ORC Condenser Heat Recovery for Anaerobic Digestion
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Solution Overview
Problem
Existing waste heat recovery systems, such as ORC systems, face inefficiencies due to heat energy loss during condensation and require additional energy for cooling, which detracts from overall system efficiency and increases operational costs.
Innovation Solution
The integration of an ORC system with anaerobic digestion processes to utilize waste heat energy for maintaining optimal digestion temperatures and providing heat for biogas generation, thereby reducing the need for supplemental heating systems and optimizing energy conversion within a closed-loop system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If waste heat is recovered using ORC systems, then power generation efficiency is improved, but heat energy is lost during condensation and additional cooling energy is required
Solution Approach 1:
The patent converts the harmful waste heat that would normally be lost during ORC condensation into a beneficial resource by directing it to heat the anaerobic digestion tank. The condensation heat exchanger serves dual purposes: condensing the ORC working fluid and providing thermal energy to maintain optimal digestion temperatures, thereby transforming an energy loss into a useful function.
Solution Approach 2:
The patent merges the ORC power generation system with the anaerobic digestion heating system by integrating the condensation heat exchanger into both systems. This combination allows the same thermal exchange process to fulfill two functions simultaneously: power cycle completion and process heating, eliminating the need for separate cooling and heating systems.
2Reliability
If separate cooling and heating systems are used, then temperature control is reliable, but system complexity and operational costs increase
Solution Approach 1:
The condensation heat exchanger is designed to perform multiple functions: it serves as the condenser for the ORC working fluid and simultaneously acts as a heat source for the anaerobic digestion tank. This multi-functional component replaces what would traditionally require separate cooling and heating systems, reducing overall system complexity while maintaining reliable temperature control for both processes.
Solution Approach 2:
The patent combines the cooling function for the ORC system and the heating function for the digestion system into a single integrated thermal exchange process. By merging these two previously separate system requirements into one heat transfer operation, the patent reduces the number of components needed while ensuring both temperature control functions are reliably performed.
3Reliability
If supplemental heating systems are used for anaerobic digestion, then temperature maintenance is reliable, but energy consumption increases
Solution Approach 1:
The patent converts the waste heat from ORC condensation, which would normally be discarded, into a useful heating source for the anaerobic digestion tank. This eliminates or reduces the need for supplemental heating systems, thereby maintaining reliable temperature control while significantly reducing the additional energy consumption that would be required for separate heating equipment.
Solution Approach 2:
The ORC system provides its own waste heat to serve the heating needs of the anaerobic digestion process. Instead of requiring external energy inputs for heating, the system uses its own internally generated thermal energy, creating a self-sufficient arrangement that reduces overall energy consumption while maintaining reliable temperature maintenance.
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 integration enhances the efficiency of biogas production, reduces energy consumption, and maximizes the utilization of waste heat energy, leading to increased economic benefits and reduced environmental impact by eliminating the need for separate cooling and heating systems.
Implementation Method 1
an ORC system that provides work through expansion of a working fluid
Implementation Method 2
Organic Rankine cycle systems for the generation of power from waste heat sources
Implementation Method 3
The heat exchanger may be the same heat exchanger that provides condensation for the ORC system
Implementation Method 4
heat energy from ORC working fluid condensation is productively utilized
Implementation Method 5
heat energy from ORC working fluid condensation
Data Source
AI summary
Apparatus, systems and methods are provided for the improved use of waste heat recovery systems which utilize the organic Rankine cycle (ORC) to generate mechanical and/or electric power from waste heat of large industrial machines (prime movers) generating power from biofuel such as biogas produced during the anaerobic digestion process. Waste heat energy obtained from prime mover(s) is provided to one or more ORC system(s) which are operatively coupled to separate electrical generator(s). The ORC system includes a heat coupling subsystem which provides the requisite condensation of ORC working fluid by transferring heat from ORC working fluid to another process or system, such as anaerobic digester tank(s), to provide heat energy that enhances the production of fuel for the prime mover(s) without requiring the consumption of additional energy for that purpose.