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organic_rankine_cycle ( organic_rankine_cycle )

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INDUSTRIAL TECHNOLOGIES PROGRAM Project Description This project will optimize the Organic Rankine Cycle for the conversion of low-temperature waste heat from gas turbine or reciprocating engine exhaust to electricity. The work entails detailed design and modeling of a direct evaporator concept that improves efficiency by eliminating the usual secondary heat exchanger loop. Thermal decomposition and flammability analyses of the organic working fluid will be performed to maximize performance and minimize risk of the system. A prototype test facility will be designed and constructed to evaluate the operation of the direct evaporator. The result of these efforts will be a safe, economically feasible direct evaporator design manufactured with the gas turbine or reciprocating engine as a single package that is easy for customers to install and operate. Barriers • Most commercial ORCs use a flammable hydrocarbon working fluid. If the evaporator were to develop a leak, the flammable working fluid would leak into the hot exhaust stream and create a potential fire hazard. Additionally, an evaporator placed directly in the exhaust stream poses the risk of heating up the working fluid to the point that it rapidly decomposes, forming decomposition byproducts. This can reduce cycle efficiency and cause potential fouling of the heat exchanger tubing. • It is common for ORCs to cost $2500/ kW and above. At this cost, most of the available waste heat recovery opportunities are not economically viable. Pathways To eliminate the limitations caused by the secondary heat transfer loop, researchers will develop advanced ORCs by using advances in direct evaporators, based on conceptual designs that have been developed by GE. This research effort will accelerate the development of the technology through research in flammability, two-phase heat transfer, and experimental validation. Milestones This project started in December 2008. • Detailed design and modeling of evaporator • Design and construction of partial prototype test facility • Working fluid decomposition chemical analyses • Test-bed heat transfer evaluation • Design, build, and test prototype evaporator in ORC cycle Commercialization GE will initially focus on pairing its ORC technology with direct evaporator, with existing GE turbines and engines; specifically the small- frame gas turbines offered by GE Oil and Gas operations, and the natural gas reciprocating engines offered by its Jenbacher operations. After GE has evaluated and proven the reliability of its ORC cycle in a sizable installed base of GE engines and gas turbines, it will then be able to adapt this ORC technology to a broader range of applications, especially industrial sources of heat. Project Partners Idaho National Laboratory Idaho Falls, ID Principal Investigator: Donna Post Guillen (Donna.Guillen@inl.gov) GE Global Research Niskayuna, NY GE Global Research Munich, Germany A Strong Energy Portfolio for a Strong America Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, and greater energy independence for America. Working with a wide array of state, community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy invests in a diverse portfolio of energy technologies. December 2008 For more information, visit www.eere.energy.gov/industry or call 1-877-337-3463

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