Power generation with ORC machines using low-grade waste heat or renewable energy

By 2030, global energy consumption is projected to grow by 71%. At the same time, energy-related carbon dioxide emissions are expected to rise by more than 40%. In this context, waste and renewable energy sources may represent alternatives to help reduce fossil primary energy consumption. This paper focuses on the technical feasibility, efficiency and reliability of a heat-to-electricity conversion, laboratory beta-prototype, 50 kW Organic Rankine Cycle (ORC) machine using industrial waste or renewable energy sources at temperatures varying between 85 °C and 116 °C. The thermodynamic cycle along with the selected working fluid, components and control strategy, as well as the main experimental results, are presented. The study shows that the power generated and the overall net conversion efficiency rate of the machine mainly depends on such parameters as the inlet temperatures of the waste (or renewable) heat and cooling fluid, as well as on the control strategy and amount of parasitic electrical power required. It also indicates that after more than 3000 h of continuous operation, the ORC-50 beta-prototype machine has shown itself to be reliable and robust, and ready for industrial market deployment.