ORC Gas Temperature Control to Prevent Condensation

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Solution Overview

Problem

Existing organic Rankine cycle (ORC) generators lack a system to maintain the temperature of a gas flow at a specified range, leading to volatile condensation and equipment damage, inefficiencies, and reduced compressor performance.

Innovation Solution

Implementing a bypass valve and flow control mechanisms in heat exchangers to adjust gas temperature by diverting gas flow and adjusting working fluid rates, ensuring the gas remains within a specified operating range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If heat transfer from gas flow to working fluid is increased to improve power generation, then electrical power output increases, but gas temperature drops below threshold causing volatile condensation

Engineering Contradiction:

Improveelectrical power outputVSAvoidvolatile condensation

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The system continuously monitors gas temperature and adjusts the working fluid flow rate through the heat exchanger based on feedback from temperature sensors. When gas temperature approaches the volatile condensation threshold, the system reduces working fluid flow to prevent condensation while maintaining adequate heat transfer for power generation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes the working fluid flow rate parameter through variable speed pumps and control valves to optimize heat transfer efficiency. By adjusting flow rates in real-time based on gas temperature conditions, the system maintains optimal operating parameters to prevent volatile condensation while maximizing power output.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If working fluid flow rate is increased to improve heat transfer efficiency, then power generation efficiency increases, but gas temperature control precision decreases

Engineering Contradiction:

Improvepower generation efficiencyVSAvoidgas temperature control precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Temperature sensors provide continuous feedback on gas temperature, enabling the control system to precisely regulate working fluid flow rates. This closed-loop control ensures accurate temperature maintenance within the optimal range while maximizing heat transfer efficiency for power generation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system employs variable speed pumps and adjustable control valves that can dynamically change working fluid flow rates in real-time. This dynamic adjustment capability allows the system to optimize both heat transfer efficiency and temperature control precision by adapting to varying gas flow conditions.

Inventive Principle:

Principle #15Dynamics

3Power

If gas flow is diverted through heat exchanger to generate power, then electrical power output increases, but gas temperature drops affecting compressor performance

Engineering Contradiction:

Improveelectrical power outputVSAvoidcompressor performance

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The system uses partial diversion of gas flow through the heat exchanger rather than complete diversion. By controlling the degree of flow diversion and optimizing working fluid flow rates, the system extracts sufficient heat for power generation while maintaining gas temperature above the compressor performance threshold.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system dynamically adjusts working fluid flow rates and heat exchanger operating parameters to optimize heat extraction. By changing flow rates and operating conditions in real-time, the system achieves adequate power generation while preserving gas temperature for maintained compressor performance.

Inventive Principle:

Principle #35Parameter changes

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

Prevents volatile condensation and maintains efficient compressor operation while generating electrical power effectively.

Implementation Method 1

heat transfer to a working fluid in the loop, causing the working fluid in the loop to change phases from a liquid to a vapor

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

heat from the heat source causes the working fluid in the loop to change phases from a liquid to a vapor

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

The condenser or heat sink may cool the working fluid, causing the working fluid to change phase from the vapor to the liquid

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS20260022647A1Systems and methods utilizing gas temperature as a power source

Publication Date: 2026.01.22 ICE THERMAL HARVESTING LLC

AI summary

Systems and generating power in an organic Rankine cycle (ORC) operation to supply electrical power. In embodiments, an inlet temperature of a flow of gas from a source to an ORC unit may be determined. The source may connect to a main pipeline. The main pipeline may connect to a supply pipeline. The supply pipeline may connect to the ORC unit thereby to allow gas to flow from the source to the ORC unit. Heat from the flow of gas may cause the ORC unit to generate electrical power. The outlet temperature of the flow of the gas from the ORC unit to a return pipe may be determined. A flow of working fluid may be adjusted to a percentage sufficient to maintain temperature of the flow of compressed gas within the selected operating temperature range.