Small (10–100 kW) and micro (0.5–10 kW) Organic Rankine Cycle (ORC) power systems are nowadays considered for local and domestic power generation. Especially interesting are micropower applications for heat recovery from dispersed low potential (85–150 °C) waste and renewable heat sources. Designing and implementing an ORC system dedicated to energy recovery from such a source is difficult. A proper working fluid must be selected together with a suitable expander. Volumetric machines can be adopted as a turbine alternative in small-capacity applications under development, like, e.g., domestic cogeneration. Scroll and screw expanders are a common choice. However, scroll and screw expanders are complicated and expensive. Vane expanders are mechanically simple, commercially available and cheap. This paper documents a study providing the preliminary analysis of the possibility of employing vane-expanders in mini-ORC systems. The main objective of this research was therefore a comprehensive analysis of the use of a vane expander for continuous operation with a low-boiling working fluid. A test-stand was designed and set up starting from system models based on thermodynamic analysis. Then, a series of experiments was performed using the test-stand. Results of these experiments are presented here, together with a model of multivane expanders and a thermodynamic-based method to select the working fluid. The analysis presented in this paper indicates that multivane expanders are a cheap and mechanically simple alternative to other expansion devices proposed for small-capacity ORC systems.

Micro (0.5–10 kW) organic Rankine cycle (ORC) power systems are nowadays considered for domestic power generation. Selection of a suitable expander is one of the most important problems connected with the domestic ORC system design. Volumetric machines or micro-turbines can be adopted as an expander in domestic ORC systems. Scroll and screw expanders are a common choice and were successfully applied in different small- and micro-power applications. However, micro-turbines as well as scroll and screw expanders are mechanically complicated and expensive. An alternative are rotary-vane machines, which are simple and cheap compared to micro-turbines. This paper documents a study providing the experimental and numerical analyses on the rotary vane expander operating conditions in a micro-ORC system. A test-stand was designed and set up and a series of experiments was performed using the test-stand. Results of these experiments were further used as an input to numerical simulations of an expander operation. In order to simulate the expander operating conditions, a three-dimensional numerical model has been prepared. The analysis presented in this paper indicates that a properly designed multi-vane expander is a cheap and mechanically simple alternative to other expansion devices proposed for domestic ORC systems.

Organic Rankine Cycle (ORC) power systems are nowadays an option for local and domestic cogeneration of heat and electric power. Very interesting are micropower systems for heat recovery from low potential (40–90 °C) waste and renewable heat sources. Designing an ORC system dedicated to heat recovery from such a source is very difficult. Most important problems are connected with the selection of a suitable expander. Volumetric machines, such as scroll and screw expanders, are adopted as turbine alternative in small-power ORC systems. However, these machines are complicated and expensive. Vane expanders on the other hand are simple and cheap. This paper presents a theoretical and experimental analysis of the operation of a micro-ORC rotary vane expander under variable heat source temperature conditions. The main objective of this research was therefore a comprehensive analysis of relation between the vane expander output power and the heat source temperature. A series of experiments was performed using the micropower ORC test-stand. Results of these experiments are presented here, together with a mathematical description of multivane expanders. The analysis presented in this paper indicates that the output power of multivane expanders depend on the heat source temperature, and that multivane expanders are cheap alternatives to other expanders proposed for micropower ORC systems.

The working fluid selection is one of the most important issues faced when designing Organic Rankine Cycle (ORC) systems. The choice of working fluid is dictated by different criteria. The most important of them are safety of use, impact on the environment, and physical and chemical parameters. The type of ORC system in which the working fluid is to be used and the type of expander applied in this system is also affecting the working fluid selection. Nowadays, volumetric expanders are increasingly used in ORC systems. In the case of volumetric expanders, in addition to the aforementioned working fluid selection criteria, additional parameters are considered during the selecting of the working fluid, such as the range of operating pressures and geometric dimensions (determining the volume of working chambers) affecting the achieved power and efficiency of the expander. This article presents a method of selecting a working medium for ORC systems using volumetric expanders. This method is based on the dimensionless rating parameters applied for the comparative analysis of different working fluids. Dimensionless parameters were defined for selected thermal properties of the working fluids, namely thermal capacity, mean temperature of evaporation, mean temperature of condensation, pressure and volumetric expansion ratio, volumetric expandability, as well as the heat of preheating, vaporization, superheating, cooling, and liquefaction. Moreover, isentropic expansion work was considered as the rating parameter. In this article, in addition to the working fluid selection method, computational examples related to the selection of the working fluid for the ORC system fed by a heat source featuring specified temperatures are presented. The results of calculations of rating parameters and their comparison gave an outlook on the selection of appropriate working fluids.