US20100263380A1 - Cascaded organic rankine cycle (orc) system using waste heat from a reciprocating engine - Google Patents
Cascaded organic rankine cycle (orc) system using waste heat from a reciprocating engine Download PDFInfo
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- US20100263380A1 US20100263380A1 US12/738,028 US73802810A US2010263380A1 US 20100263380 A1 US20100263380 A1 US 20100263380A1 US 73802810 A US73802810 A US 73802810A US 2010263380 A1 US2010263380 A1 US 2010263380A1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02G—HOT GAS OR COMBUSTION-PRODUCT POSITIVE-DISPLACEMENT ENGINE PLANTS; USE OF WASTE HEAT OF COMBUSTION ENGINES; NOT OTHERWISE PROVIDED FOR
- F02G5/00—Profiting from waste heat of combustion engines, not otherwise provided for
- F02G5/02—Profiting from waste heat of exhaust gases
- F02G5/04—Profiting from waste heat of exhaust gases in combination with other waste heat from combustion engines
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K23/00—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids
- F01K23/02—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled
- F01K23/06—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle
- F01K23/065—Plants characterised by more than one engine delivering power external to the plant, the engines being driven by different fluids the engine cycles being thermally coupled combustion heat from one cycle heating the fluid in another cycle the combustion taking place in an internal combustion piston engine, e.g. a diesel engine
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
- F01K25/00—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for
- F01K25/08—Plants or engines characterised by use of special working fluids, not otherwise provided for; Plants operating in closed cycles and not otherwise provided for using special vapours
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02G—HOT GAS OR COMBUSTION-PRODUCT POSITIVE-DISPLACEMENT ENGINE PLANTS; USE OF WASTE HEAT OF COMBUSTION ENGINES; NOT OTHERWISE PROVIDED FOR
- F02G2262/00—Recuperating heat from exhaust gases of combustion engines and heat from lubrication circuits
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E20/00—Combustion technologies with mitigation potential
- Y02E20/14—Combined heat and power generation [CHP]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- the present disclosure relates to an organic Rankine cycle (ORC) system. More particularly, the present disclosure relates to operating a cascaded ORC system using two waste heat sources from a reciprocating engine.
- ORC organic Rankine cycle
- Rankine cycle systems are commonly used for generating electrical power.
- the Rankine cycle system includes an evaporator or a boiler for evaporation of a motive fluid, a turbine that receives the vapor from the evaporator to drive a generator, a condenser for condensing the vapor, and a pump or other means for recycling the condensed fluid to the evaporator.
- the motive fluid in Rankine cycle systems is often water, and the turbine is thus driven by steam.
- An organic Rankine cycle (ORC) system operates similarly to a traditional Rankine cycle, except that an ORC system uses an organic fluid, instead of water, as the motive fluid.
- the ORC system uses a waste heat source to provide heat to vaporize the organic fluid in the evaporator.
- a reciprocating engine is a common source of waste heat for an ORC system.
- Usable waste heat from the reciprocating engine may include exhaust gas at temperatures near approximately 540 degrees Celsius (approximately 1000 degrees Fahrenheit), as well as cooling water at approximately 105 degrees Celsius (approximately 220 degrees Fahrenheit). Challenges arise in trying to use both of the waste heat sources from the reciprocating engine, particularly given the temperature difference between them. As such, the exhaust gas is typically preferred over the cooling water, given the potential for greater heat transfer.
- the ORC system typically uses an organic fluid with a high critical temperature, allowing boiling at elevated temperatures.
- expanding an organic fluid with a single turbine over a large pressure ratio causes the vapor exiting the turbine to be more superheated, thus limiting the amount of power captured by the turbine.
- the highly superheated fluid exiting the turbine may also require special condensation equipment.
- a method and system for operating a cascaded organic Rankine cycle (ORC) system utilizes two waste heat sources from a positive-displacement engine, resulting in increased efficiency of the engine and the cascaded ORC system.
- a high temperature waste heat source from the positive-displacement engine is used in a first ORC system to vaporize a first working fluid.
- a low temperature waste heat source from the positive-displacement engine is used in a second ORC system to heat a second working fluid to a temperature less than the vaporization temperature.
- the second working fluid is then vaporized using heat from the first working fluid.
- the first working fluid has a higher critical temperature than the second working fluid.
- the positive-displacement engine is a reciprocating engine and the waste heat sources are exhaust gas and jacket cooling water.
- FIG. 1 is a schematic of an organic Rankine cycle (ORC) system designed to produce electrical power using waste heat.
- ORC organic Rankine cycle
- FIG. 2 is a schematic of a cascaded ORC system with a first ORC system and a second ORC system, designed to utilize two waste heat sources from a reciprocating engine.
- FIG. 3 is a T-s diagram for the cascaded ORC system of FIG. 2 .
- a waste heat recovery system such as an organic Rankine cycle (ORC) system
- ORC organic Rankine cycle
- a reciprocating engine has two sources of waste heat that may be recoverable by the ORC system—exhaust gas (high temperature) and cooling water (low temperature).
- high temperature exhaust gas
- low temperature cooling water
- a first ORC system utilizes a high temperature working fluid to power a generator
- a second ORC system utilizes a low temperature working fluid to power a second generator.
- the first ORC system recovers heat from the exhaust gas of the reciprocating engine.
- the second ORC system recovers heat from the cooling water of the reciprocating engine, as well as the heat of condensation from the high temperature working fluid of the first ORC system.
- the cascaded ORC system and method described herein utilizes more of the waste heat from the reciprocating engine, and thus generates a greater amount of power per unit of waste heat from the reciprocating engine.
- FIG. 1 is a schematic of a single ORC system 10 , which includes condenser 12 , pump 14 , evaporator 16 , and turbine 18 .
- Working fluid 22 circulates through system 10 and is used to generate electrical power.
- Liquid working fluid 22 a from condenser 12 passes through pump 14 , resulting in an increase in pressure.
- High pressure liquid fluid 22 a enters evaporator 16 , which utilizes heat source 24 to vaporize fluid 22 .
- Heat source 24 may include, but is not limited to, any type of waste heat resource, including reciprocating engines, fuel cells, and microturbines, and other types of heat sources such as solar, geothermal or waste gas.
- Working fluid 22 exits evaporator 16 as a vapor ( 22 b ), at which point it passes into turbine 18 .
- Vaporized working fluid 22 b is used to drive turbine 18 , which in turn powers generator 28 such that generator 28 produces electrical power.
- Vaporized working fluid 22 b exiting turbine 18 is returned to condenser 12 , where it is condensed back to liquid 22 a.
- Heat sink 30 is used to provide cooling to condenser 12 .
- working fluid 22 is preferably a high temperature fluid having a high critical temperature.
- heat source 24 is able to transfer sufficient heat to the working fluid, while maintaining the working fluid below the critical temperature in evaporator 16 .
- a disadvantage of such a high temperature working fluid is that when it exits turbine 18 , it is highly superheated. At least a portion of the heat from the superheated vapor is not converted into power, and thus turbine 18 has a low efficiency.
- the high temperature working fluid requires additional cooling in condenser 12 , resulting in expensive equipment and typically a large amount of unrecoverable waste heat from the working fluid.
- heat source 24 is a low temperature heat source
- a low temperature working fluid may be used within system 10 .
- ORC system 10 In the scenario in which heat source 24 is waste heat from a reciprocating engine, ORC system 10 typically uses either the exhaust gas (i.e. high temperature waste heat) or the jacket cooling water (i.e. low temperature waste heat), since it is difficult to use both. As such, some of the waste heat from the reciprocating engine is unrecoverable by ORC system 10 .
- FIG. 2 is a schematic of cascaded ORC system 100 having first ORC system 102 and second ORC system 104 , both of which recover waste heat from reciprocating engine 106 .
- First ORC system 102 is similar to ORC system 10 of FIG. 1 and includes evaporator 110 , turbine 112 , condenser 114 , and pump 116 .
- First working fluid 118 is circulated through system 102 and used to drive turbine 112 , which enables generator 120 to produce electrical power.
- Second ORC system 104 includes turbine 122 , condenser 124 , pump 126 , heat exchanger 128 , and evaporator 114 .
- Second working fluid 130 is used in second ORC system 104 to drive turbine 122 , which powers generator 132 .
- Condenser 124 of second ORC system 104 uses heat sink 134 to provide cooling and condense vaporized working fluid 130 from turbine 122 .
- Heat sink 134 may be water or air, and in some cases, heat sink 134 may be used to provide useful heating to an external source, as discussed further below.
- First working fluid 118 and second working fluid 130 are organic working fluids, examples of which are provided below.
- Condenser 114 of first ORC system 102 also functions as the evaporator of second ORC system 104 .
- first working fluid 118 is a high temperature working fluid and second working fluid 130 is a low temperature working fluid.
- evaporator/condenser 114 is configured such that vaporized working fluid 118 from turbine 112 is condensed, thereby transferring heat to vaporize second working fluid 130 .
- Reciprocating engine 106 has two sources of waste heat recoverable by system 100 .
- the first source is exhaust gas ranging in temperature from approximately 475 to 540 degrees Celsius (approximately 885 to 1005 degrees Fahrenheit).
- the second source is jacket cooling water with a temperature range of approximately 100 to 110 degrees Celsius (approximately 212 to 230 degrees Fahrenheit).
- Heat from the exhaust gas is used by first ORC system 102 . More specifically, exhaust gas is used by evaporator 110 to vaporize working fluid 118 .
- Second ORC system 104 receives heat from the jacket cooling water.
- Heat exchanger 128 of system 104 is located between pump 126 and evaporator 114 , and is designed to transfer heat from the jacket cooling water to liquid working fluid 130 .
- jacket cooling water is a lower temperature waste heat source, as compared to the exhaust gas, the jacket cooling water is used to heat working fluid 130 to a temperature that is less than its vaporization temperature.
- working fluid 130 has a higher temperature at an outlet of heat exchanger 128 compared to its temperature at an inlet of heat exchanger 128 .
- the jacket cooling water may be recycled back to reciprocating engine 106 after exiting heat exchanger 128 .
- second working fluid 130 After passing through heat exchanger 128 , second working fluid 130 passes through condenser/evaporator 114 , which is designed to transfer heat between first working fluid 118 and second working fluid 130 , such that first working fluid 118 condenses to a liquid and second working fluid 130 is vaporized.
- First working fluid 118 preferably has a condensation temperature that is suitable to boil second working fluid 130 .
- Second working fluid 130 passes from evaporator 114 to turbine 122 , and then to condenser 124 , which may be a water-cooled condenser or an air-cooled condenser (i.e. heat sink 134 is water or air).
- heat sink 134 is water or air.
- the heated water may be used to provide heating to a source external to cascaded ORC system 100 .
- heat sink 134 may be used to heat district heating water and/or provide environmental heating, for example, to agricultural crops or greenhouses.
- cascaded ORC system 100 it is possible to utilize essentially all of the waste heat from reciprocating engine 106 .
- the high temperature waste heat source (the exhaust gas) is recovered by ORC system 102 which utilizes a high temperature working fluid.
- the low temperature waste heat source (the jacket cooling water) is recovered by ORC system 104 , which utilizes a low temperature working fluid.
- the design of cascaded ORC system 100 results in greater efficiency overall since the heat from first working fluid 118 exiting turbine 112 may be transferred to second working fluid 130 .
- An efficiency of second ORC system 104 is increased by preheating second working fluid 130 in heat exchanger 128 .
- the heat utilization efficiency of ORC system 100 may be further increased by using heat sink 134 to heat a source external to cascaded ORC system 100 .
- First working fluid 118 has a higher critical temperature than second working fluid 130 . Because exhaust gas from reciprocating engine 106 is used in evaporator 110 to vaporize first working fluid 118 , working fluid 118 preferably has a high critical temperature such that it is able to boil at a high temperature inside evaporator 110 . Operating with the working fluid in the supercritical phase presents technical challenges that are preferably avoided by remaining below the critical temperature.
- second ORC system 104 uses lower temperature heat sources (i.e. cooling water and lower-temperature condensation heat of working fluid 118 ) to vaporize second working fluid 130 , working fluid 130 preferably has a low critical temperature compared to working fluid 118 . If a working fluid with a high critical temperature were used in second ORC system 104 , the pressures inside system 104 may become too low, resulting in low fluid densities and requiring larger equipment.
- lower temperature heat sources i.e. cooling water and lower-temperature condensation heat of working fluid 118
- First working fluid 118 may include, but is not limited to, siloxanes, toluene, isobutene, isopentane, n-pentane and 4-trifluoromethy1-1,1,1,3,5,5,5-heptafluoro-2-pentene ((CF 3 ) 2 CHCF ⁇ CHCF 3 ).
- siloxanes that are suitable for first working fluid 118 include, but are not limited to, MM hexamethyldisiloxane (C 6 H 18 OSi 2 ), MDM octamethyltrisiloxane (C 8 H 24 O 2 Si 3 ), and MD2M decamethyltetrasiloxane (C 10 H 30 O 3 Si 4 ).
- siloxanes may be preferred over toluene, isobutene, isopentane, and n-pentene, which are flammable.
- Second working fluid 130 may include, but is not limited to, R123, R134a, R236fa and R245fa.
- R134a or R245fa is used in ORC system 104 . If an ambient air temperature is cooler, thereby reducing a temperature of heat sink 34 , then R134 may be preferred; if the ambient air temperature is warmer, then R245fa may be preferred.
- first working fluid 118 and second working fluid 130 may include organic working fluids not listed above. Numerous combinations of first working fluid 118 and second working fluid 130 may be used. As stated above, cascaded ORC system 100 is preferably operated with first working fluid 118 having a higher critical temperature than second working fluid 130 .
- FIG. 3 is a T-s diagram for cascaded ORC system 100 of FIG. 2 .
- temperature T is plotted as a function of entropy S.
- FIG. 3 illustrates the thermal energy transfer from the exhaust gas of reciprocating engine 106 to first working fluid 118 , and from the jacket cooling water of engine 106 to second working fluid 130 .
- first working fluid 118 transfers heat to second working fluid 130
- second working fluid 130 then transfers heat to heat sink 134 .
- first working fluid 118 Heat from the exhaust gas of reciprocating engine 106 is transferred to first working fluid 118 , which increases a temperature of working fluid 118 until fluid 118 reaches its vaporization temperature, as shown in FIG. 3 .
- Fluid 118 remains below the critical temperature T 1 critical .
- condenser 114 which also functions as an evaporator for second ORC system 104 , fluid 118 is desuperheated until it reaches its condensation temperature.
- the heat from fluid 118 is transferred to second working fluid 130 in condenser/evaporator 114 .
- the temperature of fluid 130 remains below the critical temperature T 2 critical .
- Heat from first working fluid 118 is sufficient to vaporize second working fluid 130 inside condenser/evaporator 114 . This is due, in part, to preheating of second working fluid 130 upstream of condenser/evaporator 114 . As shown in FIG. 3 , jacket cooling water from reciprocating engine 106 is used to increase a temperature of working fluid 130 to a temperature below the vaporization temperature.
- second working fluid 130 shows a decrease in temperature after passing through turbine 122 .
- superheated fluid 130 is condensed inside condenser/heater 124 using ambient air or cooling water from heat sink 134 .
- heat from second working fluid 130 is transferred to heat sink 34 , as shown in FIG. 3 .
- heat sink 34 in some embodiments, may be used to provide heating to an external source, such as, for example, a greenhouse.
- cascaded ORC system 100 uses two waste heat sources from a reciprocating engine.
- the low temperature heat source is jacket cooling water.
- other types of positive-displacement engines, in addition to reciprocating engines, that require cooling water during engine operation may also be used to supply waste heat to system 100 .
- This may include, but is not limited to, rotary engines, such as, for example, the Wankel engine.
- the cascaded ORC system described herein uses two distinct waste heat sources from a reciprocating engine. Since two ORC systems are used, the cascaded ORC system generates additional power. Because there is no change in the emission levels of the reciprocating engine, the cascaded ORC system results in a reduction in emissions from the reciprocating engine per unit of power generated. Moreover, the cascaded ORC system described herein reduces any waste heat from the first and second ORC systems. Thus, the method and system described herein results in improved efficiency of the reciprocating engine and each of the ORC systems.
Abstract
Description
- The present disclosure relates to an organic Rankine cycle (ORC) system. More particularly, the present disclosure relates to operating a cascaded ORC system using two waste heat sources from a reciprocating engine.
- Rankine cycle systems are commonly used for generating electrical power. The Rankine cycle system includes an evaporator or a boiler for evaporation of a motive fluid, a turbine that receives the vapor from the evaporator to drive a generator, a condenser for condensing the vapor, and a pump or other means for recycling the condensed fluid to the evaporator. The motive fluid in Rankine cycle systems is often water, and the turbine is thus driven by steam. An organic Rankine cycle (ORC) system operates similarly to a traditional Rankine cycle, except that an ORC system uses an organic fluid, instead of water, as the motive fluid.
- The ORC system uses a waste heat source to provide heat to vaporize the organic fluid in the evaporator. A reciprocating engine is a common source of waste heat for an ORC system. Usable waste heat from the reciprocating engine may include exhaust gas at temperatures near approximately 540 degrees Celsius (approximately 1000 degrees Fahrenheit), as well as cooling water at approximately 105 degrees Celsius (approximately 220 degrees Fahrenheit). Challenges arise in trying to use both of the waste heat sources from the reciprocating engine, particularly given the temperature difference between them. As such, the exhaust gas is typically preferred over the cooling water, given the potential for greater heat transfer.
- To effectively utilize the high-temperature exhaust heat from the reciprocating engine, the ORC system typically uses an organic fluid with a high critical temperature, allowing boiling at elevated temperatures. However, expanding an organic fluid with a single turbine over a large pressure ratio causes the vapor exiting the turbine to be more superheated, thus limiting the amount of power captured by the turbine. The highly superheated fluid exiting the turbine may also require special condensation equipment.
- There is a need for an improved method and system of recovering waste heat from a reciprocating engine in order to increase efficiency of the reciprocating engine and the ORC system.
- A method and system for operating a cascaded organic Rankine cycle (ORC) system utilizes two waste heat sources from a positive-displacement engine, resulting in increased efficiency of the engine and the cascaded ORC system. A high temperature waste heat source from the positive-displacement engine is used in a first ORC system to vaporize a first working fluid. A low temperature waste heat source from the positive-displacement engine is used in a second ORC system to heat a second working fluid to a temperature less than the vaporization temperature. The second working fluid is then vaporized using heat from the first working fluid. The first working fluid has a higher critical temperature than the second working fluid. In an exemplary embodiment, the positive-displacement engine is a reciprocating engine and the waste heat sources are exhaust gas and jacket cooling water.
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FIG. 1 is a schematic of an organic Rankine cycle (ORC) system designed to produce electrical power using waste heat. -
FIG. 2 is a schematic of a cascaded ORC system with a first ORC system and a second ORC system, designed to utilize two waste heat sources from a reciprocating engine. -
FIG. 3 is a T-s diagram for the cascaded ORC system ofFIG. 2 . - A waste heat recovery system, such as an organic Rankine cycle (ORC) system, may be used to capture heat from a prime mover, such as a reciprocating engine. The ORC system may then be used to generate electrical power. A reciprocating engine has two sources of waste heat that may be recoverable by the ORC system—exhaust gas (high temperature) and cooling water (low temperature). However, given the large temperature difference between the waste heat sources, it is difficult to effectively utilize both of these waste heat sources in a single ORC system. As described herein, in a cascaded ORC system, a first ORC system utilizes a high temperature working fluid to power a generator and a second ORC system utilizes a low temperature working fluid to power a second generator. The first ORC system recovers heat from the exhaust gas of the reciprocating engine. The second ORC system recovers heat from the cooling water of the reciprocating engine, as well as the heat of condensation from the high temperature working fluid of the first ORC system. The cascaded ORC system and method described herein utilizes more of the waste heat from the reciprocating engine, and thus generates a greater amount of power per unit of waste heat from the reciprocating engine.
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FIG. 1 is a schematic of a single ORC system 10, which includescondenser 12,pump 14,evaporator 16, andturbine 18. Working fluid 22 circulates through system 10 and is used to generate electrical power. Liquid workingfluid 22 a fromcondenser 12 passes throughpump 14, resulting in an increase in pressure. High pressureliquid fluid 22 aenters evaporator 16, which utilizesheat source 24 to vaporize fluid 22.Heat source 24 may include, but is not limited to, any type of waste heat resource, including reciprocating engines, fuel cells, and microturbines, and other types of heat sources such as solar, geothermal or waste gas. Working fluid 22exits evaporator 16 as a vapor (22 b), at which point it passes intoturbine 18. Vaporized workingfluid 22 b is used to driveturbine 18, which inturn powers generator 28 such thatgenerator 28 produces electrical power. Vaporized workingfluid 22b exiting turbine 18 is returned tocondenser 12, where it is condensed back toliquid 22 a.Heat sink 30 is used to provide cooling to condenser 12. - In those cases in which
heat source 24 is a high temperature heat source, working fluid 22 is preferably a high temperature fluid having a high critical temperature. In that case,heat source 24 is able to transfer sufficient heat to the working fluid, while maintaining the working fluid below the critical temperature inevaporator 16. A disadvantage of such a high temperature working fluid, however, is that when it exitsturbine 18, it is highly superheated. At least a portion of the heat from the superheated vapor is not converted into power, and thusturbine 18 has a low efficiency. Moreover, the high temperature working fluid requires additional cooling incondenser 12, resulting in expensive equipment and typically a large amount of unrecoverable waste heat from the working fluid. - In contrast, if
heat source 24 is a low temperature heat source, a low temperature working fluid may be used within system 10. However, there is a reduced efficiency in power output, as compared to when system 10 recovers heat from a high temperature heat source. - In the scenario in which
heat source 24 is waste heat from a reciprocating engine, ORC system 10 typically uses either the exhaust gas (i.e. high temperature waste heat) or the jacket cooling water (i.e. low temperature waste heat), since it is difficult to use both. As such, some of the waste heat from the reciprocating engine is unrecoverable by ORC system 10. -
FIG. 2 is a schematic of cascadedORC system 100 havingfirst ORC system 102 andsecond ORC system 104, both of which recover waste heat from reciprocatingengine 106. First ORCsystem 102 is similar to ORC system 10 ofFIG. 1 and includesevaporator 110,turbine 112,condenser 114, andpump 116. First workingfluid 118 is circulated throughsystem 102 and used to driveturbine 112, which enablesgenerator 120 to produce electrical power.Second ORC system 104 includesturbine 122,condenser 124,pump 126,heat exchanger 128, andevaporator 114. Second workingfluid 130 is used insecond ORC system 104 to driveturbine 122, which powersgenerator 132.Condenser 124 ofsecond ORC system 104 usesheat sink 134 to provide cooling and condense vaporized workingfluid 130 fromturbine 122.Heat sink 134 may be water or air, and in some cases,heat sink 134 may be used to provide useful heating to an external source, as discussed further below. First workingfluid 118 and second workingfluid 130 are organic working fluids, examples of which are provided below. -
Condenser 114 offirst ORC system 102 also functions as the evaporator ofsecond ORC system 104. As described further below, first workingfluid 118 is a high temperature working fluid and second workingfluid 130 is a low temperature working fluid. As such, evaporator/condenser 114 is configured such that vaporized workingfluid 118 fromturbine 112 is condensed, thereby transferring heat to vaporize second workingfluid 130. -
Reciprocating engine 106 has two sources of waste heat recoverable bysystem 100. The first source is exhaust gas ranging in temperature from approximately 475 to 540 degrees Celsius (approximately 885 to 1005 degrees Fahrenheit). The second source is jacket cooling water with a temperature range of approximately 100 to 110 degrees Celsius (approximately 212 to 230 degrees Fahrenheit). Heat from the exhaust gas is used byfirst ORC system 102. More specifically, exhaust gas is used byevaporator 110 to vaporize workingfluid 118. -
Second ORC system 104 receives heat from the jacket cooling water.Heat exchanger 128 ofsystem 104 is located betweenpump 126 andevaporator 114, and is designed to transfer heat from the jacket cooling water toliquid working fluid 130. Because jacket cooling water is a lower temperature waste heat source, as compared to the exhaust gas, the jacket cooling water is used to heat workingfluid 130 to a temperature that is less than its vaporization temperature. Thus, workingfluid 130 has a higher temperature at an outlet ofheat exchanger 128 compared to its temperature at an inlet ofheat exchanger 128. The jacket cooling water may be recycled back toreciprocating engine 106 after exitingheat exchanger 128. - After passing through
heat exchanger 128, second workingfluid 130 passes through condenser/evaporator 114, which is designed to transfer heat between first workingfluid 118 and second workingfluid 130, such that first workingfluid 118 condenses to a liquid and second workingfluid 130 is vaporized. First workingfluid 118 preferably has a condensation temperature that is suitable to boil second workingfluid 130. - Second working
fluid 130 passes fromevaporator 114 toturbine 122, and then tocondenser 124, which may be a water-cooled condenser or an air-cooled condenser (i.e.heat sink 134 is water or air). In some embodiments, after water inheat sink 134 exitscondenser 124, the heated water may be used to provide heating to a source external to cascadedORC system 100. For example,heat sink 134 may be used to heat district heating water and/or provide environmental heating, for example, to agricultural crops or greenhouses. - Using cascaded
ORC system 100, it is possible to utilize essentially all of the waste heat fromreciprocating engine 106. The high temperature waste heat source (the exhaust gas) is recovered byORC system 102 which utilizes a high temperature working fluid. The low temperature waste heat source (the jacket cooling water) is recovered byORC system 104, which utilizes a low temperature working fluid. Moreover, the design of cascadedORC system 100 results in greater efficiency overall since the heat from first workingfluid 118 exitingturbine 112 may be transferred to second workingfluid 130. An efficiency ofsecond ORC system 104 is increased by preheating second workingfluid 130 inheat exchanger 128. Moreover, the heat utilization efficiency ofORC system 100 may be further increased by usingheat sink 134 to heat a source external to cascadedORC system 100. - First working
fluid 118 has a higher critical temperature than second workingfluid 130. Because exhaust gas fromreciprocating engine 106 is used inevaporator 110 to vaporize first workingfluid 118, workingfluid 118 preferably has a high critical temperature such that it is able to boil at a high temperature insideevaporator 110. Operating with the working fluid in the supercritical phase presents technical challenges that are preferably avoided by remaining below the critical temperature. - On the other hand, since
second ORC system 104 uses lower temperature heat sources (i.e. cooling water and lower-temperature condensation heat of working fluid 118) to vaporize second workingfluid 130, workingfluid 130 preferably has a low critical temperature compared to workingfluid 118. If a working fluid with a high critical temperature were used insecond ORC system 104, the pressures insidesystem 104 may become too low, resulting in low fluid densities and requiring larger equipment. - First working
fluid 118 may include, but is not limited to, siloxanes, toluene, isobutene, isopentane, n-pentane and 4-trifluoromethy1-1,1,1,3,5,5,5-heptafluoro-2-pentene ((CF3)2CHCF═CHCF3). Examples of siloxanes that are suitable for first workingfluid 118 include, but are not limited to, MM hexamethyldisiloxane (C6H18OSi2), MDM octamethyltrisiloxane (C8H24O2Si3), and MD2M decamethyltetrasiloxane (C10H30O3Si4). In some embodiments, siloxanes may be preferred over toluene, isobutene, isopentane, and n-pentene, which are flammable. - Second working
fluid 130 may include, but is not limited to, R123, R134a, R236fa and R245fa. In preferred embodiments, R134a or R245fa is used inORC system 104. If an ambient air temperature is cooler, thereby reducing a temperature of heat sink 34, then R134 may be preferred; if the ambient air temperature is warmer, then R245fa may be preferred. - It is recognized that first working
fluid 118 and second workingfluid 130 may include organic working fluids not listed above. Numerous combinations of first workingfluid 118 and second workingfluid 130 may be used. As stated above, cascadedORC system 100 is preferably operated with first workingfluid 118 having a higher critical temperature than second workingfluid 130. -
FIG. 3 is a T-s diagram for cascadedORC system 100 ofFIG. 2 . For both first workingfluid 118 and second workingfluid 130, temperature T is plotted as a function of entropy S. As described in more detail below,FIG. 3 illustrates the thermal energy transfer from the exhaust gas ofreciprocating engine 106 to first workingfluid 118, and from the jacket cooling water ofengine 106 to second workingfluid 130. As also shown inFIG. 3 , first workingfluid 118 transfers heat to second workingfluid 130, and second workingfluid 130 then transfers heat toheat sink 134. - Heat from the exhaust gas of
reciprocating engine 106 is transferred to first workingfluid 118, which increases a temperature of workingfluid 118 untilfluid 118 reaches its vaporization temperature, as shown inFIG. 3 .Fluid 118 remains below the critical temperature T1 critical. As vaporizedfluid 118 expands inturbine 112, its temperature decreases, however fluid 118 remains in the vapor phase. Incondenser 114, which also functions as an evaporator forsecond ORC system 104,fluid 118 is desuperheated until it reaches its condensation temperature. The heat fromfluid 118 is transferred to second workingfluid 130 in condenser/evaporator 114. The temperature offluid 130 remains below the critical temperature T2 critical. - Heat from first working
fluid 118 is sufficient to vaporize second workingfluid 130 inside condenser/evaporator 114. This is due, in part, to preheating of second workingfluid 130 upstream of condenser/evaporator 114. As shown inFIG. 3 , jacket cooling water fromreciprocating engine 106 is used to increase a temperature of workingfluid 130 to a temperature below the vaporization temperature. - As similarly described for
fluid 118, second workingfluid 130 shows a decrease in temperature after passing throughturbine 122. At that point,superheated fluid 130 is condensed inside condenser/heater 124 using ambient air or cooling water fromheat sink 134. In other words, heat from second workingfluid 130 is transferred to heat sink 34, as shown inFIG. 3 . As described above, heat sink 34, in some embodiments, may be used to provide heating to an external source, such as, for example, a greenhouse. - In the exemplary embodiment of
FIG. 2 , cascadedORC system 100 uses two waste heat sources from a reciprocating engine. The low temperature heat source is jacket cooling water. It is recognized that other types of positive-displacement engines, in addition to reciprocating engines, that require cooling water during engine operation may also be used to supply waste heat tosystem 100. This may include, but is not limited to, rotary engines, such as, for example, the Wankel engine. - The cascaded ORC system described herein uses two distinct waste heat sources from a reciprocating engine. Since two ORC systems are used, the cascaded ORC system generates additional power. Because there is no change in the emission levels of the reciprocating engine, the cascaded ORC system results in a reduction in emissions from the reciprocating engine per unit of power generated. Moreover, the cascaded ORC system described herein reduces any waste heat from the first and second ORC systems. Thus, the method and system described herein results in improved efficiency of the reciprocating engine and each of the ORC systems.
- Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
Claims (22)
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/US2007/021318 WO2009045196A1 (en) | 2007-10-04 | 2007-10-04 | Cascaded organic rankine cycle (orc) system using waste heat from a reciprocating engine |
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US20100263380A1 true US20100263380A1 (en) | 2010-10-21 |
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US12/738,028 Abandoned US20100263380A1 (en) | 2007-10-04 | 2007-10-04 | Cascaded organic rankine cycle (orc) system using waste heat from a reciprocating engine |
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US (1) | US20100263380A1 (en) |
EP (1) | EP2212524A4 (en) |
JP (1) | JP2010540837A (en) |
WO (1) | WO2009045196A1 (en) |
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WO2009045196A1 (en) | 2009-04-09 |
EP2212524A1 (en) | 2010-08-04 |
EP2212524A4 (en) | 2012-04-18 |
JP2010540837A (en) | 2010-12-24 |
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