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they rotate at very high speeds, and hence require high ratio reduction gearboxes or expensive direct coupled electrical generators, as well as relatively costly lubrication systems. A closer examination was therefore made of alternative types of expanders and the most promising of these was found to be the twin screw type. The use of screw expanders in ORC systems has been proposed before (3) and a small number of these have been constructed and operated. One of the most widely publicized of these units was a geothermal plant in Birdsville, Australia (4). In those cases, the plant designers lacked expertise in the engineering science required for the optimum design of such machines. Consequently, many of the potential advantages in their use were not realized. This paper describes the combined efforts of a US company that recognized the potential for small scale ORC units, and a UK university, where research and development on screw expanders and compressors has proceeded for over 25 years, to produce a low cost ORC system. Although, primarily intended for engine waste heat recovery, these units are equally suitable for geothermal power generation. SCREW EXPANDERS Twin screw machines are mainly used as compressors, for air and refrigeration applications. As a result of much development, when operating in the oil flooded mode, they can now attain adiabatic efficiencies of up to 90%. This is comparable to that of the best aerodynamic compressors. However, unlike turbo machines, they are manufactured in large numbers and, especially when operating as air compressors, are relatively inexpensive. Their mode of operation has already been described to a GRC meeting (4). Mainly, it is worth repeating that, unlike turbo machines, in which the blading and stage requirements are completely different for expansion and compression, a screw compressor only requires alteration to the high pressure port, to obtain the optimum built-in volume ratio and reversal of direction of rotation of the rotors, to operate equally well as an expander. Rotor Profiles Given the clearance between the rotors and the rotors and the casing, which is determined, mainly by manufacturing limitations, the most important feature of a twin screw machine, which determines flow rates and efficiencies, is the rotor profile. The earliest machines used a symmetric profile, as shown in Fig 2. This is very simple, with the male rotor shape constructed from only three circles, the centers of which are positioned either at the rotor centre or on its pitch circle. The female rotor profile then mirrors this with an equivalent set of circles. The symmetric profile has a very large blow-hole area which creates significant internal leakage. This excludes it from any application where a high or even a moderate pressure ratio is involved. However, the symmetric profile performs surprisingly well in low pressure compressor applications.PDF Image | COST EFFECTIVE SMALL SCALE ORC SYSTEMS
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