ORC and Kalina Analysis and experience

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1

ORC and Kalina

Analysis and experience

Páll Valdimarsson

professor of mechanical

engineering

Sabbatical December 2003

Lecture III

2

Energy and energy use

• Energy is utilized in two forms, as heat

and as work

• Work moves, but heat changes

temperature (moves the molecules
faster)

• These are two totally different products

for a power station

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3

Convertability

• Work can always be changed into heat

(by friction since ste stone age)

• Conversion of heat into work is difficult

and is limited by the laws of
thermodynamics. A part of the heat
used has always to be rejected to the
surroundings

4

Heat and work again

• Work is the high quality, high priced

product

• Heat is second class quality, a low

priced byproduct

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5

A power plant

Source

Heat

Fuel

Rejected heat

Losses

Electricity

Sellable heat

Power

plant

6

Single flash - condensing

Production well

Injection well

Separator

Turbine

Cooling tower

Pump

Condenser

Pump

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4

7

T-s diagram

8

ORC with regenerator

Production well

Injection well

Turbine

Condenser

Pump

Regenerator

Boiler

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9

T-s diagram

-2,0

-1,5

-1,0

-0,5

0,0

0,5

1,0

-50

0

50

100

150

200

250

s [kJ/kg-K]

T

[

°C

]

2300 kPa

1000 kPa

350 kPa

90 kPa

0,2 0,4 0,6 0,8

0

,0

04

5

0

,0

26

0

,0

6

3

0

,1

5

0

,3

7

0

,8

9

m

3/

kg

Isopentane

10

ORC with paralell single flash

Production well

Injection well

Separator

Turbine

Cooling tower

Condenser

Pump

Condenser

Cooling tower

Turbine

Boiler

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11

ORC with serial single flash

Production well

Injection well

Separator

Turbine

Condenser

Cooling tower

Turbine

Boiler

Throttling valve

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15

Rogner, Bad Blumau

• The 250 kW air-cooled geothermal CHP plant

generates electrical power as well as district
heating using a low temperature geothermal
resource.

• One standard containerized ORMAT CHP

module, generating 250 kW electricity and
2,500 kW heat.

• The power plant is in commercial operation

since July 2001.

16

Mokai, New Zealand

• The 60 MW Geothermal Power Plant is

comprised of:

» one 50 MW module operating on geothermal

steam

» two 5 MW units operating on geothermal brine

• The power plant uses air-cooled condensers

and achieves 100% geothermal fluid
reinjection to produce electrical power with
virtually no environmental impact.

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18

Kalina

Production well

Injection well

Separator

Turbine

Condenser

Boiler

Throttling valve

Cooling tower

Regenerator

Pump

Brine hx

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19

Geothermal experience

• Rough surroundings

• Aggressive chemistry

• Simple and reliable solutions

• Geothermal energy - a mayor economic

factor

20

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21

Conversion of heat to electricity

• The Carnot efficiency applies for infinite

heat sources

• The maximum efficiency is lower than

the Carnot efficiency for a source
stream with finite heat capacity

• Kalina reduces entropy generation in

the heat exchange process

22

Carnot efficiency

Hot reservoir

Cold reservoir

Work output

Heat in

Heat out

1

0

1

T

T

Carnot

=

η

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23

Maximum efficiency
for a liquid source

=

2

1

2

1

0

)

(

ln

1

*

T

T

T

T

T

H

E

h

x

1

T

2

T

0

T

0

T

24

What is a Kalina process?

• A modified Rankine cycle, or rather:

a reversed absorption cycle

• Ammonia - water working fluid

• Patented by Exergy Inc and A. Kalina

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25

The characteristics

• Heat is added in a combined boiling and

separation process

» at a variable temperature

• Heat is rejected in a combined

condensation and absorption process

» as well at a variable temperature

26

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

60

80

100

120

140

160

180

200

220

240

T

e

m

p

e

ra

tu

re

[

°C

]

Ammonia mass fraction [-]

Mixture boiling at 30 bar

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27

Heat addition - boiler

Source

Kalina

ORC

28

The working fluid

• Ammonia has a molar mass of 17, so

steam turbines can be used

• The mixture properties are more

complex, usually three independent
properties are needed for the
calculation of the fourth

• Therefore the cycle is more flexible, and

can be closely optimized to the source

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29

The benefit

• The working fluid is almost at the

temperature of the source fluid when
leaving the boiler

• The variable heat rejection temperature

makes regeneration possible

30

Kalina vs. ORC

• Kalina is better when the heat source

stream has a finite heat capacity

• ORC and Kalina are similar when the

source is condensing steam

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31

Boiling curves for Húsavík

0

200

400

600

800

1000

1200

20

30

40

50

60

70

80

90

100

110

120

T

e

m

p

e

ra

tu

re

[

°C

]

Enthalpy [kJ/kg]

Water
Kalina
ORC

32

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34

Kalina again

Production well

Injection well

Separator

Turbine

Condenser

Boiler

Throttling valve

Cooling tower

Regenerator

Pump

Brine hx

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35

36

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37

38

0

200

400

600

800

1000

1200

1400

1600

0

50

100

150

200

Enthalpy [kJ/kg]

T

e

m

p

e

ra

tu

re

[

°C

]

T - h diagram

6.5

6.5

6.5

6.

5

31

31

31

31

6.5

6.5

6.5

6.5

31

31

31

31

6.5

6.5

6.5

6.

5

31

31

31

31

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39

Comparison

Power

[kW]

1. law

2. law

Max

liquid

eff.

Volum e

to

turbine

[m

3

/s]

Kalina

2000

0,13

0,45

0,56

0,57

ORC

1589

0,10

0,36

0,45

2,06

Flash cycle

1589

0,10

0,36

0,45

22,4

Themoelectricity

720

0,05

0,16

0,20

0

40

Comparison of Kalina and ORC

• Heat (10MW) is available down to 80°C

• Cooling water (120kg/s) is available at

20°C

• Heat exchangers have a pinch of 3°C

• Condensers have a pinch of 10°C

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90

95

100

105

110

115

120

125

130

135

140

0

0.05

0.1

0.15

0.2

0.25

Temperature [C]

E

ff

ic

ie

n

c

y

[

-]

Carnot
Liquid
Kalina
ORC

42

Húsavík geothermal
power plant

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43

General design parameters

44

Summary

• Commissioned in the summer 2000

• Running at ~1500 kW net 2000 - 2001

• Running at ~1700 kW net since

November 2001

• Final acceptance certificate issued

• Total investment cost 3,7 MEUR

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45

Process
diagram

G

121 °C

80 °C

90 kg/s

1950 kW

5 °C

24 °C

118 °C
31 bar

a

5,5 bar

a

12 °C

67 °C

16,3 kg/s

173 kg/s

0,81 NH

3

130 kW

11,2 kg/s

46

The power plant

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47

Design

• Standard industrial components

• Turbine-generator from KKK, Germany

• Electrical components CE marked

• Heat exchangers from USA

• Most of the tanks made in Iceland

• Installed by a local contractor

48

Equipment

• Evaporator, shell and tube, 1600 m

2

• Separator
• Turbine
• Recuperators
• Condenser, plate, 2 x 750 m

2

• Hotwell
• Circulation pump

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49

Auxillary equipment

• Ammonia storage tank

• Demineralized water tank

• Blow down tank

50

Thermal equilibrium

Power output

Power input

14.000 kW

Cooling water

1.700 kW

Electricity, net

15.700 kW

Brine

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51

Start-up problems

• Separator

• Evaporator

• Axial sealing of the turbine, ammonia leakage

• Condensers

• Miscellaneous

» Main pump

» Safety valves

» Magnetite

52

Separator

• Difficult to measure the performance of

the separator

• Mist eliminator module wrongly installed

• New separator installed November 2001

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53

Evaporator

• Ammonia leaking into the hot water

• All tubes rolled again in November

2001, no leakages since

54

Axial sealing

• One axial sealing on the low pressure

side

• N

2

used in the sealing

• The sealing has been replaced once

• Leakage caused by carry-over from

separator

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55

Condensers

• Plate heat exchangers

• Important to mix liquid and vapor

• Spraying nozzles modified

• Increase power output by improving

performance of the condensers

56

Miscellaneous

• Safety valves, leakage

• Circulation pump, seals and

guides/bushings for shaft

• Improvment of spraying system in

recuperator 2

• Magnetite (Fe

3

O

4

)

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57

Turbine corrosion

• Ferritic material in the turbine corrodes

• Austenitec material is unharmed

• Corrosion is from the turbine control

valve until abt 1 metre after the turbine

• Influence of rotor magnetic field?

» Elimination of ferritic material in the steam

side of the turbine

58

Operating experience

• Maximizing the output by optimizing the

strength of the NH

3

– H

2

O solution

• Prevent air entering the system

• Improvement of flushing and filters

• The system is stable in operation

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59

Lessons learned

• The technology is proven

• Standard equipment has been adjusted

• The plant is running according to specs

• Individual equipment still may be

improved to increase output

• Engineering details will improve future

plants

60

What do we have?

• New thermodynamic cycle with better

efficiency in particular when the heat source
cooled down while heat is extracted

• Theoretical and technical descriptions of the

processes involved.

• Mathematical models that have been tested

up against Husavik Plant

• Known media and known machinery

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61

The knowledge

• Real experience and know how from the

Husavik plant

• Mathematical models and ,,steam

tables”, worked out in cooperation with
University of Iceland.

• Over 30 years of experience in electrical

generation from low and mid heat
sources (Geothermal)

62

Kalina references

• Canoga Park, USA, demonstration plant

3 – 6 MW, 1991-1997

• Fukuoka, Japan, incineration plant, 4,5

MW, 1999

• Sumitomo, Japan, waste heat recovery

from a steel plant, 3,1 MW

• Husavik, Iceland, geothermal plant, 2,0

MW, 2000

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Krafla 1970, 60 MWel

Svartsengi 1980, 37 MWel, 60 MWdh

Nesjavellir 1990, 90 MWel, 250 MWdh

64

Were does it fit?

• Temperature above 150°C and good

size stands on its own.

• Cogeneration of electricity and water for

district heating.

• Good cold end helps

• Environmental issues and subsidizing

changes these values

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65

Budgetary unit price

• Budgetary price for 500 kW unit

720.000 USD

• Equals 1440 USD/kW

• Turbine/generator most costly unit (30-

35%)

• Presuming cooling water available

66

Opportunities

Where there may be hot water or other

fluid/gas available at temperatures
between 120 and 300°C

• Geothermal

• Waste heat

» Industrial processes

» Gas and diesel engine exhaust

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67

Kalina plant benefits

• Energy cost efficient

• Environmental issues

• Green energy

• Reduced emissions

• Standard off the shelf equipment

68

General market
conditions

• General market price 4 eurocents/kWh

• General pay-back time 4 years required

• General investment 1000 USD/kW

• So how can 1440 USD/kW be

competitive?

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69

German law

“Green” electrical power generation bonus

• 2002-2004 1,74 eurocents/kWh

• 2005-2006

1,69 eurocents/kWh

• 2007-2008 1,64 eurocents/kWh

• 2009-2010 1,59 eurocents/kWh

Provided plant in operation before end of 2005

70

Competitive investment ?

• Given 1,65 eurocents/kWh bonus

• 4 year pay-back period

• Additional investment acceptable for

“green” energy USD 528.000/MW

• Total acceptable investment cost thus

USD 1.528.000/MW

or 764.000 USD for

our 500 kW unit

.

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71

“Green” energy?

• Is waste heat recovery=green energy?

• Waste heat recovery reduces emissions

• CO

2

quotas pricing as high as 20-25

USD/tonCO

2

• Average emission 800 gCO

2

/kWh in

fossil fuel plants

• Equals values of 1,8-2,2 eurocents/kWh

72

Summary

• Given green energy bonuses or CO2

evaluation the investment in a Kalina waste
heat recovery electrical generating plant is
feasible

• The investment is competitive to other

investments for industrial improvements

• Pay-back time of 4 years in a green energy

technology is short

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73

Introduction

• Finite source heat capacity lowers this upper

bound due to the reduction of the source
temperature as heat is removed from the
source

• This results in high cost for such low

temperature power plants, as they have to
handle large heat flows

• The Kalina cycle is a novel approach to

increase this efficiency

74

The Models

• It is assumed that a fluid is available at

temperatures ranging from 100 to 150°C

• A heat customer is assumed for the primary

outlet water at the temperature of 80°C

• Primary flow of 50 kg/s is assumed
• Cooling water source is assumed at 15°C,

and cooling water outlet is fixed at 30°C

• It is assumed that a cooling water pump has

to overcome a pressure loss of 1 bar on the
cooling water side in the condenser

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75

Solution

• The software Engineering Equation Solver (EES) is

used to run the models

• The cost model keeps the logarithmic mean

temperature difference for each heat exchanger at
the same value as found in the cycle data for the
tenders for the Husavik power plant

• Estimated cost figures for individual components

were then added together in order to obtain the final
cost value

76

Process assumptions

• The OCR model is based on a system

without regeneration

• Isopenthane is assumed as a working

fluid

• A Kalina cycle for generation of

saturated vapour for the turbine is used

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77

ORC flow sheet

Production well

Injection well

Turbine

Condenser

Pump

Boiler

78

Kalina flow sheet

Production well

Injection well

Separator

Turbine

Condenser

Boiler

Throttling valve

Cooling tower

Regenerator

Pump

Brine hx

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79

Kalina assumptions

• This cycle will be limited by the dew point of the mixture,

that is when the boiling of the mixture is complete, and
no liquid remains at the boiler outlet

• The bubble temperature of the mixture has to be lower or

equal to the primary fluid outlet temperature to ensure
safe operation

• The feasible region will be in the area between the 70

and 80°C bubble contours

• The feasible area regarding the dew temperature is

limited to a value some 2-4°C lower than the maximum
temperature of the primary fluid

Bubble temperature

10

20

30

40

0.6

0.8

1

20

40

60

80

100

Pressure [bar]

Bubble temperature

Ammonia ratio [-]

B

u

b

b

le

t

e

m

p

e

ra

tu

re

[

°C

]

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Dew temperature

10

20

30

40

0.6

0.8

1

50

100

150

200

Pressure [bar]

Dew temperature

Ammonia ratio [-]

D

e

w

t

e

m

p

e

ra

tu

re

[

°C

]

Bubble contours

10

15

20

25

30

35

40

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

Pressure [bar]

A

m

m

o

n

ia

r

a

ti

o

[

-]

Bubble temperature contours

3

0

4

0

4

0

5

0

5

0

6

0

6

0

70

7

0

7

0

8

0

8

0

80

90

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Dew contours

10

15

20

25

30

35

40

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

Pressure [bar]

A

m

m

o

n

ia

r

a

ti

o

[

-]

Dew temperature contours

80

90

100

100

11

0

110

110

12

0

120

120

120

13

0

13

0

130

130

140

140

14

0

14

0

150

150

15

0

160

16

0

16

0

170

17

0

180

19

0

84

More Kalina

• Both high pressure level and ammonia content are

design variables in the Kalina cycle

• This gives flexibility in the design of the cycle, and

requires as well a certain design strategy

• The plant can be designed for maximum power
• or with strong demands on the investment cost
• The cost is 100 for the lowest cost, and the power

100 for the highest power

• An x denotes an infeasible solution, the cycle will not

be able to run at these ammonia content – pressure
combinations

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Cost contours

15

20

25

30

35

40

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

Pressure [bar]

A

m

m

o

n

ia

r

a

ti

o

[

-]

Cost contours, 100°C source

10

1

101

101

1

0

2

102

1

0

2

10

2

10

3

103

10

3

10

3

103

104

104

10

4

104

105

105

1

0

5

105

10

6

10

6

1

0

6

106

10

7

10

7

1

0

7

10

7

107

10

8

10

8

1

0

8

1

0

8

10

9

109

1

0

9

1

0

9

11

0

11

0

110

1

1

0

110

Power contours

20

25

30

35

40

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

Pressure [bar]

A

m

m

o

n

ia

r

a

ti

o

[

-]

Power contours, 100°C source

90

90

90

90

90

90

90

90

90

9

0

9

0

90

90

90

91

91

9

1

91

91

91

91

91

91

91

91

91

91

92

9

2

92

92

92

92

92

92

92

92

92

92

9

3

93

93

93

93

93

93

93

93

93

93

94

94

9

4

94

94

94

94

94

94

94

94

95

95

95

95

95

95

95

95

95

95

96

96

96

96

96

96

96

96

97

97

9

7

97

97

97

97

97

98

98

98

98

98

99

99

99

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Cost surface

10

20

30

40

0.6

0.8

1

0

200

400

600

Pressure [bar]

Cost function

Ammonia ratio [-]

C

o

s

t

Power surface

10

20

30

40

0.6

0.8

1

0

50

100

Pressure [bar]

Power function

Ammonia ratio [-]

P

o

w

e

r

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89

Discussion

• The best power and best cost points are

different

• The lowest cost is at 32 bar, 92% ammonia, but

highest power is at 34 bar and 88% ammonia

• This leads to the definition of two different Kalina

cycles, the best power and the best cost cycles,
with different pressure and ammonia content

15

20

25

30

35

40

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

Pressure [bar]

A

m

m

o

n

ia

r

a

ti

o

[

-]

Cost contours, 120°C source

10 1

10 1

1

0

1

10

2

10 2

102

10

2

10 2

10 2

10 3

10

3

1

0

3

10 3

10 3

10

4

10

4

1

0

4

10 4

10 4

105

1

0

5

1

0

5

10 5

10 5

10 6

1

0

6

1

0

6

10 6

10 7

1

0

7

1

0

7

10 7

10

8

10 8

10 8

1

0

8

10

8

10 9

10 9

1

0

9

1

0

9

11 0

1

1

0

1

1

0

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46

22

24

26

28

30

32

34

36

38

40

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

Pressure [bar]

A

m

m

o

n

ia

r

a

ti

o

[

-]

Power contours, 120°C source

7

0

7

0

7

2

7

2

7

4

7

4

76

7

6

7

6

7

8

7

8

78

8

0

8

0

80

8

2

8

2

82

8

4

8

4

84

84

8

6

86

86

8

8

88

88

9

0

90

90

9

1

91

91

9

2

92

92

9

3

93

93

94

94

9

5

95

9

6

96

97

98

9

9

18

20

22

24

26

28

30

32

34

36

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

Pressure [bar]

A

m

m

o

n

ia

r

a

ti

o

[

-]

Cost contours, 150°C source

10 1

10

1

101

10 2

1

0

2

102

10

3

10

3

10 3

10 3

10 4

1

0

4

10 4

10 4

10 5

1

0

5

10 5

10 6

1

0

6

10 6

10

7

1

0

7

10 7

10 8

1

0

8

1

0

8

10 8

10 9

1

0

9

1

0

9

1

1

0

1

1

0

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47

22

24

26

28

30

32

34

36

38

40

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

Pressure [bar]

A

m

m

o

n

ia

r

a

ti

o

[

-]

Power contours, 150°C source

7

0

7

0

7

2

7

2

7

4

7

4

7

6

7

6

7

8

7

8

8

0

8

0

8

2

8

2

8

4

8

4

8

6

8

8

9

0

9

1

9

2

9

3

9

4

9

5

9

6

9

7

94

Comparison

• Two ORC companies made a tender in

the Husavik bid

• Manufacturer A offered a high power,

high cost power plant, where
manufacturer B took a more
conservative approach

• Following is a comparison with both the

low cost and high power Kalina power
plants

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48

Cost comparison

100

110

120

130

140

150

1000

1200

1400

1600

1800

2000

2200

2400

Source inlet temperature [°C]

N

e

t

c

o

s

t

[$

/k

W

]

Kalina vs ORC cost comparison

ORC B

ORC A

Kalina HP

Kalina LC

Power comparison

100

110

120

130

140

150

0

500

1000

1500

2000

Source inlet temperature [°C]

N

e

t

p

o

w

e

r

[k

W

]

Kalina vs ORC power comparison

Kalina HP

Kalina LC

ORC A

ORC B

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49

97

Results

• The maximum power generated for a

given source is greater for the Kalina
cycle

• Kalina cycle is well positioned against

an ORC cycle for applications with high
utilization time, a base load application

98

Results II

• A heat consumer is beneficial for the ORC

cycle as it results in less temperature change
of the primary fluid during the boiling process

• The Kalina cycle has the boiling or

vaporization of the fluid happening over a
temperature range up to 100°C, which is
beneficial when the primary fluid return
temperature has to be minimized

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50

99

The debate

• The theoretical efficiency and cost/production

ratio are better for Kalina as shown above

• Other arguments like difficulties with

machinery and lesser operational security or
uptime are only temporary discussion items,
as always for a new technology

• These arguments were exactly the same

between conventional flash cycle and ORC
when the latter popped up 30 years ago with
better efficiency but little track record

100

Conclusion

• The Kalina cycle is thermodynamically

superior or equal to the ORC cycle

• There is no black magic behind the

Kalina cycle

• The startup problems that have either

been solved, or are solvable

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