowest possible temperature, insofar as the acid
dew point is not reached. To achieve this, two heat transfer loops are
used: a high temperature loop and a low temperature loop. The low
temperature loop is installed after the high temperature loop on the
ue gases to reduce their outlet temperature (Fig. 3).
The main competing technology for electricity generation from
solid biofuels is biomass gasication: in this technology, biomass
is transformed into a synthetic gas composed mainly of H2, CO,
CO2 and CH4. This synthetic gas is treated and ltered to eliminate
solid particles, and is nally burned in an internal combustion
engine or in a gas turbine.
When comparing the technology and the costs of biomass CHP Fig. 3. Working principle of a biomass CHP ORC system.
using an ORC with gasication, it can be shown that gasication
involves higher investment costs (about 75%) and higher operation
and maintenance costs (about 200%). On the other hand, gasication
Table 1
yields a higher power-to-thermal ratio, which makes its exploitation Potential for geothermal energy in Europe for different heat source
more protable [6]. It should also be noted that ORC is a well-proven temperature ranges [9].
technology, while gasication plants in actual operation are mostly
prototypes for demonstration purposes. Temperature (1C) MWth MWe
CO2 emissions from the cement industry amount for 5% of the latter case, the working uid ow rate can be controlled inde-
total world GHG emissions, and half of it is due to the combustion pendently, which makes the regulation of such a system much
of fossil fuels in the kilns [14]. Other examples include the iron easier.
and steel industries (10% of the GHG emission in China for The control of the system is particularly complex due to the
example), reneries and chemical industries. (often) transient regime of the heat source. However, optimizing
the control is crucial to improve the performance of the system. It
is generally necessary to control both the pump speed and the
2.4.2. Heat recovery on internal combustion engines
expander speed to maintain the required conditions (tempera-
An Internal Combustion Engine (ICE) only converts about
ture, pressure) at the expander inlet [21].
one-third of the fuel energy into mechanical power on typical
Another technical constraint is the heat rejection capacity. The
driving cycles: a typical 1.4 l Spark Ignition ICE, with a thermal
size of the front heat exchanger (either an air-cooled condenser or
efciency ranging from 15% to 32%, releases 1.745 kW of heat
the radiator connected to a water-cooled condenser) is limited by
through the radiator (at a temperature close to 80100 1C) and
the available space and depends on the presence of an engine
4.6120 kW via the exhaust gas (400900 1C) [17].
radiator, and possibly a charge air cooler, an EGR cooler or an air-
The heat recovery Rankine cycle system (both organic and
conditioning condenser. The system should be controlled such
steam based) is an efcient means for recovering heat (in
that the rejected heat remains within the cooling margin, dened
comparison with other technologies such as thermo-electricity
as the cooling capacity without operating the cooling fans.
and absorption cycle air-conditioning). The concept of applying a
Otherwise, fan consumption can sharply reduce the net power
Rankine cycle to an ICE is not new and the rst technical
output of the system [22].
developments appeared after the 1970 energy crisis. For instance,
The performance of recently developed prototypes of Rankine
Mack Trucks [18] designed and built a prototype of such a system
cycles is promising: the system designed by Honda [23] showed a
operating on the exhaust gas of a 288 HP truck engine. A 450 km
maximum cycle thermal efciency of 13%. At 100 km/h, this
on-road test demonstrated the technical feasibility of the system
yields a cycle output of 2.5 kW (for an engine output of
and its economical interest: a reduction of 12.5% in the fuel
19.2 kW) and represents an increase of the engine thermal
consumption was reported. Systems developed today differ from
efciency from 28.9% to 32.7%.
those of 1970 because of advances in the development of expan-
A competing technology under research and development is
sion devices and the broader choice of working uids. However,
the thermoelectric generator (TEG), which is based on the
currently, no commercial Rankine cycle solution is available.
Seebeck effect: its main advantages are a substantially lower
Most of the systems under development recover heat from the
weight than the ORC system, and the absence of moving parts.
exhaust gases and from the cooling circuit [19]. By contrast, the
Major drawbacks are the cost of materials (which include rare
system developed by [20] only recovers heat from the cooling
earth metals) and the low achieved efciency.
circuit. An additional potential heat source is the exhaust gas
recirculation (EGR) and charge air coolers, in which non-
negligible amounts of waste heat are dissipated.
The expander output can be mechanical or electrical. With a
mechanical system, the expander shaft is directly connected to the 3. ORC manufacturer and market evolution
engine drive belt, with a clutch to avoid power losses when the ORC
power output is too low. The main drawback of this conguration is ORC manufacturers have been present on the market since the
the imposed expander speed: this speed is a xed ratio of the engine beginning of the 1980s. They provide ORC solutions in a broad
speed and is not necessarily the optimal speed for maximizing cycle range of power and temperature levels, as shown in Table 2. Note
efciency. In the case of electricity generation, the expander is that only manufacturers with several commercial references have
coupled to an alternator, used to rell the batteries or supply been detained in this survey.
auxiliary utilities, such as the air conditioning. It should be noted The three main manufacturers in terms of installed units and
that current vehicle alternators show a quite low efciency (about installed power are Turboden (Pratt & Whitney) (45% of installed
5060%), which reduces the ORC output power. units worldwide, 8.6% of cumulated power), ORMAT (24% of
As for the expander, the pump can be directly connected to the installed units, 86% of cumulated power) and Maxxtec (23%
drive belt, to the expander shaft, or to an electrical motor. In the of installed units, 3.4% of cumulated power) [24]. The large share
Table 2
Non-exhaustive list of the main ORC manufacturers.
Sources: Manufacturers websites; [2432].
ORMAT, US Geo., WHR, solar 20070,000 150300 Fluid : n-pentane and others, two-stage axial turbine,
synchronous generator
Turboden, Italy Biomass-CHP, WHR, Geo. 2002000 100300 Fluids : OMTS, Solkatherm, Two-stage axial turbines
Adoratec/Maxxtec, Germany Biomass-CHP 3151600 300 Fluid: OMTS
Opcon, Sweden WHR 350800 o 120 Fluid: Ammonia, Lysholm Turbine
GMK, Germany WHR, Geo., 505000 120350 3000 rpm Multi-stage axial turbines (KKK)
Biomass-CHP
Bosch KWK, Germany WHR 65325 120150 Fluid: R245fa
Turboden PureCycle, US WHR, Geo. 280 91149 Radial inow turbine, Fluid: R245fa
GE CleanCycle WHR 125 4121 Single-state radial inow turbine, 30,000 rpm, Fluid: R245fa
Cryostar, France WHR, Geo. n/a 100400 Radial inow turbine, Fluids: R245fa, R134a
Tri-o-gen, Netherlands WHR 160 4350 Radial turbo-expander, Fluid: Toluene
Electratherm, US WHR, Solar 50 493 Twin screw expander, Fluid: R245fa
174 S. Quoilin et al. / Renewable and Sustainable Energy Reviews 22 (2013) 168186
of ORMAT in the cumulated power is explained by its focus on the curve is much closer to vertical for organic uids. As a
large-scale, low temperature geothermal binary plants. consequence, the limitation of the vapor quality at the end of
It should be noted that, in addition to the manufacturers listed the expansion process disappears in an ORC cycle, and there is no
in Table 2, many companies are entering the ORC market with need to superheat the vapor before the turbine inlet. (2) The
low-capacity units, e.g. for micro-CHP or for WHR on IC engine entropy difference between saturated liquid and saturated vapor
exhaust gases. However, these companies have not yet reached is much smaller for organic uids. Hence, the vaporization
sufcient technical maturity for large-scale competitive commer- enthalpy is smaller. Therefore, to take up equal thermal power
cialization [25]. in the evaporator, the organic working uid mass ow rate
The ORC market is growing rapidly. Since the rst installed must be much higher than for water, leading to higher pump
commercial ORC plants in the 1970s, an almost-exponential consumption.
growth has been stated, as visualized in Fig. 6, where the
evolution of installed power and the number of plants in opera-
tion, based on a compilation of manufacturer data, is depicted.
Fig. 6 also reveals that the ORC is a mature technology for
waste heat recovery, biomass CHP and geothermal power, but is
still very uncommon for solar applications. Moreover, systems are
mainly installed in the MW power range and very few ORC plants
exist in the kW power range.
The variety of ORC modules is large and can be categorized
according to unit size, type of technology, and target application.
In Fig. 7 some typical ORC module costs, for different applications,
are plotted as a function of their size. Note that the provided costs
are indicative only and partially collected from a non-exhaustive
set of ORC manufacturers and from scientic publications
[26,3335]. The scattering in the data is due to different prices
for different manufacturers, different market strategies, different
integration costs, etc. Therefore, individual costs should not be
generalized, but are given merely to illustrate the general trend of
system prices relative to the output power. Fig. 7 indicates that, Fig. 7. Module (empty dots) and total (plain dots) cost of ORC systems depending
for a given target application, the cost tends to decrease when the on the target application and on the net electrical power.
output power increases. Lowest costs are reported for waste heat
recovery applications, while geothermal and CHP plants exhibit
higher total cost. Total cost differs from module cost in that it
includes engineering, buildings, boiler (in case of CHP), process
integration, etc., and can amount to two to three times the
module cost. These surplus costs should therefore never be
neglected when evaluating the economics of an ORC plant.
Fig. 6. Market evolution (left) and share of each application in terms of number of units (right) Data Source: [24].
S. Quoilin et al. / Renewable and Sustainable Energy Reviews 22 (2013) 168186 175
The main differences between ORCs and steam cycles are the Table 3
following: Advantages and drawbacks of each technology.
for each specic thermodynamic property independently. The (11) Low Ozone Depleting Potential (ODP): the ozone depleting
most common approach consists in simulating the cycle with a potential is 11, expressed in terms of the ODP of the R11, set
thermodynamic model while benchmarking different candi- to unity. The ODP of current refrigerants is either null or very
date working uids. close to zero, since non-null ODP uids are progressively
(2) Positive or isentropic saturation vapor curve: as previously being phased out under the Montreal Protocol.
detailed in the case of water, a negative saturation vapor (12) Low Greenhouse Warming Potential (GWP): GWP is mea-
curve (wet uid) leads to droplets in the later stages of the sured with respect to the GWP of CO2, chosen as unity.
expansion. The vapor must therefore be superheated at the Although some refrigerants can reach a GWP value as high
turbine inlet to avoid turbine damage. In the case of a as 1000, there is currently no direct legislation restricting
positive saturation vapor curve (dry uid), a recuperator the use of high GWP uids.
can be used in order to increase cycle efciency. This is (13) Good availability and low cost: uids already used in
illustrated in Fig. 9 for isopentane, R11 and R12. refrigeration or in the chemical industry are easier to obtain
(3) High vapor density: this parameter is of key importance, and less expensive.
especially for uids showing a very low condensing pressure
(e.g. silicon oils). A low density leads to a higher volume ow
rate: the sizes of the heat exchangers must be increased to While uid selection studies in the scientic literature cover a
limit the pressure drops. This has a non-negligible impact on broad range of working uids, only a few uids are actually used
the cost of the system. It should however be noted that larger in commercial ORC power plants. These uids are summarized in
volume ow rates can allow a simpler design in the case of Table 4, classied in terms of critical temperature [32].
turboexpanders, for which size is not a crucial parameter. In general, the selected uid exhibits a critical temperature
(4) Low viscosity: low viscosity in both the liquid and vapor slightly higher than the target evaporation temperature: if the
phases results in high heat transfer coefcients and low evaporation temperature is much higher than the critical
friction losses in the heat exchangers. temperaturefor example if toluene (Tc 319 1C) is evaporated
(5) High conductivity is related to a high heat transfer coef- at 100 1Cvapor densities become excessively low in both the
cient in the heat exchangers. high and low pressure lines.
(6) Acceptable evaporating pressure: as discussed for the case of Table 5 summarizes the scientic literature in the eld of
water as working uid, higher pressures usually lead to working uid selection for ORC systems. To compare the different
higher investment costs and increased complexity. papers, three characteristics are taken into account: the target
(7) Positive condensing gauge pressure: the low pressure should application and the considered condensing/evaporating tempera-
be higher than the atmospheric pressure in order to avoid air ture ranges. The papers comparing the working uid performance
inltration into the cycle. as a function of the turbine inlet pressure (for example [57]) and
(8) High temperature stability: unlike water, organic uids not the temperature are excluded since the main limitation in the
usually suffer chemical deterioration and decomposition at ORC technology is the heat source temperature and not the high
high temperatures. The maximum heat source temperature pressure.
is therefore limited by the chemical stability of the working From Table 5 it becomes apparent that, despite the multiplicity
uid. of working uid studies, no single uid has been identied as
(9) The melting point should be lower than the lowest ambient optimal for the ORC. This is due to the different hypotheses used
temperature through the year to avoid freezing of the to perform uid comparisons:
working uid.
(10) High safety level: safety involves two main parameters
toxicity and ammability. The ASHRAE Standard 34 classies Some authors consider the environmental impact (ODP,
refrigerants in safety groups and can be used for the GWP), the ammability, and the toxicity of the working uid,
evaluation of a particular working uid. while other authors do not.
Table 4
Common working uids in commercial ORC installations.
HFC-134a Used in geothermal power plants or in very low temperature waste heat recovery.
HFC-245fa Low temperature working uid, mainly used in waste heat recovery.
n-pentane Used in the only commercial solar ORC power plant in Nevada. Other applications include waste heat recovery and medium temperature geothermy.
Solkatherm Waste heat recovery
OMTS Biomass-CHP power plants
Toluene Waste heat recovery
S. Quoilin et al. / Renewable and Sustainable Energy Reviews 22 (2013) 168186 177
Table 5
Summary of different working uid studies.
Ref. Application Tcd (1C) Tev (1C) Considered uids Recommended uids
The part of the study evaluating supercritical working uids has not been taken into account.
n
Max/min temperature of the heat source/sink instead of evaporating or condensing temperature.
Table 6
Overview of previous experimental studies on positive-displacement expanders.
Badr et al. [38] Rotary vane expander f luid R113 es,mech 55%
psu o 7 bar W_ mech 1:6kW
Zanelli and Favrat [66] Hermectic, lubricated scroll expander T su 1701C es,el 65%
psu 6:4bar; j 95120%
N rot 24003600rpm; _ el 13:5kW
W
f luid R134a
r p 2:44
Yanagisawa et al. [67] Oil-free scroll air machine V s,cp 100cm3 psu 6:5bar es,mech 60%
r v,nin 3:18 N rot 2500rpm; j 76%
f luid air
Manzagol et al. [76] Cryogenic scroll expander, V_ s, 10l=h psu 7bar es,mech 60%
T su 35K
f luid Helium
Kane et al. [77] Hermectic, lubricated scroll expander rv,nin 2.3 N rot 3000rpm es,el 68%
_ el 6:5kW
W
Ingley et al. [78] Scroll expander Nrot 2000 rpm; uid amomnia es,mech 18.2%
W_ mech 0:209kW
Xiaojun et al. [79] Scroll expander (fuel cell) psu 14bar; es,mech 69%
f luid air W_ mech 3:5kW
Aoun and Clodic [68] Oil-free scroll air machine V s,ext 31:5cm3 T su 1901C es,2,mech 48%a
r v,nin 3:18 N rot 16002500rpm; j 62%
f luid steam _
W mech 500W
r p 35
Peterson et al. [75] Kinematically rigid scroll expander V s,exp 12cm3 T su 1701C es,mech 49:9%
r v,nin 4:57 psu 6:4 bar; j 4050%
N rot 1287rpm; _ mech 0:256kW
W
f luid R123
r p 3:82
Kim et al. [80] Self-designed double-sided scroll expander f luid steam es,mech 34%
psu 13:8bar j 0:420:52
N rot 10001400rpm _ mech 11:5kW
W
Mathias et al. [82] Refrigeration Scroll expander f luid R123 es,el 48.3%b
r p 38:3 _ el 2:9kW
W
Lemort et al. [69] Oil-free open-drive scroll air machine rv,nin 4 T su 1431C es,mech 68%
V s,exp 36:54 cm3 psu 10bar; j 11:34
f luid R123 _ mech 1:8kW
W
Wang et al. [83] Compliant scroll expander derived from an existing T su 1251C; es,mech 77%
psu 1018 bar; _
W
compressor V s,exp 6:5cm3 mech 1kW
r v,nin 2:5 N rot 20053670rpm;
f luid R134a
rp 2:654:84
Manolakos et al. [70] Automotive A/C scroll expander f luid R134a es,mech o 50%
N rot 891rpm
Harada [84] Refrigeration scroll expander with direct shaft connection f luid R245f a es,mech 87%
r p 27; _ mech 1kW
W
S. Quoilin et al. / Renewable and Sustainable Energy Reviews 22 (2013) 168186 181
Table 6 (continued )
Lemort et al. [74] Hermetic refrigeration scroll machine rv,in E3 f luid R245 f a es,el 68%
r p 26 j 11:1
T su 92140 1C; _ el 2:2kW
W
psu 616bar;
Qiu et al. [87] Compressed-air-driven vane-type air expander f luid HFE7000 es,el 26%b
psu 6:7 bar _ el 850W
W
T su 117 1C;
N rot 1689 rpm:
a
The authors only provided the enthalpy ratio denition of the isentropic efciency (Eq. (4)).
b
Recalculated with the measured values provided in the paper.
higher than 60%. Screw expander performance seems to be usually using thermal oil. Direct evaporation, although more
slightly lower: none of the experimental studies reports perfor- efcient and conceptually simpler, involves a number of issues:
mance much higher than 60%. Other types of positive-displace-
ment expanders such as the vane or gerotor types also show low
efciencies, which may be due to the fact that experimental At high temperatures (e.g. during start-up and transients),
studies on these machines are scarce in the literature. the working uid can deteriorate when its maximal chemical
stability temperature is reached, or when hot spots appear in
the heat exchanger.
7. Heat exchangers The controllability and the stability of the systems are harder
to achieve in case of direct evaporation. In contrast, a heat
The remaining components of the cycle, although well-known, transfer loop damps the fast variations of the heat source and
also deserve some attention, particularly in light of their selection allows smoother cycle operation (e.g. to control the super-
and integration into ORC systems. Heat exchangers represent a heating in a solar ORC system).
major share of the total module cost. Their optimization should
therefore be carefully performed. As a consequence, most commercial ORC installations make
Key characteristics regarding heat transfers are the efciency use of an intermediate heat transfer loop (see for example Fig. 3).
(or pinch point) and pressure drops. Each heat exchanger in the Advanced architectures also focus on the integration of the heat
cycle is sized according to these two parameters. Different types exchangers. A good example is provided by the Turboden unit
of heat exchangers can be used, the most common being shell & (Fig. 14): the condenser and the recuperator are integrated into a
tube (mainly in larger-scale systems) and plate heat exchangers single component together with the turbine and the liquid receiver,
(mainly in small-scale systems, due to their compactness). which increases compactness, avoids piping and reduces leakages.
A critical heat exchanger is usually the exchanger installed on
the heat source. Depending on its nature, this heat exchanger
must withstand high temperatures and can be subject to fouling 8. Pump
and/or corrosion. In case of waste heat recovery, the heat
exchanger must not interfere with the process, i.e. the pressure ORC feed pumps are key components and should be given
drop should be limited and its dimensions must comply with the particular care during the selection and sizing process. They
available space. Moreover, in case of ue gases with sulfur should comply with the cycle requirement in terms of controll-
content, the acid dew point should be avoided. This explains ability, efciency, tightness and NPSH, as described below.
why in most commercial plants the exhaust gases are not cooled
below 120180 1C, depending on the sulfur content of the gases. 8.1. Controllability
Research is being carried out to design heat exchangers able to
withstand and evacuate acid condensates. In most ORC systems, the pump is used to control the working
Heat can be recovered by means of two different setups: uid mass ow rate. The electrical motor is connected to an
(1) direct heat exchange between heat source and working uid inverter which allows varying the rotating speed. In positive-
and (2) an intermediate heat transfer uid loop that is integrated displacement pumps, the ow rate is roughly proportional to the
to transfer heat from the waste heat site to the evaporator, rotating speed, while in centrifugal pumps this ow rate also
182 S. Quoilin et al. / Renewable and Sustainable Energy Reviews 22 (2013) 168186
8.2. Efciency
W_ pp
BWR 7
_ exp
W
Fig. 15 shows the BWR for a few typical uids as a function of the
evaporating temperature. Two conclusions can be drawn from this
gure:
(1) The higher the critical temperature of the working uid, the Fig. 15. BWR as a function of evaporation temperature for different uids.
lower the BWR.
(2) BWR increases with Tev, and gets signicantly high when According to manufacturer data, centrifugal pumps (usually
operating the cycle close to the critical point. used in larger-scale units) should exhibit efciencies higher than
60%, and diaphragm pump should operate over 4050%. However,
Therefore, the pump efciency is a crucial parameter in low no actual data is available in the literature to conrm these
temperature cycles and in transcritical cycles. Few pump efcien- gures.
cies are reported in the literature, and they are usually quite low
for low capacity units:
8.3. Tightness
An overall isentropic efciency of 25% has been reported by Organic uids are expensive and can be ammable, toxic and
some of the authors in a 2 kWe ORC unit [89]. have high GWP or ODP values. Hence, it is important to ensure
Reid [90] reports a pump efciency of 7% on kW-scale ORC full tightness of the cycle. This explains why diaphragm pumps
cycle using HFE-7000; are usually preferred to piston pumps. Note that diaphragm
Quoilin [91] obtained a 22% efciency on a diaphragm pump pumps generate a pulsed ow rate, which can, in some cases,
using RHFC-245fa. constitute a drawback (e.g. because of uctuations in pressure
Bala et al. [92] studied the inuence of different working and ow rate measurements). When using centrifugal pumps,
uids on the overall efciency of sliding-vane refrigerant tightness is ensured by a shaft seal.
pumps; the highest reported efciency was about 20%.
Melotte [88] performed an experimental study on a centri- 8.4. Low net pressure suction head (NPSH)
fugal pump working with solkatherm, and obtained an ef-
ciency varying between 10% and 20%. This parameter is critical for the design of the ORC. Strategies
must be set up to avoid pump cavitation, which can lead to
Note that these efciencies are all electrical efciencies, i.e. damages in the pump, to a reduction of the working uid ow
incorporate the motor efciency, which can be low for small units rate, and to the necessity to shut down the cycle. The most
or if the motor is oversized. common strategies are briey described in the next sections.
S. Quoilin et al. / Renewable and Sustainable Energy Reviews 22 (2013) 168186 183
8.4.1. Pre-feed pump therefore subcooled [93]. This subcooling is expressed in terms of
A rst pump with low NPSH is added before the main feed the difference between the saturation temperature corresponding
pump (see Fig. 16) to provide the required pressure head. This is to the total pressure and the actual condensing temperature (i.e.
the strategy selected e.g. in the Tri-O-Gen Unit, in which the main the temperature measured in the condenser and at the pump
pump is directly connected to the turbine shaft and enclosed in a inlet):
hermetic container with the generator to avoid leakage of toluene
DT sc T sat ptot T cd 11
(Fig. 16). To avoid cavitation, the pressure head provided by the
pre-feed pump must be higher than the main pump NPSH for all The condition for no cavitation states that the amount of
ow rates: subcooling must be sufcient to provide the NPSH required by
_ 4 NPSHpp the pump, i.e. the partial pressure of the introduced non-
Dppref eed M 8
condensing gases must be higher than NPSH:
DpDT sc ptot ppart,wf ppart,ncg 4 NPSHpp 12
8.4.2. Gravity fed working uid pump
The required pressure head can be provided by a static
pressure difference due to the vertical distance between the 8.4.4. Thermal subcooling
condenser (or the liquid receiver) and the pump. This strategy The required NPSH can be obtained by thermally subcooling
was selected by companies such as Turboden (typically for large- the working uid. As shown in Fig. 17, this can be performed in
scale ORC plants), which install the feed pumps in a cavity about three different ways:
4 m lower than the condenser (Fig. 14). The no-cavitation condi-
tion can be written
rg Dh4 NPSHpp 9 (A) Using an additional heat exchanger (subcooler) after the
liquid receiver. It should be noted that a separate liquid
where r is the uid density in liquid state, g is the gravity and Dh
receiver is not compulsory. The shell of the condenser (e.g.
is the level difference.
in case of shell and tube heat exchanger) can also play this
role and absorb the level uctuations of the working uid.
8.4.3. Addition of non-condensing gases (B) Adding the subcooler directly into the liquid receiver. This
When adding non-condensable gases (e.g. nitrogen), a small solution avoids the use of an additional heat exchanger. It is
fraction of them is dissolved in the working uid and circulates the one selected in the Eneftec unit.
through the cycle. However, the main part remains in gaseous (C) Subcooling in the condenser by ensuring that a part of it is
state and is carried by the main ow to the condenser, where it ooded by liquid. This solution corresponds to a very simple
accumulates because of the condensation of the working uid. It architecture but is also the most difcult to control: the
is therefore in the condenser and in the liquid receiver that the refrigerant charge must be exactly adapted to the required
concentration of non-condensable gases is highest. subcooling (too much refrigerant in the cycle entails a larger
The pressure at the pump inlet is the sum of two partial liquid zone in the condenser and therefore excessive subcool-
pressures: ing) and the operating conditions cannot vary since this
causes uctuations of the liquid level.
When the working uid leaves the gasliquid interface toward 9. Next generation organic Rankine cycles and current R&D
the pump (i.e. it is no longer in contact with the non-condensing
gases), its pressure is higher than the saturation pressure. It is At the present time, most commercial ORC plants exhibit a
simple architecture: sub-critical working conditions, pure work-
ing uids, single evaporation pressure, and possible use of a
recuperator.
Fig. 16. ORC system with common pump and expander shaft and pre-feed pump. Fig. 17. Different strategies for thermal subcooling.
184 S. Quoilin et al. / Renewable and Sustainable Energy Reviews 22 (2013) 168186
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