Organic Rankine Cycle (ORC) heat engines convert low-grade heat to other forms of energy such as electrical and mechanical energy. They achieve this by vaporizing and expanding the organic fluid at high pressure, turning the turbine which can be employed to run an alternator or any other mechanism as desired. Conventional Rankine Cycles operate with steam at temperatures above 400 ℃. The broad aspect of the research focussed on the generation of electricity to cater for household needs. Solar energy would be used to heat air which would in turn heat rocks in an insulated vessel. This would act as an energy storage in form of heat from which a heat transfer fluid would collect heat to supply the ORC heat engine for the generation of electricity. The objective of the research was to optimize power output of the ORC heat engine operating at temperatures between 25℃ at the condenser and 90 to 150℃ at the heat source. This was achieved by analysis of thermal energy, mechanical power, electrical power and physical parameters in connection with flow rate of working fluid and heat transfer fluids.

A high demand of both electricity and heat exists in Arizona Chemical (a chemical plant dedicated to the distillation of Crude Tall Oil) for production processes. Due to the rising cost of resources and electricity, more and more companies are trying to decrease the energy expenses to increase their competitiveness in a global market, thus increasing their profit. Some companies look at their energy consumption in order to diminish it or to explore the opportunity to generate their own and cheaper energy. In companies where the production of steam already takes place, cogeneration can be a good solution to palliate the cost of the energy used. This study addresses this issue through three actions such as the characterization of the boiler, a better steam flow measurement grid and the generation of electricity. The first one addresses the state of one of the key parts of steam production, the boiler, through the calculation of its efficiency with two different methods (direct and indirect calculation). These methods require some measurements which were provided afterwards by the company supervisor. This will allow the company to identify the weaknesses of the boiler to be able to improve it in the future. The second one aims to improve the knowledge about the steam system. New flow measurement points were suggested after doing an analysis of the current controlled flows to have a better overview outline of the steam use.The third one studies the generation of electricity with a Rankine cycle. The limitations in the characteristics of the steam were identified and different configurations are proposed in accordance to the restrictions identified. An efficiency of 93% is obtained for the boiler with the direct method and 82.3 % for the indirect one. The difference between them can be explained by the use of datafrom different time frames for both methods. The main contributors to the losses are the ones related to the dry flue gas and the hydrogen in the fuel. In the current status only 40% of the steam flows are identified, a number which is expected to raise with the new measurement points. It was not possible to estimate the effect of the new points due to the desire of the company to not disturb the current production. Due to the fuel price the production of steam for only electricity was not profitable and instead the generation of both electricity and heat from the same steam is proposed. This integrated system is now possible to implement due to its low payback time (2.3 years). This solution can generate 758 kW of electricity and provide the company with 6437 MWh of electricity each year. Then, the effect of the variation of different variables over the performance of the cycle were studied: different electricity prices, steam rate production, fuel cost and the state of the condensate recovery were discussed. The variation of both the condensate recovery and fuel cost did not affect the payback time due to their costs being neutralised by the revenues obtained from them. The variation of the electricity prices and steam production affects the payback but due to the high revenue that is expected it does not hamper the good nature of the investment. The generation of electricity is recommended due to the low payback time obtained. The different variations studied in the system did not change the payback time notably and showed that the investment is highly profitable in all the scenarios considered. The use of two smaller turbines instead of the one chosen (with a maximum rated power of 6 MW while only 758 kW is generated with the proposed solution) should be studied since the turbines would work closer to their maximum efficiency.

This study is an attempt at achieving Net Zero Energy Building (NZEB) using a solar Organic Rankine Cycle (ORC) based on exergetic and economic measures. The working fluid, working conditions of the cycle, cycle configuration, and solar collector type are considered the optimization parameters for the solar ORC system. In the first section, a procedure is developed to compare ORC working fluids based on their molecular components, temperature-entropy diagram and fluid effects on the thermal efficiency, net power generated, vapor expansion ratio, and exergy efficiency of the Rankine cycle. Fluids with the best cycle performance are recognized in two different temperature levels within two different categories of fluids: refrigerants and non-refrigerants. Important factors that could lead to irreversibility reduction of the solar ORC are also investigated in this study. In the next section, the system requirements needed to maintain the electricity demand of a geothermal air-conditioned commercial building located in Pensacola of Florida is considered as the criteria to select the optimal components and optimal working condition of the system. The solar collector loop, building, and geothermal air conditioning system are modeled using TRNSYS. Available electricity bills of the building and the 3-week monitoring data on the performance of the geothermal system are employed to calibrate the simulation. The simulation is repeated for Miami and Houston in order to evaluate the effect of the different solar radiations on the system requirements. The final section discusses the exergoeconomic analysis of the ORC system with the optimum performance. Exergoeconomics rests on the philosophy that exergy is the only rational basis for assigning monetary costs to a system’s interactions with its surroundings and to the sources of thermodynamic inefficiencies within it. Exergoeconomic analysis of the optimal ORC system shows that the ratio Rex of the annual exergy loss to the capital cost can be considered a key parameter in optimizing a solar ORC system from the thermodynamic and economic point of view. It also shows that there is a systematic correlation between the exergy loss and capital cost for the investigated solar ORC system.

The shift towards renewable energy has steered the focus of power plant operation towards flexibility and fast response which are more attainable through the use of combined-cycle power plants. These aspects are required to account for the fluctuation of the supply as well as the demand of power that is associated with renewable energy. Combined-cycle power plants consist of a gas turbine as the topping cycle, forming the core of the plant, and a Rankine cycle with a steam turbine as the bottoming cycle. A component called the Heat Recovery Steam Generator (HRSG) forms a connection point between the two cycles. It uses the heat released from the gas turbine to produce high pressure and temperature steam to be sent to the steam turbine. The objective of this project is to develop a model of a combined-cycle power plant in Flownex which can be solved in off-design conditions in order to compare it to plant data. The verification of this model will show that Flownex can be used to effectively and efficiently model a combined-cycle power plant. The process of development of the final Flownex model was achieved using various additional software. Initially, an analytical model was developed in Mathcad (software used for engineering calculations). This software provides a tool for understanding knowns, unknowns and what is being calculated in the system. Manual calculations of the Heat Recovery Steam Generator (HRSG) were done using heat balance equations. A temperature profile of the gas and water/steam in the HRSG was developed so that the duties of each component (economiser, evaporator, superheater) could be calculated. The overall conductance (UA) of each component was calculated in the design mode for the system to be evaluated in off-design mode. The development of an analytical model provided detailed understanding of the process of mathematical modelling used in commercial tools. Thereafter, a model was built in Virtual Plant, a thermodynamic modelling software for assessing plant performance. Virtual Plant uses plant design information and first engineering principles to predict plant performance. Finally, the Flownex model was designed. Flownex uses endpoint values (initial pressure and temperature and outgoing mass flow) and the UA of each component to calculate the characteristics of the flow at each intermediate point. For the single-, double-, and triple-pressure combined-cycle power plant systems, the analytical, Virtual Plant and Flownex models were compared. The results of all the models agreed closely with one another. The triple-pressure design and off-design Virtual Plant and Flownex models were also compared to plant data and it was concluded that Flownex was successful in modelling the design and off-design conditions of a combined-cycle power plant.

In most previous studies that have been conducted on converting waste heat energy from exhaust gases into useful energy, the engine waste heat recovery system has been placed along the exhaust flow pipe where the temperature differs from the temperature just behind the exhaust valves. This means that an important fraction of the energy from the exhaust gases is still lost to the environment. The present work investigates the potential thermodynamic analysis of an integrated exhaust waste heat recovery (EWHR) system based on a Rankine cycle on an engine's exhaust manifold. The amount of lost energy contained in the exhaust gases at the exhaust manifold level, at average temperatures of 500 °C and 350 °C (for petrol and diesel), and the thermodynamic composition of these gases were determined. For heat to occur, a temperature difference (between the exhaust gas and the working fluid) at the pinch point of 20°C was considered. A thermodynamic analysis was performed on different configurations of EWHR thermal efficiencies and the selected suitable working fluids. The environmental and economic aspects of the integrated EWHR system just behind the exhaust valves of an internal combustion engine (ICE) were analysed. Among all working fluids that were used when the thermodynamic analysis was performed, water was selected as the best working fluid due to its higher thermal efficiency, availability, low cost and environmentally friendly characteristics. Using the typical engine data, results showed that almost 29.54% of exhaust waste heat can be converted. This results in better engine efficiency and fuel consumption on a global scale by gaining an average of 1 114.98 Mb and 1 126.63 Mb of petrol and diesel respectively from 2020 to 2040. It can combat global warming by recovering 56.78 1 011 MJ and 64.65 1 011 MJ of heat rejected from petrol and diesel engines, respectively. A case study of a Volkswagen Citi Golf 1.3i is considered, as it is a popular vehicle in South Africa. This idea can be applied to new-design hybrid vehicles that can use the waste heat to charge the batteries when the engine operates on fossil fuel. / Dissertation (MSc)--University of Pretoria, 2016. / Mechanical and Aeronautical Engineering / MSc / Unrestricted

Thesis. 1977. B.S. cn--Massachusetts Institute of Technology. Dept. of Mechanical Engineering. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING / Bibliography: leaves 60-61. / B.S.cn

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In this master thesis an implementation of an Organic Rankine Cycle (ORC) on a stepping furnace in a steel mill is modeled and proposed. The study is a case study at the company Štore&STEEL d.o.o. with intentions of realization. In a steel mill a stepping furnace is used to preheat the steel billets for later forging. The stepping furnace is gas fired and already has recuperation of the inlet air implemented. Still there is high temperature of the stack after recuperation, which makes application of an ORC worth of researching and modeling.First the flue gas over one year of furnace operation is analyzed in terms of temperature and volumetric flow. Mass flow and heat capacity are calculated. A layout of an ORC is proposed and modeled in IPSEpro for different temperatures of the flue gas resulting in different output powers and efficiencies. For each temperature an economic viability calculation with the method of reference cost of electric energy is done.The results are presented and the best design and conditions are proposed. The results of the thesis proved that further detailed measurements and calculation are worthwhile , as the flue gas from the stepping furnace has satisfactory conditions to make an application of an Organic Rankine cycle viable. Also the least ammount of state support to fulfill the companies conditions on return of investment is calculated and presented. Finally there are additional measurements and calculations suggested.

This thesis describes the modifications made to the Cal Poly Thermal Science Laboratory’s steam turbine experiment. While the use of superheating or reheating is commonly used to increase efficiency in a Rankine cycle the methods prove unfeasible in a small scale project. For this reason, a mathematical model and proof of concept design using hydrostatic head generated by elevation and venturi ejection for use by the condenser is developed along with the equations needed to predict the changes to the system. These equations were used to create software to predict efficiency as well as lay down the foundation for future improvements of the system.

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