The performance of a 300 kW organic Rankine cycle (ORC) prototype was experimentally investigated for low-grade waste heat recovery in industry. The prototype employed a specially developed single-stage radial turbine that was integrated with a semi-hermetic three-phase asynchronous generator. R245fa was selected as the working fluid and hot water was adopted to imitate the low-grade waste heat source. Under approximately constant cooling source operating conditions, variations of the ORC performance with diverse operating parameters of the heat source (including temperature and volume flow rate) were evaluated. Results revealed that the gross generating efficiency and electric power output could be improved by using a higher heat source temperature and volume flow rate. In the present experimental research, the maximum electric power output of 301 kW was achieved when the heat source temperature was 121 °C. The corresponding turbine isentropic efficiency and gross generating efficiency were up to 88.6% and 9.4%, respectively. Furthermore, the gross generating efficiency accounted for 40% of the ideal Carnot efficiency. The maximum electric power output yielded the optimum gross generating efficiency.
Keywords: electric power output; heat source temperature and volume flow rate; isentropic efficiency; organic Rankine cycle (ORC); single-stage radial turbine; waste heat recovery.