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Abstract Diesel generators produce waste heat as well as electrical power. Considering diesel engine application in rural Alaska, in general, less than 40% of the fuel energy is used for electrical power generation and the rest is dissipated through different mediums or directly radiated into the environment in the form of low temperature heat (versus heat directly from fuel combustion). This project conducted an experimental reliability study and both analytical and experimental performance studies of an emerging heat engine technology, a low temperature organic Rankine cycle (ORC) system with a capacity of 50kW and using a screw expander to convert low temperature heat into electrical power. This project also involved performance comparison between the 50kW ORC system and a conventional 250kW ORC system. 50kW low temperature heat to power conversion system is currently considered an emerging technology, which is in the testing stage, and 250kW system, which uses radial turbine for power conversion and is commercially available, is considered a matured technology. Detailed performance characteristic charts and economic analysis have also been completed for the 50kW ORC system. The project began with a survey of existing technologies and selection of the most promising and deliverable technology for testing. The technology has been delivered for testing was an ElectraTherm (ET) 50kW organic Rankine cycle (ORC) system. Test location was selected based on the potential cost and availability of resources (e.g., heat source, cooling source). Among two potential test locations, an available space in the power plant on the UAF campus was selected due to the availability of heating (steam), cooling (cooling water), and human resources and the potential of less total cost for installation and operation. The supporting systems (from now on it is called testing system) needed for the include thermal fluid systems for heating and cooling, an electrical circuit for power up-loading/consumption control, an instrument and signal process circuits for data acquisition/performance monitoring and control and an dedicated internet line for remote monitoring/control. Detailed designs of the supporting system were completed largely through the cooperation between the engineers of ACEP, facility services, and power plant of the UAF. Associated management personnel have also contributed a lot on schedule and resources controls. A 600-hour reliability test was conducted after the installation and instrumentation. No major system break downs occurred during the test and the performance of the system and every component of the system appeared very consistent with the screw expander power (ORC heat to power converter) output of 50.1kW and net ORC system output of 46.4kW (i.e. a parasitic power of 3.7kW). During the 600 hours of the reliability test, the only flaw occurred was the inability to start the ORC system due to the defect of a pressure switch. The flaw was automatically detected by the ORC system software displayed on the system monitor screen. Pressure switch is one of a series of safety guards to prevent the machine from overload and its defect will not affect the system to continue to operate with any compromise in system security. According to the ET engineering group, the defect of this type of pressure switch is rarely occurs. Based on data obtained from the reliability test, the net efficiency of the ORC system is about 7.6%, potential annual energy generation 395,328 kW-hours (355 working days and 10 3PDF Image | Optimizing Heat Recovery Systems for Power Generation in Rural AK
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