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The design of turbines used to convert thermal energy into electrical energy in an organic Rankine cycle (ORC) is crucial. A high-speed turbine requires high-performance bearings, which increases turbine manufacturing costs. In this study, a high-efficiency two-stage axial turbine at a low rotational speed was developed, and the ORC performance was presented. We designed a 180-kW axial turbine of 12,000 rpm. To increase turbine efficiency, the number of turbine stages was set to two, and turbine blades were designed to reduce pressure losses. One-dimensional design parameters of blades that minimized the total pressure loss were selected using an in-house code based on a generalized reduced gradient (GRG) nonlinear algorithm. Three-dimensional turbine blade modeling and numerical analysis were performed using commercial software. The total-to-static isentropic efficiency and output of the two-stage axial turbine were predicted to be 85.1% and 176 kW, respectively. ORC performance was assessed using the predicted turbine performance results. Assuming the temperature of the condenser outlet working fluid to be 25 °C, the ORC thermal efficiency and exergy efficiency were found to be 7.40% and 34.49%, respectively. Our findings highlight the applicability of various rotational speeds and number of stages for an axial turbine in an ORC.

The organic Rankine cycle (ORC) is a thermodynamic cycle in which electrical power is generated using an organic refrigerant as a working fluid at low temperatures with low-grade enthalpy. We propose a turbine embedded in a generator (TEG), wherein the turbine rotor is embedded inside the generator rotor, thus simplifying turbine generator structure using only one bearing. The absence of tip clearance between the turbine rotor blade and casing wall in the TEG eliminates tip clearance loss, enhancing turbine efficiency. A single-stage axial-flow turbine was designed using mean-line analysis based on physical properties, and we conducted a parametric study of turbine performance, and predicted turbine efficiency and power using the tip clearance loss coefficient. When the tip clearance loss coefficient was applied, turbine isentropic efficiency and power were 0.89 and 20.42 kW, respectively, and ORC thermal efficiency was 4.81%. Conversely, the isentropic efficiency and power of the turbine without the tip clearance loss coefficient were 0.94 and 22.03 kW, respectively, and the thermal efficiency of the ORC was 5.08%. Therefore, applying the proposed TEG to the ORC system simplifies the turbine generator, while improving ORC thermal efficiency. A 3D turbine generator assembly with proposed TEG structure was also proposed.

Evaporators used in organic Rankine cycles (ORC) are designed using existing flow boiling correlations that are mainly based on HVAC&R data. However, the ORC evaporators employed in the industry typically have larger diameters and operational conditions at higher reduced pressures compared to the HVAC&R applications. The present study presents the results of flow boiling heat transfer experiments in operational conditions that are representative for an industrial waste heat recovery low-temperature ORC’s evaporator tube, by being performed at high reduced pressures and in a large-diameter horizontal tube with R245fa as working fluid. The measurements are performed within a range of mass flux, saturation temperature and heat flux at 83–283 kg/m2s, 85–120 °C (8.9–19.2 bar) and 17–29 kW/m2, respectively. Test section is a round and plain horizontal carbon steel tube with 21 mm I.D., 2.5 m length. 513 local two-phase heat transfer coefficients are recorded. The experimental results are compared with each other to reveal heat transfer coefficient trends with respect to varying experimental conditions. Four distinctive heat transfer zones are observed, namely, the nucleate boiling dominant (NBD) zone, weakening nucleate boiling dominance (WNBD) zone, flow boiling zone (FBZ) and the dry-out zone (DOZ). Heat transfer coefficient vs vapor quality trends partly resembled CO2 flow boiling results reported in the literature. Two flow boiling correlations moderately predicted the data.

This paper describes an ejector model for the prediction of on-design performance under available conditions. This is a direct method of calculating the optimal ejector performance (entrainment ratio or ER) without the need for iterative methods, which have been conventionally used. The values of three ejector efficiencies used to account for losses in the ejector are calculated by using a systematic approach (by employing CFD analysis) rather than the hit and trial method. Both experimental and analytical data from literature are used to validate the presented analytical model with good agreement for on-design performance. R245fa working fluid has been used for low-grade heat applications, and Engineering Equation Solver (EES) has been employed for simulating the proposed model. The presented model is suitable for integration with any thermal system model and its optimization because of its direct, non-iterative methodology. This model is a non-dimensional model and therefore requires no geometrical dimensions to be able to calculate ejector performance. The model has been validated against various experimental results, and the model is employed to generate the ejector performance curves for R245fa working fluid. In addition, system simulation results of the ejector refrigeration system (ERS) and combined cooling and power (CCP) system have been produced by using the proposed analytical model.

This study explored effects of off-design heat source temperature (TW,in) or flow rate (mW) on heat transfer characteristics and performance of an organic Rankine cycle system by controlling the flow rate of working fluid R245fa (i.e., the operation flow rate of R245fa was controlled to ensure that R245fa reached saturation liquid and vapor states at the outlets of the preheater and evaporator, respectively). The results showed that the operation flow rate of R245fa increased with TW,in or mW; higher TW,in or mW yielded better heat transfer performance of the designed preheater and required higher heat capacity of the evaporator; heat transfer characteristics of preheater and evaporator differed for off-design TW,in and mW; and net power output increased with TW,in or mW. The results further indicated that the control strategy should be different for various off-design conditions. Regarding maximum net power output, the flow rate control approach is optimal when TW,in or mW exceeds the design point, but the pressure control approach is better when TW,in or mW is lower than the design point.