POTENTIAL OF ORGANIC RANKINE

CYCLE BASED HEAT RECOVERY

SYSTEMS FOR POWER GENERATION
Research for MEng. in Energy Technology

Advisors : Prof. R. A. Attalage &

Dr. R. A. C. P. Ranasinghe

16th December 2015

Presented by:
B. S. Rumesh Fernando
118358 C
 OVERVEIW

 Research Background
 Aim and Objectives
 WH in Thermal Plants
 Technology Selection
 Modeling of ORC system
 Analysis of ORC
 Economic Evaluation
 Conclusions
 BACKGROUND & OBJECTIVES

 Electricity generation – Around 60% based on thermal

power generation
 Fossil Fuel Imports - Government spend 1/3 of national GDP
 World Market – All the fossil fuel prices are steadily
increased in last few decades
 Generation Efficiencies – Thermal plant eff. vary 20% ~ 43 % &
overall eff. recorded 2013 is 32%

Highlighting Point
If overall plant efficiencies increased by 1%, approximately Rs: 15 million
can be saved annually.
BACKGROUND & OBJECTIVES Cont…

Aim
To investigate WHR potential in thermal plants; carryout
techno-economic feasibility analysis and evaluate viability of
implementation.

Objectives
 To investigate WH opportunities of thermal plants in Sri
Lanka.
 To analyses WHR methods and technologies.
 To evaluate the viability of implementation, technically and
economically with appropriate recovery technologies.
 WH in Thermal Plants

 Following table represent WH energy of selected thermal plants

 Calculations has been done on average basis

Avg. Exhaust Stack Temp. to Specific Heat Exhaust

Avg. Exhaust
Plant Gas Temp. be maintained Capacity Cp Energy at the
Gas Qty (kg/hr)
(OC) (oC) (kJ/kgK) Stack (kW)

SPS Side A 440 180 140160 1.1095 11231.099

SPS Side B 430 180 79200 1.1095 6102.25
Coal Plant 150 90 1,000,000 1.075 17916.667
Coal Plant
275 100 8700 1723.4458
Blowdown
Jaffna Plant 417 240 6800 1.1307 378.03
Kelewarapitiya
510 160 1,512,000 1.1307 598366440
GT
 Waste Heat Recovery Methods
& Classification

Passive Heat Recovery Active Heat Recovery

- Recuperators Available Emerging

- Regenerators Technologies Technologies
- Heat Wheels
- Heat Pipe
- Economizers
- Shell & Tube Heat - Steam Rankine Cycle - High Temperature Fuel Cells
Exchanges - Organic Rankine Cycle - Stirling Cycle
- Plate Heat Exchangers - Kalina Cycle - Low Temperature Fuel Cells
- Run Around Coil - Absorption Cycle - Thermal Photovoltaic
Exchangers
- Waste Heat Recovery
Boilers
- Heat Pumps
 Technology Selection
 Here, power generating WHR systems were selected and
evaluated. They are as follows;
- Kalina Cycle – Performance less than ORC
- Goswami Cycle – Still in the implement state
- Trilateral Flash Cycle – Not in commercial state due to lack of
efficient two-phase expander
- Organic Rankine Cycle (ORC) – Better performance and
commercially viable

Accordingly ORC has selected for further study in the research

 Fluid Selection
 Selection of working fluid is the most critical factor for
ORC.
 Ideal Fluid – Fluid Properties, Saturated Line,
High Output, ODP, GWP, etc…

Considering all, 11 fluids were selected;

 Organic Fluids - Toluene, Benzene,
Decane, Pentane, Heptane
 Refrigerant Fluids - R245fa, R123, R113,
R245ca, R134a, R114
 Modeling of ORC system
Equations
- Expander 𝑊ሶ 𝑒𝑥𝑝 = 𝑚ሶ × ℎ1 − ℎ2 × 𝜼𝑖𝑠
- Evaporator 𝑄ሶ 𝑒𝑣𝑎𝑝 = 𝑚ሶ × (ℎ1 − ℎ4) Model
𝑚ሶ ×𝒱𝑝𝑢𝑚𝑝 × 𝑃4 −𝑃3 × 100
- Working Pump 𝑊ሶ 𝑝𝑢𝑚𝑝 = ൗ𝜼𝑝𝑢𝑚𝑝.𝑖𝑠
𝑊ሶ 𝑜𝑢𝑡 𝑊ሶ 𝑒𝑥𝑝
- Efficiency 𝜼𝑐𝑦𝑐𝑙𝑒 =
𝑊ሶ 𝑖𝑛
=
𝑄ሶ 𝑒𝑣𝑎𝑝 + 𝑊ሶ 𝑝𝑢𝑚𝑝

1 Expander

Analysis
Evaporator
- Varying the evaporator temperature
2
- Varying pressure ratio of the expander
4 Condenser

Pump
3
Combined graph on temperature analysis - Output
140

120
R 245fa

R 123
100
Toluene
Expander Work, (kW)

R 113
80

Benzene

60 R 245ca

Decane
40
R 134a

R 114
20
Pentane

0 Heptane
0 50 100 150 200 250 300 350

-20

Evaporator Temperature, (oC)

Combined graph on temperature analysis - Efficiency
45

40
η R245fa %

35 η R123 %

η Toluene %
η Organic Rankine Cycle, %

30
η R113 %

25 η Benzene %

η R 245ca %
20

η Decane %
15
η R 134a %

10 η R 114 %

η Pentane %
5
η Heptane %

0
0 50 100 150 200 250 300 350

Evaporator Temperature, (oC)

 Expander Output, (kW)

100
120
140

0
20
40
60
80
20.22

20.43

27.34

26.07

2.82

13.75

Working Fluid
η cycle %
84.61

5
0
10
15
25
30
35
45

20
40
73.18
17.31

119.51
18.97

71.83
25.19

94.06
20.02

3.40

17.27
Working Fluid
28.91

25.02

40.29

26.41

33.51
Temp. Analysis – Output & Efficiency
 Temp. Analysis – Working Fluid Operating Range
350

40
300
Temperature Range, (oC)

40
250 50
40

200
40
40
150 40
40
40
40
100
20
50

Here, working fluid operating range size is mentioned in middle of the blue colour column
Combined graph on pressure analysis - Output
120

R 245fa
100
R 123

Toluene
Expander Work Output, (kW)

80
R 113

Benzene

60 R 245ca

R 114

Pentane
40

Heptane

Decane
20
R 134a

0
0 5 10 15 20 25

P1/P2 Pressure Ratio Graphs

 Combined graph on pressure analysis - Efficiency
40

35 η R 245fa %

η R 123 %
30
η Toluene %
Cycle Efficiency, η %

25 η R 113 %

η Benzene %
20
η R 245ca %

15 η Decane %

η R 134a %
10
η R 114 %

η Pentane %
5

η Heptane %
0
0 5 10 15 20 25

P1/P2 Pressure Ratio

 Expander Output, (kW)

100
120

0
20
40
60
80
23.52

19.84

23.54

23.52

5.09

13.29

Working Fluid
77.49
η cycle %

0
5
10
15
20
25
30
35
40
45 66.52

18.84
100.28

18.44
64.62

23.48
84.60

20.18

5.48

17.14

Working Fluid
28.08

23.94

38.12

25.15

32.19
Pressure Analysis – Output & Efficiency
 Pressure Analysis – Working Fluid Operating Range
60

50
Expander Pressure, (bar)

40
26

30 20

18 18 20 14
16 16
12 10
20
6

10

Here, working fluid operating range size is mentioned in middle of the blue colour column
 EONOMIC EVALUATION
 Investment Criteria & Cost
 Plants below 250kW - USD 2500 per kW
 Plants above 250kW - USD 2200 per kW
 Plants above 1MW - USD 1800 - 2000 per kW
Expected Estimated Investment Total
Waste Heat Recovery Organic
Electric Plant Capacity Cost (USD) Investment
Opportunity Fluid
Output (kW) (kW) per kW Rs.

Sapugaskanda Power R113 458.831 460 2200 131,560,000.00

Station
Lakvijaya Coal Plant R114 335.807 340 2200 97,240,000.00

Jaffna Diesel Plant Heptane 24.730 25 2500 8,125,000.00

Keravalapitiya Plant Pentane 6797.654 6800 1800 1,591,200,000.00

Kelanithissa GT R113 1393.187 1400 1800 327,600,000.00

(20MW) Plant

Lakvijaya Plant Boiler R114 44.850 45 2500 14,625,000.00

Blow Down
 Economic Evaluation Cont…

 Defined scenarios for NPV calculations

Average Unit Selling Price Bank Interest Rate

Practical Situations
(Rs. Per kWh) %
Scenario 1 14.00 8%
Scenario 2 15.00 8%
Scenario 3 15.40 8%
Scenario 4 14.00 10%
Scenario 5 15.00 10%
Scenario 6 14.00 12%
Scenario 7 Actual running hours + Rs. 15.00 /kWh + 10% int. rate

NPV Calculations
 Economic Evaluation Cont…
 Evaluate the investment by NPV method with next 5
year income generation

WHR
Scenario 1 Scenario 2 Scenario 3 Scenario 4 Scenario 5 Scenario 6 Scenario 7
Opportunity
Sapugaskanda
Power Station
x √ √ x √ x √
Lakvijaya Coal
Plant
x √ √ x x x √
Jaffna Diesel
Plant
x x x x x x x
Kelevarapitiya
Plant
√ √ √ √ √ √ √
Kelanithissa GT
Plant
√ √ √ √ √ √ x
Lakvijaya
Blowdown
x x x x x x √
 CONCLUSIONS
 Theoretical Evaluation
- No ideal fluid (vary with T & P range)
- Optimum working fluid selecting depends on heat source
temperature
- Recommended to operate in Sub-critical region (Dry or
isentropic)
- In both analysis fluid Decane has show highest outputs
- Both analysis shows fluid R 134a not suitable
- Analysis shows, refrigerant fluids suitable below 200 oC,
organic fluids suitable higher than 200 oC
 CONCLUSIONS Conts…
 Economic Evaluation

- Sapugaskanda Plant
- Lakvijaya Plant Feasible for WHR
by ORC plant
- Lakvijaya Plant Blowdown
THANK YOU