Poligeneration ORC system

The system is a model of professional poligeneration unit for the production of electric energy, heat and cold for power range 0.1 – 1MWe. It utilizes available medium-temperature heat (at about 350oC). The system contains:

  • gas boiler of power 500 kW,
  • ORC unit working with MDM of power 80 kWe with an axial multi-stage turbine and radial single-stage turbine,
  • connection to electric grid,
  • heating instalation,
  • system for production of cold of power 20 kW.


Schematic of the 80 kWe ORC system

 

Main ORC parameters:

  • turbine - from 12 bar/280oC to 0.17 bar/230oC,
  • recuperator – vapour 230oC/130oC, liquid 90oC/190oC,
  • evaporator – 280oC,
  • condenser – 90oC,
  • hot water – 80oC/60oC.

 


ORC installation
Gas boiler for heating thermal oil


Classical turbogenerator

    • hybrid bearings lubricated by oil,
    • multistage axial turbine of 9 000 rev/min,
    • partial admission,


    Hermetic turbogenerator

    • hybrid bearings lubrication by liquid fraction of MDM,
    • magnetic longitudinal bearing,
    • radial turbine for 20 000 rev/min.


    Ejector cold production unit

    Gas-vapour ORC system

    The installation is a container system for cogeneration of electric energy and heat with a high efficiency of electric energy production. The main unit is a gas combustion piston engine. Another unit is an ORC unit that utilizes the heat of exhaust gases from the engine. The system cointains:

    • piston engine of MAN of power 380 kWe,
    • heat recovery boiler of 280 kW,
    • ORC unit working with SES36 with two pneumatic engines with rotating pistons and alternatively a radial-axial single-stage turbine of power 40 kWe,
    • connection to electric grid,
    • heating installation.


    Schematic of the gas-vapour ORC system


    Piston engine  

    Parameters of 12 cylinder piston engine:

    • Electric power - max 420 kWe,
    • Heat power in exhaust gases - 280 kW,
    • Heat power from engine cooling - 230 kW,
    • Electric efficiency for natural gas - 40% el.


    Heat exchanger – recovery boiler


    ORC unit

    Parameters of the ORC unit:

    • Brut electric power: 40 kWe
    • Heat source: thermal oil Veco 5HT, heat power 280 kW, temperatures inlet/outlet: 170oC/110oC
    • Cooling: 40% glycol, cooling power 265 kW, temperatures inlet/outlet: 35oC/55oC

    Expander

    • Pneumatic engine with rotating engines in a hermetic capsule,
    • 1500 rpm,
    • Ball bearings with membrane lubricated by injection of oil.

    Radial-axial turbine with a high rotating generator of 40 kWe

    •  mass – 1,162 kg/s,
    • pressure drop from 14.64 to 2.20 bara,
    • rotational velocity – 15000 rev/min.

    Combustion piston engines facility

    The facility serves for investigation of combustion of low caloric gases from gasification of biomass in piston engines. The facility includes:

    • installation of combustion pistom engines - CEZ of power 60 kWe supplied by syngaz and PERKINS of power 30 kWe supplied by biogas,
    • station for mixing of technical gases,
    • supply system,
    • system AVL for engine indication.


    Installation for mixing technical gases


    Installation of piston combustion engines

    Biogas turbine facility

    The facility serves for investigation of combustion of low caloric gases from methane fermentain of biomass in a gas turbine. The facility contains:

    • gas turbine TURBEC 100 kW supplied by biogas,
    • biogas compressor,
    • station for mixing of technical gases,
    • supply system.


    TURBEC 100 kW

    Model gas turbine GTM 140


    Model gas turbine GTM 140

    Software

    • CAD (computer aided design) software TURBINA and SimAx based on 0/1D model for calculation and design of turbine flow systems of axial, radial, radial-axial turbines,
    • AGILE (AXIAL, RITAL) software for design of turbine flow systems of axial and radial turbines,
    • 3D RANS solvers for investigations of gas flow in turbomachinery -  Fluent, CFX (ANSYS) and FlowER (Yershov, Rusanov),
    • CSM (computational structure mechanics) software – ANSYS and solver solwer WYKA based on finite elements of shells of medium thickness,
    • Optimisation packages such as Opti_turb for interdisciplinary efficiency optimisation of turbomachinery blading systems.