Improving the performance of μ-ORC systems

This thesis contributes to the knowledge and the characterization of micro Organic Rankine Cycles (ORC). It is based on experimental data and simulation models.

An oil-free scroll expander is tested in a wide range of operating conditions in order to better characterize its performance. Particular attention is paid to the tightness of the machine which is obtained using a magnetic coupling. The measured isentropic efficiency reaches 75% which is higher than typical values reported in the literature. From the experimental results, a performance map of the expander is generated. This performance map can be used to provide fast and accurate calculation of the volumetric and isentropic performance of the expander in a wide range of operating conditions.

Five displacement pumps adapted to μ-ORC systems are also tested. These pumps are diaphragm, piston, plunger and gear types. The measured values include the overall efficiency, the volumetric efficiency and the NPSH. A deep analysis of the performance is performed to quantify the losses of each pump, of their electric motor and of their frequency drive. This analysis shows that the weakness of the overall effectiveness (max. 46%) of the pumps tested is mainly due to the low efficiency of the electric motor. A semi-empirical model of the diaphragm pump is proposed and validated based on manufacturer data. This model can predict the mechanical power of the pump and the flow delivered with a good accuracy.

The simulation models developed for the expander and the pump are used to simulate a configuration including the pump, the generator and the expander on a single shaft. This configuration aims to avoid the use of a motor and a frequency drive whose performance is poor in the range of power consumed by the pump of a μ-ORC system. The results show a significant increase in the net power produced using the integrated configuration

Finally, performance of a prototype of μ-ORC suitable for recovering heat from a two-stage screw compressor are measured and analyzed. The prototype allows generating maximum 3.9% of the electrical power consumed by the compressor. Several optimization options of the prototype are evaluated numerically, showing that the power generation could be increased up to 5.4% of the compressor consumption. These options include using the integrated configuration and optimizing the intercooler boiler design.