ORGANIC RANKINE CYCLE AND ITS FLUID SELECTION

INTRODUCTION
The global warming in recent years has compelled the energy planners to develop a new energy conversion technology which produces electricity without causing environmental pollution. The Organic Rankine Cycle (ORC) is a Clausius Rankine cycle in which an organic or non-conventional working fluid is used instead of water-steam. ORC is an environmentally friendly system of small sizes with no emissions of exhaust gases such as CO, CO2, NOX, SOX and other atmospheric pollutants. The most important feature for an ORC is its capability of utilization of various kinds of low-grade heat sources for power generation. Rankine cycle is the theoretical cycle on which the steam turbine (or engine) works. Every steam power plant is based on rankine cycle. The thermal efficiency of simple rankine cycle is low. To increase the efficiency of simple rankine cycle, the rankine cycle is modified. For modification steam is superheated and reheated after doing some work in HPT. Regenerative feed heating system in also employed to increase the efficiency of the cycle. One of the major disadvantages of rankine cycle is that it requires a very high steam temperature, which requires a high temp heat source due to which heat cannot be recovered, which is available at low temp. Waste heat in Thermal Power Plant, industries is available as a combination of low temperatures (up to a temperature of approximately 400C), which makes it hard to use this heat economically. Based on this reason heat sources of this kind cannot be used for the production of electricity with regular water steam power plants economically because of the high specific investment costs. The Organic Rankine Cycle (ORC) is another name for a binary system taking heat from a source and transferring it to a working liquid in a closed system to be vaporized and pressurized, typically turn a turbine, and then condense back to liquid form before flowing through the heat exchanger again to repeat the cycle. Organic Rankine Cycle was invented by William John Macquorn Rankine. In the mid-19th century he discovered that, in operating steam turbines, other organic

heat sources besides water can be used which can be convert into gas at low temperature. In this way, energy losses can be minimized and efficiency in power generation can be increased using waste heat. One of the application of the technology is geothermal energy. Here, the heat stored in the earth's crust is used to heat water and drive steam turbines. Due to the relatively low temperatures of up to approximately 200C, electricity generation in a geothermal power plant would hardly be profitable. However ORC system could be operated economically at this temperature level. The Organic Rankine Cycle (ORC) is similar to the cycle of a conventional steam turbine, except for the fluid that drives the turbine, which is a high molecular mass organic fluid. The selected working fluids allow to exploit efficiently low temperature heat sources to produce electricity in a wide range of power outputs (from few kW up to 3 MW electric power per unit). The challenges, when ORC is used in a process, are of low thermal efficiency, limited ways to improve the work output, selection of working fluids matching to available heat source and sink temperatures and their effects up on environment[1]. The working fluids for ORCs are basically categorized in three groups based on their slope of saturation vapour curves in Ts diagram. The fluids having positive slope are dry fluids. The fluids having negative slope are wet fluids. The fluids having nearly infinitely large slopes are isentropic fluids [1]. The presence of hydrogen bond in certain molecules like water, ammonia and ethanol results in wet fluids due to larger vaporisation enthalpy and is regarded as inappropriate for ORC system [2]. More and more attention has been paid to the technology in recent years and many researches about it mainly focused on working fluid selection and parametric optimization of organic Rankine cycle [Zq Wang3]. Saleh et al. [4] compared the thermodynamic performances of 31 pure working fluids for organic Rankine cycles on the basis of the BACKONE equation of state. Tchanche et al. [5] analysed the thermodynamic characteristics and performances of 20 fluids in a low-temperature solar organic Rankine cycle and R134a was recommended. Based on the thermal efficiency, cyclopentane was recommended as the best working fluid [6]. Aljundi et al. [7] compared the thermal and exergetic efficiencies of different working fluids in ORC system. The results showed that n-hexane was the best working fluid while R227ea was the worst. The important criteria for organic rankine cycle are selection of working fluid and parametric optimization. Many researchers conducted the studies limited to the

first law efficiency and second law efficiency. A few researches considered the optimal parameters of ORC system with different criteria. A certain challenge is the choice of the organic working fluid and of the particular design of the cycle. The process should have a high thermal efficiency

th

and allow a high utilization of the available heat source. Moreover, the working fluid should fulfil safety criteria, it should be environmentally friendly, and allow low cost for the power plant. An important aspect for the choice of the working fluid is the temperature of the available heat source, which can range from low temperatures of about 100oC to medium temperatures of about 350oC[4]. Environmental aspects are the ozone depletion potential (ODP), the global warming potential (GWP) and the atmospheric lifetime (ALT). These properties are given for many of the working fluids considered here in Ref. [8]. Regarding the safety aspects, the flammability and the auto ignition are important features. For sure, many of the substances considered are flammable but it is not a serious problem because in existing ORC processes at even higher temperatures R601 is used as working fluid [9]. Auto ignition may be a problem, in particular, for longer alkanes at temperatures above 2000C. For many substances the degree of flammability and the auto ignition temperature can be found on safety data sheets [10]. The chemical stability of the considered working fluids is also should be discuss. Not that much research has been done on this topic[9]. Solar desalination with an Organic Rankine Cycle is a economic use of orc. A stand-alone solar desalination system driven by an Organic Rankine Cycle can be used to produce drinking water from seawater. The advantage of such a system is that it combines an efficient desalination technology (Reverse Osmosis) with a renewable energy source (solar radiation). The presented system has been developed in the European research project COOP-CT-2003-507997 called RO-Solar-Rankine [11]. A further application for ORC is the combined heat and power production in a power range from a few kWel, often called Micro-CHP. In this application range the system will be driven in a way that the heat from the condenser will be completely used for heating purposes. Therefore orc coupling with waste heat recovery from biogas digestion plants or micro-CHP systems provide very promising solutions for low cost,

decentralised applications. Additionally, the lack of fuel costs makes these applications even more attractive [12].

SYSTEM DISCRIPTION: WORKING:

The basic components that make up an ORC are similar to the conventional Rankine cycle. ORC system consists of an evaporator, a turbine, a condenser and a working fluid pump. The layout of the components of a system working on ORC shown in fig(1). The exhaust from the heat source is assumed to be routed through the evaporator, where heat transfer occurs between the exhaust stream and the organic working fluid. A counter flow heat exchanger (evaporator) configuration is considered to maximize heat transfer between the exhaust and the organic fluid. Thermodynamically, this is a preferred configuration because the temperature difference between the hot fluid and the cold fluid is minimized, reducing exergy destruction. The heated organic fluid then is expanded in a turbine, heat is rejected to the ambient in the condenser, and the cooled working fluid is pumped back into the evaporator.

Fig. 1 Basic components of a system working on ORC[1]

fig.(2) shows the typical T-S diagram for process occurring in system.

Fig. 2 A typical Ts process diagram of ORC during superheating [1]

CALCULATION METHODS: Process 1-2: The dry saturated vapor expands through a turbine, generating power. Turbine converts heat energy into work energy. This process assumed as isentropic process but in actually turbine efficiency is never reached to 100%. Thus the exhaust point from turbine is located at 2 in place of 2s.The work of turbine is: Wt= m (h1-h2) Process 2-3: The condensation temperature of ORC is fixed by the temperature of the available cooling water. It is an isobaric condensation process. Q= m (h2-h3) Process 3-4: In this process working fluid is pumped to evaporator. This process also assumed as isentropic. But pump efficiency not reached at 100%. Thus it represented as point 4 not 4s.Work done on pump is: Wp= m (h3-h4) Process 4-1: In this process working fluid is heated at constant pressure in evaporator. The waste heat is circulated in evaporator. The heat transfer to working fluid is Q= m (h4-h1)

Thermal efficiency of cycle is:

th=
RRESULT AND DISSCUTION:
Several studies regarding the working fluids utilization of different working fluids that are more appropriate for low temperature heat source done. For example R11, R113, R134, R134a, R123, isobutane, n -pentane, ammonia. Working fluids also have low ODP and GWP. R11 has an ODP = 1.0. The less the value of the ODP, the better the refrigerant is for the ozone layer and the environment. The fluid must not only possess thermo physical properties that match the application but also have adequate chemical stability at the desired working temperature. TABLE-1:

Refrigerant Ozone-depletion Potential (ODP), Global Warming Potential (GWP)

Chlorofluorocarbons (CFC) Controlled Substance Trichlorofluoromethane Dichlorodifluoromethane Trichlorotrifluoroethane Controlled Substance R-11 R-12 R-113 1 1 0.8 1 4000 2400 4800 3.9 NT, NF NT, NF NF ODP GWP Properties

Dichlorotetrafluoroethane R-114 Hydrochlorofluorocarbons (HCFC) Controlled Substance Dichlorofluoromethane Chlorodifluoromethane Dichlorotrifluoroethane Controlled Substance R-21 R-22 R-123

ODP 0.04 0.05 0.02 0.02 0

GWP

Properties

1700 0.02 620 1000

NT, NF NF

Chlorotetrafluoroethane R-124 Trifluoroethane R-143a

Hydrofluorocarbons (HFC) Controlled Substance Trifluoromethane Difluoromethane Pentafluoroethane Pentafluoropropane Tetrafluoroethane OTHERS Controlled Substance Ammonia, NH3 Propane Isobutane Controlled Substance R-717 R-290 R-600a R245fa cyclopentane n- hexane NT=nontoxic T=toxic NF=non-flammable SF=slightly flammable F =flammable Some working fluids suffer chemical decomposition and deterioration at high temperature and pressure. They have relatively low critical pressure. Hence the ORC using the above working fluids must be operated to narrow temperature range and low pressure. PROPERTIES OF WORKING FLUID: C6h14 0 0 0 0 0 0 20 0 20 4 820 T, NF NT, F F ODP GWP Properties Controlled Substance R-23 R-32 R-125 R-245a R-134a 0 0 0 0 1300 650 3400 SF NF ODP GWP Properties

 Appropriate high critical temperature and pressure for the use in the high-temperature stage. specific volume should be low Low cost of instillation, equipment, maintenance, and operation Low latent heat for lowering heat Low viscosity for lowering the fluid friction in the return pipe Low cost and easy purchasing Not combustible High thermal conductivity, suitable thermal stability High adiabatic enthalpy drop for obtaining large power output High specific heat for increased heat capacity High chemical and thermal stability The selection of working fluid and operation conditions has a great effect on the system operation, and its energy efficiency and impact on the environment. But temperature levels and criteria that are set can lead to controversial conclusions. Among others, the environmental requirements have changed over the last years, making some previous research to be re-evaluated. Fluids with higher critical temperature have better performance in the ORC. Thus working fluid should have high critical temperature. According to this R-113 is suitable for that, because it has 417C critical temperature.

Table:2
Freezing Point Boiling point at atmospheric Refrigerant at atmospheric pressure14.7 pressure No. psia, 1 bar abs 14.7 psia, 1 bar abs o ( F) (oF) R-12 R-13 R-13B1 -21.8 -114.6 -270 -252 -294 153 Critical Point Temperature (oF) 234 84 575 Pressure (psia) 597 561 0.0215 Specific Volume (Cu.Ft./lb.) 0.0287 0.0277

Freezing Point Boiling point at atmospheric Refrigerant at atmospheric pressure14.7 pressure No. psia, 1 bar abs 14.7 psia, 1 bar abs o ( F) (oF)

Critical Point Temperature (oF) Pressure (psia) Specific Volume (Cu.Ft./lb.)

R-14 R-14 R-21 R-22 R-40 R-113 R-114 R-115 R-123 R-134a R-140a R-142b R-143a R-170 R-290 RC-318 R-410A

-198.2 142 48.1 -41.3 -10.7 118 38.4 -38.0 82 -15 165 14 -53.5 -127 -44 22 -55.4

-299

-50

543

0.0256

-211 -256 -144 -31 -137 -149 -161 -142 205 290 417 294 176 363 214 722 969 499 473 458 533 590 0.0290 0.0305 0.0454 0.0278 0.0275 0.0261

-204

279

598

0.0368

-278 -309.8 -43

90 206 240 162

710 617 404 690

0.0830 0.0728 0.0258

Freezing Point Boiling point at atmospheric Refrigerant at atmospheric pressure14.7 pressure No. psia, 1 bar abs 14.7 psia, 1 bar abs o ( F) (oF) R-500 R-502 R-503 R-600 R-600a R-611 R-702 R-717 -28 -50 -128 31.2 10.8 89 -423 -28 -217 -229 -146 -434.6 -107.9 -254

Critical Point Temperature (oF) 222 180 67 306 275 417 Pressure (psia) 642 591 607 551 529 870 Specific Volume (Cu.Ft./lb.) 0.0323 0.0286 0.0326 0.0702 0.0725 0.0459

271

1657

0.0680

Hung et al. [13] worked on seven different working fluids, most of them were organic, and after comparison it was suggested that R113 is the most appropriate for organic Rankine cycle. Borsukiewicz-Gozdur and Nowak [14] compared seven organic fluids and some of their mixtures; the result showed that R245fa and propylene have the highest efficiency, whereas R227ea and propylene have the highest power output. Maizza and Maizza [15] were tested twenty fluids, including many azeotropic mixtures, in an ORC for waste heat recovery. They found that R123 and R124, when the evaporation temperature is lower than 110 C, are the most appropriate to be used. Saleh et al. [4], many organic fluids were tested with an evaporation temperature equal to 100C for waste heat recovery and there were a number of fluids that met their requirements. Its basis was BACKONE equation. They got many fluids according to their requirements, eg. R236ea, R245ca, R245fa, E134 and E245.[G.Kosm 16]. Hung et al. [17] did a comparative study between wet, dry, and isentropic fluids in ORC system and the isentropic fluids were considered to be the best[ from zq wong 3]. The thermodynamic characteristics and performances of 20 fluids in a low-temperature solar organic Rankine cycle analysed and he recommend R134a was recommended.on the

comparision a Aljundi found that n-hexane was the best working fluid while R227ea was the worst. This shows that for every operational condition there is a different working fluid which is suitable for that particular atmosphere. That range of temperature is also greatly affect the working fluid performance.R-113 is suitable for below temperature of 350 c Hung et al. [13].at the temperature of 150C Borsukiewicz-Gozdur and Nowak [14] explore that R245fa and R227 is suitable for operation and suitable output. Saleh et al [4] discussed about working fluid in evaporation temperature of 100 C, and he got different fluid for that temperature. Beside these zeotropic mixture of working fluids also shows better performance on organic rankine cycle. J.L. Wang et al [18] studied about mixture of working fluids. They said limitation of using pure fluids is the constant temperature evaporation which is not suitable for sensible heat sources such as waste heat. The mixtures have variable temperature during the phase change process, which could be used to reduce the mismatch of temperature profiles between heat transfer fluid and the evaporating or condensing working fluid mixtures. Angelino and Paliano compared n-pentane and mixture of n-butane and n-hexane (50%/50%). Result shows that mixture produce 6.8% more electricity then n-pantane, and 25% less air used. The study focused on 33 organic working fluids; according to various criteria that were followed, the most appropriate found was the R245fa. Although it was not the most efficient, nor produced the maximum mechanical work, it performed quite well and, in addition, its use is not restricted by any international regulations [16]. JL WANG [18] studied pure M1 (R245fa) and zeotropic mixtures M2 (R245fa/R152a, 0.9/0.1) and M3 (R245fa/R152a, 0.7/0.3)are compared, respectively, based on the experimental prototype. The power output of M3 is higher than that of M1 and M2 by 29.10% and 28.03%, respectively. Overall efficiency of M1, M2 and M3 is 0.88%, 0.92% and 1.28%, respectively. It shows that zeotropic mixture can improve overall efficiency of system. Due to environmental impact so many organic fluids and refrigerants has been banned. So many international lows implemented in recent years. CFCs are banned at 2000 and HCFC has to be phase out completely. So there is a specific amount of fluid remain for study as working fluid.

Table-3: Rejected organic fluids due to environmental impact and safety hazards Working fluids ODP Thermal efficiency Mechanical work of R21 R113 R114 R123 R123a R141b R142b R143 R11 R600 n-pentane i-pentane E134 0.1 0.9 0.85 0.02 NA 0.1 0.05 0 1 0 NA 0 0 (%) 13.53 12.73 12.34 13.08 12.78 13.15 12.17 13.01 13.29 12.63 12.37 12.31 12.47 Rejected fluids [16] The decision parameters include thermal efficiency, which is one of the most important and reliable criteria that can be used. It depends on the specific temperature limits that have been set, as well the lower/higher operational pressure. It also depends on and is limited by the irreversibility due to the entropy changes of the working fluid during various stages of the cycle. All the above conditions affect each other, and it is a difficult task over all working fluid for all conditions. the turbine (kJ/kg) 28.7 21.4 15.3 22.9 23.3 31.4 22.5 34.3 24.2 45.1 51.7 48.3 23.4

CONCLUSION:
Based on the thermal efficiency, cyclopentane was recommended as the best working fluid. With respect thermal and exergic efficiency n-hexane is the best working fluid while R227ea is the worst. At lower temperatures R123 and R124 also give appropriate result. In

low-temperature solar organic Rankine cycle R134a is recommend as good working fluid. R245fa is also most suitable for the selection upon other working fluids, because it has no impact on environment then it is ozone safe working fluid.

REFERENCES
[1] J.P. Roy, M.K. Mishra, Ashok Misra, Performance analysis of an Organic Rankine Cycle with superheating under different heat source temperature conditions, Applied Energy 88 (2011) 29953004. [2] Liu BT, Chein KH, Wang CC. Effect of working fluids on organic Rankine cycle for waste heat recovery. Energy 2004;29:120717. [3] Z.Q. Wang , N.J. Zhou , J. Guo, X.Y. Wang. Fluid selection and parametric optimization of organic Rankine cycle using low temperature waste heat. Energy 40 (2012) 107-115. [4] Saleh B, Koglbauer G, Wendland M, Fischer J. Working fluids for lowtemperature organic Rankine cycles. Energy 2007;32:1210-21. [5] Tchanche BF, Papadakis G, Lambrinos G, Frangoudakis A. Fluid selection for a lowtemperature solar organic Rankine cycle. Applied Thermal Engineering 2009;29:246876. [6] Lai NA, Wendland M, Fischer J. Working fluids for high-temperature organic Rankine cycles. Energy 2011;36:199-211. [7] Aljundi IH. Effect of dry hydrocarbons and critical point temperature on the efficiencies of organic Rankine cycle. Renewable Energy 2011;36:1196-202.

[8] US Environmental Protection Agency. Global warming potentials of ODS substitutes.

Washington, DC: US Environmental Protection Agency, 2006. See also http://www.epa.gov/docs/ozone/geninfo/gwps.html.

[9] Bayerisches Landesamt fu r Umweltschutz. Niedertemperaturverstromung mittels

einer ORC-Anlage im Werk Lengfurt der Heidelberger Zement AG. Endbericht 2001. Order number: lfu_klima_00009. Bayerisches Landesamt fu r Umwelt, Augsburg. (in German). See also: www.bayern.de/lfu/bestell/orc_endbericht.pdf.

[10]

Aug. Hedinger GmbH&CoKG. EG-Sicherheitsdatenblatt: n-Pentan: Stand

24.03.2004. Stuttgart: Aug. Hedinger GmbH&CoKG, 2006 (in German). See also: http://hedinger.de/bilder/6/Pentan_n-_v003.pdf. [11] A. Schuster, S. Karellas, J. Karl, Simulation of an innovative stand-alone solar desalination system with an Organic Rankine Cycle, SIMS 2005, in: 46th Conference on Simulation and Modeling, Trondheim, Norway, 1314 October 2005. [12] [13] [14] A. Schuster, S. Karellas , E. Kakaras , H. Spliethoff. Energetic and economic T.C. Hung, T.Y. Shai and S.K. Wang, A review of organic Rankine cycles A. Borsukiewicz-Gozdur and W. Nowak, Comparative analysis of natural and investigation of Organic Rankine Cycle applications. (ORCs) for the recovery of low-grade waste heat. Energy, 22(7) (1997) 661667. synthetic refrigerants in application to low temperature ClausiusRankine cycle. Energy, 32(4) (2007) 344352. [15] [16] V. Maizza and A. Maizza, Unconventional working fluids in organic RankineG. Kosmadakis, D. Manolakos, S. Kyritsis, G. Papadakis. Comparative cycles for waste energy recovery systems. Appl. Thermal Eng., 21 (2001) 381390. thermodynamic study of refrigerants to select the best for use in the high-temperature stage of a two-stage organic Rankine cycle for RO desalination, Desalination 243 (2009) 7494. [17] [18] 3373. Hung TC. Waste heat recovery of organic Rankine cycle using dry J.L. Wang, L. Zhao , X.D. Wang, A comparative study of pure and zeotropic fluids.Energy Conversion Management 2001;42:539-53. mixtures in low temperature solar Rankine cycle, Applied Energy 87 (2010) 3366