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Fostering development of innovative solutions to Alaska’s energy challenges. How the Organic Rankine Cycle (ORC) Works Step 1: Heat is captured by the evaporator and boils the working fluid into pressurized vapor. Step 2: The vapor flows through the twin screw expander, spinning an electric generator to produce power. Step 3: The vapor is cooled and condensed back into liquid in the condenser. Step 4: The working fluid is pumped to higher pressure and returned to the evaporator to repeat the cycle. Courtesy of ElectraTherm, Inc. Is the Green Machine Right for Alaska? The goal of the Green Machine project in Alaska is to deter- mine whether the device is an economical way to utilize waste heat from rural power plants, taking excess heat from the first power cycle and using it as the input to the organic Rankine cycle, wringing out a bit more power before finally discharging the lowest-temperature exhaust heat into the environment. In rural villages, where diesel is flown in and costs from $5 to $20 a gallon, to effectively increase the overall efficiency of the power generator makes economic and practical sense. The Green Machine is estimated to increase overall fuel efficiency by 3% to 4% and reduce CO2 emissions by 22.2 pounds for every gallon of diesel conserved. Using those figures, payback time for the Green Machine can be as little as two years, de- pending on the exact input and output temperatures and the cost of fuel. ORC Technology The Rankine cycle extracts energy when a working fluid, usu- ally water, undergoes a phase transformation between liquid and steam. The working fluid is boiled by the heat source and expands into steam. This expansion powers a turbine. Once the usable energy is released through steam, it condenses back to a liquid, expelling waste heat in the process. The Ran- kine cycle is widely used in fossil fuel power generation and in solar thermal, biomass and nuclear power plants, generating about 90% of all electric power used worldwide today.1 The organic Rankine cycle operates on exactly the same principle, only it uses an organic compound specially chosen to operate at a lower working temperature as a working fluid, which enables it to extract power from lower-temperature heat sources. The organic Rankine cycle is used to power the hotel and resort at Chena Hot Springs, the lowest-temperature geothermal resource used for commercial power production in the world.2 Initial Product Assessment In 2009-2010, the ORC research team at UAF performed an extensive literature and product search and found that Electra- Therm’s Green Machine was the only ORC machine that was close to commercial release that would work on the small- scale and low-temperature heat output that would come from a typical village generator set. Large-scale ORC units (approxi- mately 100 kW or more) are an established technology, but small- to mid-sized applications still need testing for feasibility and economic viability.3 The Green Machine was also an ideal candidate because it has a simple design with routine mainte- nance requirements that a village power plant operator would be familiar with (for example, lubricating bearings). It also promised to be robust through potentially rough shipping, and the manufacturer was cooperative and very interested in hav- ing a field test in a harsh Alaska environment. ACEP Research Engineer David Light sets up the Green Machine at the UAF power plant for the first round of testing and performance evaluation. The UAF Power Plant was a main partner in this phase of the project, allowing ACEP researchers to use surrogate heat and water sources from the university’s combined heat and power plant to simulate a diesel gen- erator in a controlled setting. UAF photo by Todd ParisPDF Image | Means for Increasing Diesel Engine Efficiency in Alaska
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