This document is a thesis submitted by Sh. Anandkumar singh for their Bachelor's degree in Production and Industrial Engineering. The thesis studies the design of an Organic Rankine Cycle (ORC) power plant for renewable energy applications. ORC technology uses organic fluids instead of water to convert low-grade heat into electricity. The thesis analyzes ORC working fluids, components, advantages over traditional Rankine cycles, and applications for biomass, solar, geothermal and waste heat. It also includes calculations for an example ORC system using R-123 fluid and specifications for generator and pump components. The aim is to model and prototype a small-scale ORC plant to compete with photovoltaics.

1. (An institute of national importance)
Major project on
ORGANIC RANKINE CYCLE POWER PLANT FOR RENEWABLE ENERGY RESOURCES
IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE DEGREE OF BACHELORS OF
TECHNOLOGY IN PRODUCTION AND INDUSTRIAL ENGINEERING
Submitted by
Sh. Anandkumar singh
091116257
B.Tech
Production and industrial engineering
VII Sem to VIII Sem
Guided by
Asst Prof: Alok singh
(Mechanical Engg. Dept.)

2. Introduction
water vapor, as
a working fluid
Biomass
Solar energy
Heat sources
Organic Rankine cycle is a
thermodynamic cycle which
convert thermal energy into
mechanical
energy
ORC
technology is similar to a
traditional steam turbine, but
important difference.
vaporizes a highmolecular-mass organic
fluid butane, pentane etc.
Renewable energy
sources
excellent performance and several key advantages:
slower turbine rotation, lower pressure, and no
erosion of metallic parts and blades.
Industrial waste heat
Geothermal

3. Power Plants based on the Organic Rankine Cycle (ORC) have been increasingly employed
over the last 10 years to produce power from clean energy renewable sources. The cycle is
well adapted to low moderate temperature heat sources and is widely used for producing
small scale to moderate power production (200KW to 10MW). These plants are
environmentally friendly.

4. Power range and efficiency of
common power plant
power range [MW]
The aim of this work is the study
and the modeling of an Organic
Rankine Cycle power plant for
small scale purpose.
And study of different working
fluids selection criteria.
Finally three prospective studies are
propose
Industrial
Waste heat ORC
efficiency [%]
Link : [2]
Biomass ORC
Solar ORC

5. The Rankine Cycle
The Rankine cycle is a cycle that converts heat into work. The heat is supplied
externally to a closed loop. This cycle generates about 90% of all electric power used
throughout the world The Rankine cycle is the fundamental thermodynamic
underpinning of the steam engine and thermal power plant
Steam turbine
Boiler
Condenser
There are four processes in the Rankine cycle. These states are identified by
numbers in the above Ts diagram.
Link : [3]

6. Rankine cycle
Working fluid: usually water
Advantages:
 cheap, widely available
 non toxic
 high heat capacity: excellent medium for heat transport
 chemical stable: less material requirements
 low viscosity: low friction losses
Disadvantages:
 due to low condensation t°: very low pressure, high specific volume, big
installations needed (turbine, condenser )
 high pressure drop to become a high enthalpy drop: expensive multi stage
turbines needed
 expansion has to start in the superheated area to avoid too high moisture
content after expansion: need of a high t°- heat source but very practically use
because of this: efficiency loss and limited suitability to waste heat recovery

7. The Organic Rankine Cycle
Disadvantages of water probably to correct using other
working fluids, The ORC uses organic substances instead of
water as working fluid :
Organic Rankine Cycle working fluids are:
 Toluene
 Butane
 Pentane
 Ammonia
 Refrigeration fluids
 Silicone oils

8. Thermodynamic Process behind
the Organic Rankine Cycle
The ORC Turbogenerator uses medium-to-high-temperature thermal oil to preheat
and vaporize a suitable organic working fluid in the evaporator (7,4).
The organic fluid vapor rotates the turbine (4,5), which is directly coupled to the
electric generator, resulting in clean, reliable electric power.
The exhaust vapor flows through the regenerator (5-6), where it heats the organic
liquid (2,7)
and is then condensed in the condenser and cooled by the cooling circuit (6,1).
The organic working fluid is then pumped (1,2) into the regenerator and
evaporator, thus completing the closed-cycle operation.

9. Organic Rankine Cycle in the T-s
diagram
Link : [4]

10. Working Fluids
Rankine cycle
ORC
Water
• Silicone Oils
• Hydrocarbons
• Fluorocarbons
Lower boiling
temperature
Very large flow rate
No wear of blades
and metal parts
Small, fast-moving Molecules
Erosion of blades and metal
parts
superheated water vapor steam
required
Multistage turbine and
high mechanical stress
Organic fluids lead to
• higher turbine efficiencies due to the higher mass flow (leakage ↓)
• low maintenance operation
• good part load behavior

11. ORC Main Components
Regenerator
Condenser
Thermo oil
heat input
Evaporator
Turbine
Generator
Feed Pump
Link : [7]
ORC Unit from Turboden, Brescia Italy
Organic fluid
Cooling water

12. Applications:
Solar
Energy
Biomass
ORC unit
ORC units
Geothermal
• Concentrating solar power systems
with ORC units allow conversion of
heat harnessed by solar collectors
into electricity through an efficient
thermodynamic cycle.
• simple and efficient generation of
electric power and heat from
biomass
• electricity from geothermal
resources with medium-to-lowtemperatures, generally ranging
between (90° C - 180° C).
• by recovering heat from sources
such as industrial processes,
Waste heat

13. Advantage of ORC
Technical Advantages
 High cycle efficiency
Very high turbine efficiency
Low turbine mechanical stress
due to low peripheral speed
Low turbine rpm, allowing the
direct drive of the electric
generator without gear reduction
in many applications
No erosion of blades, thanks to
the absence of moisture in the
vapor nozzles
Operational Advantages
Simple start-stop procedures
Automatic and continuous
operation
No operator attendance
needed
Quiet operation
High availability (typically
98%)
High efficiency at partial
load
Lower maintenance cost
Long life

14. Appendix - 1
by taking R-123 as working fluid (2,2dichloro-1,1,1 trifluroethane)
Physical properties
Molecular weight
152.93
Boiling point
27.85 C
At 1 atm
Critical
temp
183.6C
Pressure
3668.0 kpa
density
550.0 kg/m3
Why? R-123
Non inflammable
Exposure time is longer
easily available at Market
We are taking max pressure at 1.2Mpa and heating the fluid upto 120C and
minimum pressure 0.101Mpa (atm) and temp 28C (normal boiling) as a operating
condition for ease of calculation. And mass flow rate at 0.2kg/s since our plant is for
small kw of output
Data Link [5]

15. Appendix - 2
Specification
AC generator
model no. F.D 3.0-300-72/144
Rated output 3kw
Max output 7.5kw
Min RPM 300
Max RPM 10000
Starting torque 1.8NM
Effi. 80 %
Wt. 85Kg
Suction pump
model No. SP2402A01-01
240watt
Inlet dia 63mm
Outlet dia 63mm
Max head 9m
Working voltage 110v-220vAC
RPM 300-3300
Wt.3.4Kg
Link : Dong Guan Youthen Metal Co., Ltd.

16. Appendix - 3
B= boiler
P= feed pump
T= turbine
C= condenser

17. From the steam table of R-123
Data Link [5]

18. Appendix - 4
Calculation
From steam table 2 at temp 120C
and 1.2Mpa
enthalpy H1= 448.6kj/kg
Entropy S=1.6896 kj/kgK
Specific volume V= 0.0136 m3/kg
Specific heat Cp= 0.9393
From steam table 1 temp 28C and
0.10192Mpa
Enthalpy of fusion Hf=226.4Kj/kg
Enthalpy of vaporization Hg= 396.8kj/kg
Latent enthalpy Hfg= 170.4kJ/kg
Enthalpy at turbine outlet H2= Hf + x(Hg-Hf)
x= 0.99 (properties of R-123)
H2 = 226.4 + 0.99(396.8 – 226.4)
H2 = 395.096kj/kg
Turbine work output Wt = m* . (H1 - H2)
m* = 0.2kg
Wt = 0.2 (448.6 – 395.096)
Wt = 10.708 kw
Again taking the efficiency of
steam expander (Turbine ) = 90%
Power of shaft = 0.9 X 10.708
= 9.637kw
Form our Ac generator efficiency = 80%
Electrical power output = 0.8 X 9.637
= 7.7096 kw

19. Plan of the project
Prototype ORC Unit
This prototype is going to
compete with photovoltaic cell.

20. References
1. Angelino, G. Invernizzi and Molteni, : The potential role of organic bottoming rankine cycle
power station 1999 . Vol 231(A): page No. 75-91
2. Liu, B.T, chien K.H and Wang, : effect of working fluid on organic rankine cycle for waste heat
recovery , 2004 vol 29 page No. 1207-1217.
3. ing. Bruno Vanslambrouck, Howest, dept Masters Industrial Sciences Laboratory of Industrial
Physics and Applied Mechanics
4. Prof. Dr.-Ing. H. Spliethoff Technische Universität München : The Organic Rankine Cycle Power
Production from Low Temperature Heat Institute for Energy Systems.
5. Experimental Study and Modeling of a Low Temperature Rankine Cycle for Small Scale
Cogeneration. By Sylvain Quoilin may- 2007
6. ORGANIC RANKINE CYCLE POWER PLANT FOR WASTE HEAT RECOVERY by Lucien Y.
Bronicki, Chairman ORMAT International Inc. 980 Greg St., Sparks, Nevada 89431-6039 –
USA Tel: +1 775 356 9029, Fax: +1 775 9039 email:ormat@ormat.com
7. Pratt & Whitney Power Systems
www.pw.utc.com
www.turboden.com http://www.youtube.com/watch?v=jU2AlRRlQDc

21. Thank You