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cycle engines
E. Casati
a,b
, A. Galli
b
, P. Colonna
a,
a
Process and Energy Department, Delft University of Technology, Leghwaterstraat 44, 2628 CA Delft, The Netherlands
b
Dipartimento di Energia, Politecnico di Milano, via Lambruschini 4, 20156 Milano, Italy
Received 13 May 2013; received in revised form 15 July 2013; accepted 16 July 2013
Available online 15 August 2013
Communicated by: Associate Editor Robert Pitz-Paal
Abstract
The feasibility of energy storage is of paramount importance for solar power systems, to the point that it can be the technology enabler.
Regarding concentrated solar power (CSP) systems, the implementation of thermal energy storage (TES) is arguably a key advantage over
systems based on photovoltaic (PV) technologies. The interest for highly ecient and modular CSP plants of small to medium capacity
(5 kW
E
5 MW
E
) is growing: organic Rankine cycle (ORC) power systems stand out in terms of eciency, reliability and cost-eectiveness
in such power-range. In this paper a thorough investigation on thermal storage systems tailored to high-temperature (~300 C) ORCpower
plants is addressed rst, stemming fromthe observation that the direct storage of the ORCworking uid is eective thanks to its favourable
thermodynamic properties. The concept of complete ashing cycle (CFC) is then introduced as a mean of achieving an unmatched system
layout simplication, while preserving conversion eciency. This is a newvariant of the Rankine cycle, whereby the vapour is produced by
throttling the organic working uid from liquid to saturated vapour conditions. The presentation and discussion of a case study follows: a
100 kW
E
CFCsystemwith direct thermal energy storage, coupled with state-of-the-art parabolic trough collectors. The proposed turbogen-
erator achieves an estimated 25%eciency, which corresponds to a value of 18%in design conditions for the complete system. Considering
siloxanes as working uids, the estimated values of storage density are around 10 kW
e
h=m
3
storage
.
2013 Elsevier Ltd. All rights reserved.
Keywords: Thermal energy storage; Organic Rankine cycle (ORC); Complete ashing cycle (CFC)
1. Introduction
It is generally agreed that the clean energy revolution is
required in order to nally decouple economic growth from
the adverse environmental impact of the fossil-fuel econ-
omy (Galiana and Green, 2009), and its geo-political impli-
cations. Variable-output renewable energy technologies
such as wind and solar PV power systems are negatively
aected by dispatchability issues. The growing share of
electricity generated with these technologies demands for
storage capability in order to ensure continued and reliable
supply of electricity (Inage, 2009). The feasibility of energy
storage integrated into a conversion system for renewable
energy sources is a key enabler of such technology. The
demand for a viable energy storage technology is particu-
larly relevant for solar conversion systems, which, accord-
ing to recent analysis, could provide up to one-third of the
world nal energy supply after 2060 (IEA, 2011).
The debate over the advantages and disadvantages of var-
ious solar technologies is lively (Fthenakis et al., 2009; Price-
WaterHouseCoopers, 2010). Peters et al. (2011) compared
PV- and CSP-based systems for large-scale solar power
plants (> 50 MW
E
), and concluded that the cost and e-
ciency of storing energy can turn the competitiveness in
favour of CSP systems. Another potentially important
0038-092X/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.solener.2013.07.013
reg
0.85 g
is,turbine
0.85
g
is,pumpsfans
0.75 g
ME
0.97
Dp
ef
50 (%p
cond
) Dp
fa
10 (%p
cond
)
Dp
a
/
b
0 (bar) Dp
Fan
50 (Pa)
Design data for the exemplary system
Fluid D
4
p
cond
0.035 (bar)
T
c,R
= T
st,R
0.998 T
c
= T
st
312.6 (C)
p
c
= p
st
14.2 (bar)
Calculated design performance of the exemplary system
_ m
fluid
1.81 (kg/s) _ m
air
8.61 (kg/s)
g
ORC
0.251 g
glob,SF
0.71
g
glob,sys
0.18 A
mirrors
704 (m
2
)
VR
turb
246 EEED 6.2 (kW h
E
=m
3
storage
)
V
st
65 (m
3
) m
uid,st
3E
4
(kg)
212 E. Casati et al. / Solar Energy 96 (2013) 205219
and minimum temperature (state points a, b, c, g, h, f, and
1, 2, 5, 6 for water) (Dipippo, 2008). However, if the work-
ing uids is an organic compound, it can be shown that the
eciency penalty aecting the ashing cycle may be com-
paratively low. A detailed treatment is reported in Appen-
dix A. Flashing ORC power systems for waste-heat
recovery applications have been recently investigated by
Ho et al. (2012).
The ashing cycle boasts notable benets in case of a
solar ORC power system with thermal storage: (i) it avoids
phase transition in the SF, with major advantages (Odeh
et al., 2000; Eck et al., 2004; Casati et al., 2011); (ii) it
decouples the SF and the ORC power block by means of
a suitable direct thermal storage system, see Fig. 4(a). A
minor eciency reduction can thus be accepted, in view
of the substantial simplication it allows for, both in terms
of plant layout and operation.
5.3. Flashing the organic vapour down to saturated
conditions
A further simplication of the plant conguration
derives from the possibility of reaching complete vapouri-
zation of the working uid by ashing (see Section 2, point
Ia). In this way several components become redundant,
namely the ashing vessel and the liquid drain circuit.
More details are provided in Appendix B. To the authors
knowledge, ORC power systems working according to the
ashing cycle principle, whereby the working uid is throt-
tled down to saturated vapour conditions before entering
the turbine, refer to Fig. 4(b), have not been considered
before, thus this concept is named here complete ashing
cycle (CFC).
5.4. Results
The steady state modelling of the system is performed
with an in-house code implemented in a well known com-
puter language for technical computing (MathWorks,
2011), coupled with an in-house library for the accurate
estimation of the thermophysical properties of the uids
(Colonna et al., 2012). The calculated performance is
reported in Table 2, while Table 3 shows the thermody-
namic properties of the state points of the thermodynamic
cycle. Notwithstanding the selected high design value for
T
cond
, the calculated eciency of the ORC power system
exceeds 25% which, combined with the eciency of the
SF, yields a global eciency in design conditions close to
18%. This value can be compared to the measured values
of recently-built state-of-the-art CSP plants. These steam
power plants are much larger, and adopt an indirect stor-
age system with synthetic oil as HTF, and their eciency
is of the order of 22% (Giostri et al., 2012).
Even if no index of annual performance has been esti-
mated yet, ORC power systems are characterized by excel-
lent o-design performance. This characteristic can
partially overcome the lower design eciency in a highly
dynamic application such as CSP (Casati et al., 2011).
The calculated values of equivalent electrical energy
density (EEED) storage are lower than those characterizing
traditional TES solutions, and this holds for all the consid-
ered working uids (see Fig. A.7). The proposed system
approaches, for the EEED, the limiting value of 6.2
[kW h
E
=m
3
ST
[, see Table 2, assuming that the storage vessel
delivers its full energy content without any variation in the
discharged uid properties (conditions corresponding to
state c). Thermal losses, as well as exergy losses due to dete-
rioration of the stratication (Haller et al., 2010) are thus
neglected: such simplications are typically justied for
daily charge-discharge cycles (relatively short standstill
times). A recently designed displacement storage system
using synthetic oil as HTF, and proposed as an add-on
to the APS Saguaro ORC-based CSP plant (Canada
et al., 2006), reaches the value of approximately 15
[kW h
E
=m
3
ST
[ (Kolb and Hassani, 2006). The lower value
calculated for the proposed system is mainly due to the
low specic work extracted from the turbine, which causes
the uid to be injected back in the storage vessel at high
temperature (T
b
= T
out,ORC
).
6. Conclusions
This paper documents a study about extending direct
ow-storage methods applicable to steam power plants to
ORC power systems. So-called direct thermal storage sys-
tems are feasible, whereby the same uid is circulated in
the heat source, serves as thermal storage medium, and is
also the working uid of the ORC turbogenerator. A case
Table 3
Thermodynamic properties of the state points of the ORC system. State labels refers to the layout of Fig. 4(a) and to the T s diagram of Fig. 1(a). States
1 and 2 refer to the cooling air stream.
state T (C) p (bar) v (m
3
/kg) h (kJ/kg) s (kJ/kg/K) q (kg
sv
/kg
tot
)
a 80.0 0.04 0.001 172.6 0.43 0
b 205.6 14.20 0.001 59.1 0.12
c 312.7 14.20 0.002 291.8 0.56
d 283.2 8.49 0.011 291.8 0.57 1
e 234.9 0.06 2.489 233.6 0.59
f 87.6 0.04 2.551 4.5 0.07
1 30.0 1.01 0.880 0.0
2 67.0 1.01 1.052 37.2
E. Casati et al. / Solar Energy 96 (2013) 205219 213
study regarding a 100 kW
E
solar plant implementing such
concept is presented: the proposed system features a con-
stant-pressure thermocline storage system, with vapour
generation through external ashing of the liquid extracted
from the storage vessel.
The thermal storage system can be integrated into the
plant, thus decoupling the thermal energy source from
the ORC power block: the system can be classied as con-
stant-parameters storage, whereby the uid enters and
leaves the vessel (in principle) in the same thermodynamic
condition, see states c and b in Fig. 4(a). Apart from a sub-
stantial simplications in terms of both plant layout and
operational strategy, this conguration ensures high exer-
getic performance of the thermal charge and discharge pro-
cesses (Beckam and Gilli, 1984).
The power cycle operates according to a variant of the
Rankine cycle, whereby a ashing evaporation process pre-
cedes the power-generating expansion of the working uid.
The properties of the adopted complex-molecule working
uids are such that ashing can lead to saturated or super-
heated vapour conditions. This characteristic implies fur-
ther simplications of the system if compared to
conventional steam power plant systems with thermal stor-
age. The eciency penalty of an ORC power plant working
according to the newly introduced complete ashing cycle
(CFC) may be small, under the described assumptions, if
compared to the eciency of a conventional evaporative
ORC power system.
A design value of the solar-to-electric eciency of 18%
is calculated for the exemplary 100 kW
E
solar ORC power
system with direct thermal storage and the ashing cycle
conguration, while no index of annual performance has
been evaluated yet. The advantages in terms of simplica-
tion of the plant layout could overcome the relatively low
values of storage densities, the need of pressurization,
and the specic cost of the uids. A detailed techno-eco-
nomic analysis of the proposed system aimed at clarifying
these open questions will be developed as the next step of
the project. In order to improve system performance, par-
ticularly in terms of storage density, it might be worth
investigating the binary cycle conguration, whereby direct
thermal storage is implemented in the topping cycle.
Acknowledgements
This research is supported by the Dutch Technology
Foundation STW, Applied Science Division of NWO and
the Technology Program of the Ministry of Economic Af-
fairs, grant # 11143. The authors thankfully acknowledge
the fruitful discussions with their friends and colleagues
Ryan Nannan, Francesco Casella, and Adriano Desideri.
Appendix A. Thermodynamic comparison between ashing
and evaporative organic Rankine cycles
This section presents the thermodynamic evaluation of
the steady-state evaporative (EC) and ashing (FC) cycle
congurations, as introduced in Section 5. The eect of dif-
ferent working uids is also addressed. The general design
data, common to all the modeled ORC systems, are those
reported in Table 2, and Fig. A.5 shows the conceptual
plant layouts of the considered systems. The working prin-
ciple is the same described in Section 5, whereby the ORC
power block shown in Fig. 4(a) has been lumped here into
a single component, and no storage system is considered.
The thermodynamic evaluation is carried on by varying
the maximum temperature of the cycle, which is kept the
same, i.e., T
max
= T
c
= T
g
. It is further assumed that:
1. In the EC the working uid exits from the thermal
energy source (the solar eld) as saturated vapour at
T
max
, i.e., state point g in Fig. A.5(a);
2. In the FC the working uid exits from the thermal
source (c) in the state of saturated liquid at T
max
, and
then undergoes the ashing process. It is assumed here
that the ash evaporation leads to saturated vapour con-
ditions at the outlet of the ashing subsystem (process
c d, where q
d
= 1): a critical assessment of this
assumption is presented in Appendix B. As a conse-
quence, no liquid drains from the ash vessel have to
be recirculated ( _ m
liq
= 0).
P
SF
b
g
b
m
Solar eld (SF)
ORC plant
(a) EC
P
SF
b
c
b
d
vs
d
ls
d
ls
d
m
liq
m
vap
Solar eld (SF) Flash system
ORC plant
P
ash
(b) FC
Fig. A.5. (a) simplied plant layouts of ORC power systems working according to the conventional evaporative cycle, and (b) single-stage ash cycle.
State points correspond to those in the T s chart of Fig. 1(a).
214 E. Casati et al. / Solar Energy 96 (2013) 205219
From these assumptions follows that, for each value of
T
max
, all the state points dening the two thermodynamic
cycles can be determined for a given working uid. Note
that the condensation temperature T
cond
is xed and spec-
ied. The results of the steady state simulations, performed
with an in-house code implemented in a well-known lan-
guage for technical computing (MathWorks, 2011), are
presented in Figs. A.6 and A.7.
The main term of comparison is the global system e-
ciency g
glob,SYS
, dened as
g
glob;SYS
= g
ORC
g
glob;SF
; (A:1)
where
g
ORC
=
_
W
net
=
_
Q
in;ORC
(A:2)
is the thermal eciency of the ORC system.
_
W
net
=
_
W
turbine
_
W
aux
is the electrical power output of
the plant, decreased of the power consumption for auxilia-
ries;
_
W
net
is constrained to be the same for all the simulated
cases.
_
W
aux
is obtained by summing the power consump-
tion of all the pumps (subscripts P in Eq. (A.3)) and the
fans in the system and it is therefore evaluated as
_
W
aux
=
_
W
P
ORC
_
W
P
SF
_
W
P
flash
_
W
Fan
: (A:3)
_
W
P
flash
in Eq. (A.3) is zero for both the EC and the FC sys-
tems (in this last case by virtue of Assumption 2), since no
liquid drains from the ash are present.
_
Q
in;ORC
is the ther-
mal power supplied to the ORC system and, for the FC, it
reads
_
Q
in;ORCFC
= _ m
vap
(h
c
h
/
b
) _ m
liq
(h
c
h
d
/
ls
): (A:4)
Here the 2
nd
term in the right-hand side vanishes because of
Assumption 2. In the EC case, Eq. (A.4) becomes
_
Q
in;ORCEC
= _ m (h
g
h
b
/ ): (A:5)
The global eciency of the solar eld is
g
glob;SF
=
_
Q
in;ORC
=
_
Q
av
; (A:6)
and it accounts for the optical and thermal eciency. The
thermal power made available by the direct radiation of the
sun at the given design point is given by
_
Q
av
= DNI
des
A
SF
: (A:7)
The area of the solar eld A
SF
can be evaluated as
A
SF
=
_
W
net
=[g
ORC
( _ q
abs
_ q
hl
_ q
piping
)[ (A:8)
All the terms of the denominator in Eq. (A.8) represent
thermal power specic to the m
2
of SF aperture area.
_ q
abs
= DNI
des
g
opt
is the thermal power absorbed by the
collectors. Having assumed a null incidence angle for de-
T
c,R
[-]
0.7 0.75 0.8 0.85 0.9 0.95 1
0.05
0.1
0.15
0.2
D
6
-EC
D
6
-FC
D
4
-EC
D
4
-FC
MDM-EC
MDM-FC
g
l
o
b
,
S
Y
S
[
-
]
q
ls
3600
kW h
E
=m
3
storage
h i
(A:9)
In this case, _ m
liq
becomes zero because of Assumption 2.
This simplied approach assumes that the storage, initially
fully charged with uid in conditions corresponding to
state c, delivers its full energy content without any varia-
tion in uid properties. Thermal losses, as well as exergy
losses due to deterioration of the stratication (Haller
et al., 2010) are thus neglected. Such simplications are
typically justied for daily charge-discharge cycles, that is
for relatively short standstill times. The EEED reaches a
maximum value for all the working uids considered here.
This maximum value does not correspond to the maximum
storage temperature; furthermore, the EEED line is quite
at in the region where the maximum is reached. The dif-
ferences among uids are comparatively large, as well as
the conditions of the stored uid in terms of pressure and
temperature.
In order to summarize these results, Table A.4 reports
the main values obtained with the simulations that are
needed to select the working uid, if D
6
and D
4
are consid-
ered. Only these uids are evaluated here since they allow
for higher g
glob,SYS
values. The comparison is then carried
on, aiming at the same value of g
glob,SYS
, which is taken
equal to the maximum value reached in case D
4
is the
working uid. Storing D
6
at higher temperature is not con-
sidered here given the corresponding extremely high values
of VR
turb
, though it allows for the higher values of g
glob,SYS
(up to 0.185).
As expected, the two working uids allow attaining the
same eciency at almost the same value of T
c
, which how-
ever corresponds to a storage pressure p
c
2.2 times larger in
case D
4
is the working uid. On the other hand, the con-
densing pressure in case D
6
is the working uid is 16 times
1
The coecients adopted in the correlation proposed in the reference
have been slightly modied, as a consequence of the dierent uids and
ow regimes, as discussed in Casati et al. (2011).
Table A.4
Main information needed to compare solar ORC power systems with thermal storage operating according to the ashing cycle, in case siloxane D
6
and D
4
are considered as the working uids.
Fluid g
glob,SYS
T
c,R
T
c
p
c
p
cond
VR
turb
EEED m
uid
(kg/kW h
E
)
D
6
0.178 0.895 333.6 6.3 0.002 954 8.2 66
D
4
0.178 0.998 312.7 14.2 0.035 246 6.2 74
216 E. Casati et al. / Solar Energy 96 (2013) 205219
lower. Its very low value constitutes a design criticality for
the condenser and the turbine. The volumetric expansion
ratio of the turbine, for instance, is almost 4 times larger
in case D
6
is the working uid, whereby the inlet volumet-
ric ows are similar.
The value of EEED is nonetheless 25% lower if D
4
is the
working uid, and the corresponding specic mass of uid
is 12% larger: these eects, combined with the higher pres-
sure needed, would make D
6
the preferred working uid if
only the benets for the thermal storage are considered.
Appendix B. Complete ash evaporation as a working
condition for ORC power systems
The analysis of the performance of a ashing ORC, see
Fig. A.5(b), as a function of the ashing conditions is pre-
sented in this section. Only the results for working uid D
4
are reported, since they are representative of all the other
investigated systems featuring siloxanes as working uid.
The system performance is evaluated according to the pro-
cedure and the parameters dened in Appendix A; in this
case, however, no simplifying assumption based on the
absence of liquid drains can be applied (see Eqs. (A.3)
and (A.4)): the liquid drains from the ashing vessel have
to be compressed and circulated back to the heat source,
see Fig. A.5(b). This stream is supposed to merge with
the main one in the solar eld, such that temperature equal-
ity between the ows is ensured, while the vapour is deliv-
ered to the ORC turbogenerator.
Fig. B.8(a) and (b) show the trends of the quantities of
interest as a function of the ashing temperature T
ash
=
T
d
, and the corresponding vapour pressure p
ash
= p
d
.
Each curve corresponds to a given maximum temperature
which, as discussed in Appendix A, can also be seen as
the storage temperature T
max
= T
c
= T
st
; the storage pres-
sure is assigned a value of 1 bar higher than the corre-
sponding vapour pressure (p
max
= p
c
= p
st
). For each
value of T
max
, the value of T
d
whereby complete ashing
evaporation is reached (T
d
for which q
d
= 1) is also plotted
(ash evaporation is considered as an isenthalpic process).
Fig. B.8(a) shows how, for each maximum temperature
T
max
, the system eciency g
glob,SYS
initially grows for
decreasing T
d
until it reaches a relative maximum
(g
glob,SYSMAX
): this is a consequence of the total mass ow
which need to be circulated, see Fig. B.8(b), and the corre-
sponding power consumption of the auxiliary components.
As it is characteristic of CSP power systems, the thermal
eciency of the solar eld g
glob,SF
is a decreasing function
of the temperature of the uid owing in the collector.
Since g
glob,SYS
includes this eect, lower storage tempera-
ture (and pressure) levels lead to comparatively higher val-
ues of g
glob,SF
; such an eect, however, does not
counterbalance the concurrent decrease of g
ORC
.
For increasingly higher T
max
, the corresponding g
glob,SYS
line tends to atten in the region where g
glob,SYSMAX
occurs. This implies that, for higher values of T
max
, extend-
ing the throttling down to saturated vapour conditions leads
to a comparatively low eciency decrease with respect to
g
glob,SYSMAX
. Fig. B.8(a) shows the variation of the SFarea
A
SF
, which, having imposed the system net power output, is
directly related with g
glob,SYS
.
If EEED (Eq. (A.9)) is considered, Fig. B.8(b) shows
how strongly this quantity is dependent upon T
d
. The g-
ure displays that a relative maximum of the EEED corre-
sponds to the situation whereby the working uid is
ashed down to saturated vapour conditions. The locus
T
flash
=T
d
[
o
C] T
flash
=T
d
[
o
C]
p
flash
= p
d
[bar]
A
S
F
[
m
2
]
100 150 200 250 300
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
500
600
700
800
900
1.00 1.83 3.09 4.92 7.47 0.50 0.09 0.22
N
line
T
max,R
T
max
p
max
T
d
@q
d
=1
1 0.808 253.1 6.19 192.1
2 0.888 278.2 8.86 228.0
3 0.949 297.3 11.50 257.5
4 0.998 312.7 14.20 288.2
1 4 3 2
10.9
g
l
o
b
,
S
Y
S
[
-
]
m
(b) Solid black lines : equivalent electrical energy density.
Dashed black lines : total mass ow entering the ashing
subsytem (i.e., extracted from the storage vessel)
Fig. B.8. Detailed analysis of the performance of a ashing-cycle ORC system, in case D
4
is the working uid. For dierent maximum temperature levels
(T
max
= T
c
= T
st
), the quantities of interest are plotted as a function of the ashing temperature (T
ash
= T
d
); The corresponding vapour pressure is also
indicated. For each value of T
max
, the value of T
d
whereby complete ashing evaporation is reached (T
d
for which q
d
= 1) is plotted as a solid grey line.
E. Casati et al. / Solar Energy 96 (2013) 205219 217
of such maxima, for varying T
max
, corresponds to the line
for D
4
of Fig. A.7. Since this operating condition allows for
important advantages (such as maximum storage density
for the given T
max
, and simplication of the ashing system
layout), without implying noteworthy eciency penalties,
it can be considered as a reasonable working condition
for a system implementing the FC conguration, especially
when storage temperatures close to the critical temperature
of the working uid are considered.
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