Organic Rankine Cycle (ORC) power generation is a process in which heat is absorbed from waste heat sources (such as hot water, steam, water vapor, etc.) through a heat exchanger, and work is produced by expansion in an expander, thereby driving a generator to produce electricity.
The 125kW, 315kW, and 500kW class ORC waste heat power generation systems developed by Xiangtan Electric Manufacturing Co., Ltd. (XEMC) with fully independent intellectual property rights have completed industrial operation tests and are operating stably for power generation. The thermal-to-electric conversion efficiency has reached the leading level among systems of the same class, filling the technological gap in China's industrial waste heat recovery and utilization field.
Technical Advantages
High-Speed Linear Bearing Technology
A novel high-speed linear bearing design technology is adopted, with combined cold-state and hot-state adjustment design. The bearings adaptively adjust during operation, improving efficiency by approximately 20%, with speeds up to 12,000 rpm. Bearing loads are borne through high-speed bearings.
High-Speed Turbine Expansion Wheel Direct-Drive Permanent Magnet Power Generation Technology
The turbine expander adopts five or more stages. The novel impeller design of the high-speed turbine expansion wheel, through continuous iteration under various operating conditions, achieves high isentropic efficiency, stable operation, and high efficiency utilization. The turbine bearings, expansion wheel, overall unit, and permanent magnet generator are integrated in a direct-drive configuration.
Low-Temperature Heat Transfer High-Efficiency Heat Exchanger Technology
Through research on media with different workpiece parameters, heat exchanger inlet temperatures, the degradation performance and pressure of the heat transfer temperature difference between the heat transfer fluid and the working fluid, and maximum heat recovery efficiency technology, the heat of the working fluid is further reduced, maximizing the system's heat exchange efficiency.
Integrated Design Technology of High-Speed Permanent Magnet Generator and Frequency Converter
The generator's internal design is optimized, adopting WH magnetic suspension bearing design and variable-speed motor design, solving the variable-frequency speed control problem from a system perspective, including the rotor and static rotating key components and assembly structure. The integrated technology of the turbine WH generator and frequency converter is adopted, applying advanced frequency converter power modules, which can greatly reduce operating noise and electromagnetic radiation, and reduce the footprint of motor accessories. The fully enclosed frequency converter adopts dust-proof and waterproof measures.
Economic Benefits
After investing in this system, the owner can utilize the waste heat resources originally discharged into the atmospheric environment, converting them into high-grade electrical energy for the owner's use, reducing electricity expenses, lowering the unit energy consumption index of products, and improving product competitiveness.
Under normal circumstances, after investing in this system, the owner can recover the cost within 3-5 years.
Reduce electricity expenses
Lower the unit energy consumption index of products
Improve product competitiveness
Application Scope
Iron and steel metallurgy
Glass and building materials
Petroleum and chemical industry
The high-speed electromagnetic bearing technology ORC system can be widely used for waste heat recovery power generation in high-energy-consumption industries such as iron and steel metallurgy, glass and building materials, and petroleum and chemical industry. Minimum applicable heat source temperature: pressurized hot water ≥120°C; water vapor ≥120°C; steam ≥220°C.
