| Organic Rankine cycle
160 kWe; 210 kWe; 450 kWe; 600 kWe; 850 kWe (gross electric power).
The refrigerant R1233zd(E) is employed as working fluid.
For these capacities, modular, compact and standardised technology enables, on the one hand, faster installation, construction and reduction in overall system costs, and on the other hand, with the selection of a specific working fluid, promises high performance in compliance with the necessary requirements of safety, non-flammability and low environmental impact.
The resulting low mass and volumetric flow rates, which are considerably lower than those found in medium and large size ORC plants, required some adjustments to the ROT turbine, the component with the highest level of what might be called technological content. The new machine was therefore scaled down to a smaller size, with higher rotational speeds, than the reference ROT turbine, in order to maintain its high performance.
The high rotational speeds required (up to about 20 000 rpm) led to the development of specific methodologies for modelling and performing calculations for ‘fast’ rotors, as well as the design and manufacturing of vibration reduction systems known as SFDs (squeeze film dampers), see Figure 2, typically used in the aviation industry on commercial and military engines, to stabilise rotors operating at high
rotational speeds. The great usefulness of SFD systems lies in their dampening effect on the machine.
Also, the pressurised oil chamber employed in the new machine and its fixed anchorage to the bearings provides a considerable further reduction in vibrations, which are exacerbated by the destabilising action of the rotor’s sealing labyrinths, designed to contain the fluid during its expansion.
Figure 3 shows rotor balancing in progress. In addition to the rotational issues, it was necessary to adopt a speed reducer for the mechanical coupling to the electric generator. While the efficiency of the turbomachine is a function of blade rotational speed, typically the generator has a rotational speed determined by the number of poles it has and the frequency of the electricity grid to which it is connected. A ‘slow’ generator is preferable to a ‘fast’ one due to efficiency losses in the machine itself and in the frequency converter (inverter) needed at high frequencies. With the aim of limiting transmission losses between the turbine and generator, a straight-tooth, seven-satellite, low service factor planetary type gearbox was selected, manufactured, and fully integrated into the new machine.
Right: Figure 3. Rotor balancing in progress
Family of Smart ORC modules Following the promising results obtained on the test bench, through the R&D project described above, Exergy has acquired the necessary know-how to propose a family of Smart ORC modules plus associated development of small and standardised turbomachinery. This broadens application of Exergy’s radial outflow turbine to very small (micro and mini) ORC systems for electricity production from such sources as diesel engine exhaust systems and waste heat available in several industrial processes.
Application of the R&D to date is expected to increase the efficiency of mini and micro ORC systems by about 5 to15%.
Eliminate premature failures in 7F and 9F turbine EGTs
Conax Technologies’ patented Spring Loaded Exhaust Gas Sensors
Our patented sensors are built to withstand vibrations caused by gas flows, input vibrations, and thermal expansion mismatch in 7F and 9F class turbines.
A high temperature compression spring inserted between two spacer tubes dampens vibrations and keeps the sensor tip seated within the radiation shield to avoid premature failure, enabling the turbines to run longer.
Learn more and view our video at
ConaxTechnologies.com/Springloaded
Conax Spring Loaded Exhaust Gas Sensor benefits • Interchangeable with OEM parts • Tested to OEM specifications • Significantly increases sensor life
• Proven to provide thousands of hours of field operation without failures
• Patented solution available only from Conax
AS9100 with ISO 9001 Certified
+1 800 223 2389 |
ConaxTechnologies.com
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