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SELECTION AND CONVERSION OF TURBOCHARGER AS TURBO-EXPANDER FOR ORGANIC RANKINE CYCLE (ORC) Choon Seng Wong1, David Meyer2 and Susan Krumdieck3 1,2,3Department of Mechanical Engineering, University of Canterbury, Private Bag 4800, Christchurch 8041, New Zealand 1choon.wong@pg.canterbury.ac.nz 2david.meyer@canterbury.ac.nz 3susan.krumdieck@canterbury.ac.nz Keywords: Organic Rankine Cycle, Radial Turbine, Selection of Off-shelves Turbine, Turbocharger, ORC Turbine ABSTRACT Turbo-expander is the most crucial and expensive component in Organic Rankine Cycle (ORC) power generation systems. The turbine engineering, design and research development process for ORC system is costly, time-consuming, and difficult for new-entrants in the ORC field. This paper investigates the re-design and retrofit of an off-the-shelf turbocharger for use in a 1 kW ORC system. The expander requirements were determined for the 1 kW Capstone Gas Turbine bottoming cycles from the ORC system design. A radial turbine was selected and an off-the- shelf turbocharger from a small petrol-driven vehicle was acquired. The turbocharger was simulated to study the off- design performance in an ORC system. The turbocharger was evaluated by expansion of compressed air at room temperature to assess the leakage of working fluid and the lubrication requirements. A preliminary design was developed to deal with leakage and lubrication issues. The conceptual design of an ORC turbine was presented including the casing design and selection of auxiliary components such as bearings, seals and lubrication systems. 1. INTRODUCTION The potential for utilization of low grade heat sources for power generation is contributing to increasing research and development of ORC systems. The ORC uses refrigerants as the working fluid to provide higher thermal cycle efficiency compared to the conventional steam Rankine cycle at resource temperatures below 300oC (Vankeirsbilck, Vanslambrouck, Gusev, & De Paepe, 2011). The design and development of a turbo-expander for an ORC is the most expensive component in the whole system. Stosic found that the turbo-expander in a 1MW ORC system typically costs over half of the total capital cost (Leibowitz, Smith, & Stosic, 2006). The high cost of the turbo-expander is attributed to the intensive research and engineering development required in the turbine design and manufacturing process. The type of turbine has to be selected before proceeding to turbine design and analysis. A wide variety of turbo- expanders can be chosen for ORC applications. Positive displacement machines are popular for small scale ORC systems due to their simplicity and low cost, while turbo- expanders are widely applied for large scale power generation systems and have achieved high turbine efficiency and high reliability. The type of turbo-expander is determined by shaft speed, mass flow rate and the nominal power range. Recent developments in small scale ORC systems for research applications have produced an expander selection methodology, which covers the scroll expander, screw expander, and radial turbine (Quoilin, Declaye, & Lemort, 2010). Application of scroll expanders is limited to power generation below 30 kW due to the excessive leakage at increasing scroll diameter and scroll height (Quoilin et al., 2010). A screw expander was adopted by ElectraTherm for a 100 kW ORC system (Qiu, Liu, & Riffat, 2011). However, the screw expander is not as widely validated as the scroll expander and radial turbine. Turbo- expanders are preferable for a wide range of power generation systems ranging from 10 kW to a few MW. A 20-115 kW turbo-expander was developed by Verdicorp, a 175 kW radial impeller was commercialized by Tri-O-Gen and a 250 kW turbo-expander was designed by UTC for the ORC systems. Large power units above 500 kW are mainly monopolized by axial turbine. The current market available ORC units are shown in Figure 1. There are some gaps between 20 kW and 500 kW in which a flexible design approach of the turbo-expander would contribute to fill in the market gap. ORC unit powered by Axial Turbine (Turboden) 0.5– 15 MW 250 kW 20 –115 kW 1–10 kW 1. 2. 3. Conversion of centrifugal chiller into an ORC system powered by radial impeller (Pratt and Whitney) ORC unit powered by screw expander (ElectraTherm) ORC unit powered by radial impeller at 175 kW (Tri-O-Gen) Conversion of a Compressor into a Turbo-Expander (Verdicorp Company) Scroll Expander (Air Squared Company) Conversion of an Automotive Scroll Compressor into a Scroll Expander for research application 1MW 100kW 10kW 1. 2. 1 kW Figure 1: Current Market Available ORC Unit Figure 2 shows the capital cost of installed ORC units based on different turbine development schemes. The cost per kWh in Figure 2 is only valid for the ORC system over 100 kW. At small scale power generation system, the prototype 35th New Zealand Geothermal Workshop: 2013 Proceedings 17 – 20 November 2013 Rotorua, New ZealandPDF Image | TURBOCHARGER AS TURBO-EXPANDER FOR ORGANIC RANKINE CYCLE
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