Single Regenerator for Multi-Level ORC Heat Recovery
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Solution Overview
Problem
Traditional multi-pressure level Organic Rankine Cycle (ORC) systems require separate regenerators for each pressure level, leading to increased construction complexity, costs, and potential losses due to back pressures.
Innovation Solution
A single regenerator with a single containment casing, comprising multiple finned batteries for different pressure levels, is used to recover heat from the turbine exhaust steam, simplifying the system and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If separate regenerators are used for each pressure level, then heat recovery efficiency is improved, but device complexity and construction costs increase
Solution Approach 1:
The patent combines multiple separate regenerators into a single integrated regenerator that serves multiple pressure levels. This single regenerator includes multiple heat exchange circuits, each handling a different pressure level, but all contained within one unified device. This merging approach maintains the heat recovery function for each pressure level while reducing overall system complexity and construction costs compared to having separate regenerators for each level.
2Loss of energy
If separate regenerators are used for each pressure level, then heat recovery function is improved, but manufacturing costs increase
Solution Approach 1:
The invention merges multiple regeneration functions into a single manufacturable unit. The single regenerator is designed with multiple internal circuits that can be manufactured as an integrated structure, reducing the total number of separate components that need to be produced, assembled, and maintained. This approach lowers manufacturing costs while preserving the heat recovery function for each pressure level through the multiple internal circuits.
3Loss of energy
If separate regenerators are used for each pressure level, then heat exchange capability is improved, but back pressure losses increase
Solution Approach 1:
The single integrated regenerator design consolidates the exhaust steam flow path, allowing the steam to pass through one unified device rather than multiple separate regenerators. This reduces the cumulative back pressure that would be generated by multiple separate components in series. The internal design includes multiple circuits within the single regenerator that maintain effective heat exchange capability while minimizing the overall pressure loss compared to using separate regenerators for each pressure level.
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
The single regenerator design simplifies construction, reduces costs, and minimizes back pressures, thereby enhancing the overall efficiency and performance of the ORC system.
Implementation Method 1
a regenerator or recuperator which recovers a good portion of the sensible heat of the low pressure organic fluid vapor, which heat is used to preheat the organic working fluid in the liquid phase
Implementation Method 2
at least one turbine for the expansion of the fluid, mechanically connected to an electrical generator
Implementation Method 3
a condenser that returns the organic working fluid to the liquid state
Implementation Method 4
one or more feed pumps for moving the organic working fluid in the liquid state from the low pressure zone to the high pressure zone
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
A two or more pressure level organic Rankine cycle system (100), operated by a heat source flow (5) and working fluid flows (10, 12, 15), the system (100) having a single regenerator (50) provided with a casing (55) containing within it at least one finned battery (60, 65) for each pressure level of the system (100), and wherein the regenerator (50) is configured to perform a heat exchange between a single flow (12) of working fluid in the vapor phase and two or more flows (10, 15) of working fluid in the liquid phase, wherein each flow (10, 15) of working fluid in the liquid phase is at a different pressure level and flows in a respective finned battery (60, 65).