Multi-Pressure Organic Rankine Cycle for Waste Heat Recovery
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Solution Overview
Problem
Current systems for generating electricity from waste heat, such as Organic Rankine Cycle (ORC) and Externally Fired Gas Turbine (EFGT) systems, face limitations in maximizing power output due to the constraints of working fluids, especially when dealing with waste heat sources of different temperature levels, and struggle to efficiently incorporate solid fuels.
Innovation Solution
A system utilizing two vaporizers and a two-pressure level turbine system, where high-temperature and low-temperature waste heat sources are used to drive a common working fluid through separate vaporizers, optimizing energy extraction with a recuperator and common condenser setup to enhance power generation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single fluid ORC is used for waste heat systems with different temperature levels, then the system structure is simple, but the power output cannot be maximized
Solution Approach 1:
The patent divides the single ORC system into multiple independent ORC systems, each operating at different pressure levels. The high-pressure ORC handles high-temperature waste heat while the low-pressure ORC handles low-temperature waste heat, allowing each system to be optimized for its specific temperature range and maximizing overall power output from multi-temperature waste heat sources.
2Productivity
If multiple independent ORC systems are used for different temperature levels, then power output is maximized, but system complexity increases
Solution Approach 1:
The patent combines multiple ORC systems into an integrated multi-pressure level system where high-pressure and low-pressure ORCs work together. The systems share common infrastructure including the condenser, pump, and control systems, while maintaining independent evaporators optimized for different temperature levels. This merging approach maximizes power output while minimizing the increase in system complexity through shared components.
3Loss of energy
If waste heat is discharged into the environment, then the system operation is simple, but energy is lost
Solution Approach 1:
The patent converts the harmful waste heat discharge into a beneficial resource by capturing waste heat at multiple temperature levels and using it to drive ORC systems for electricity generation. The high-temperature waste heat drives the high-pressure ORC while low-temperature waste heat drives the low-pressure ORC, transforming energy that would otherwise be lost into useful electrical power.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for more efficient energy extraction from waste heat sources of varying temperatures, increasing overall power output and improving the system's ability to handle different thermal inputs, making it scalable and adaptable for various industrial applications.
Implementation Method 1
A first vaporizer of the system utilizes waste heat from a high-temperature heat source to heat a working fluid
Implementation Method 2
A second vaporizer of the system utilizes waste heat from a low-temperature heat source to heat the working fluid
Implementation Method 3
A first turbine of the system receives heated working fluid from the first vaporizer and expands the heated working fluid to drive the first turbine
Implementation Method 4
A condenser of the system condenses an output of the first turbine and a output of the second turbine
Data Source
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AI summary
A waste heat recovery system includes a high pressure turbine and a low pressure turbine, in which the high pressure turbine receives high pressure working fluid vapor, the low pressure turbine receives low pressure working fluid vapor and the high pressure turbine also supplies low pressure working fluid vapor to the low pressure turbine. A recuperator receives working fluid vapor from the low pressure turbine. The recuperator produces heated condensate, at least a portion of which is provided to a high pressure vaporizer. The high pressure vaporizer is configured to receive from a high temperature heat source and produces high pressure working vapor used to power the high pressure turbine. The remaining condensed fluid is provided to a low pressure vaporizer which is configured to receive heat from a low- temperature heat source, thereby producing low pressure working fluid vapor used to power the low pressure turbine.