Heat recovery from Diesel engines: A thermodynamic comparison between Kalina and ORC cycles

Abstract In the context of heat recovery for electric power generation, Kalina cycle (a thermodynamic cycle using as working fluid a mixture of water and ammonia) and Organic Rankine Cycle (ORC) represent two different eligible technologies. In this work a comparison between the thermodynamic performances of Kalina cycle and an ORC cycle, using hexamethyldisiloxane as working fluid, was conducted for the case of heat recovery from two Diesel engines, each one with an electrical power of 8900 kWe. The maximum net electric power that can be produced exploiting the heat source constituted by the exhaust gases mass flow (35 kg/s for both engines, at 346 °C) was calculated for the two thermodynamic cycles. Owing to the relatively low useful power, for the Kalina cycle a relatively simple plant layout was assumed. Supposing reasonable design parameters and a logarithmic mean temperature difference in the heat recovery exchanger of 50 °C, a net electric power of 1615 kW and of 1603 kW respectively for the Kalina and for the ORC cycle was calculated. Although the obtained useful powers are actually equal in value, the Kalina cycle requires a very high maximum pressure in order to obtain high thermodynamic performances (in our case, 100 bar against about 10 bar for the ORC cycle). So, the adoption of Kalina cycle, at least for low power level and medium–high temperature thermal sources, seems not to be justified because the gain in performance with respect to a properly optimized ORC is very small and must be obtained with a complicated plant scheme, large surface heat exchangers and particular high pressure resistant and no-corrosion materials.