Binary-Cycle ORC Simulator: Geothermal Power Plant Design

simulator intermediate ~10 min
Loading simulation...
P_e = 1.5 MW — viable binary-cycle plant output

A 130°C brine at 50 kg/s through a binary-cycle ORC with 80% turbine efficiency produces approximately 1.5 MW electric — enough to power ~1,500 homes with zero combustion emissions.

Formula

η_Carnot = 1 - (T_cold + 273) / (T_hot + 273)
η_actual = η_Carnot × η_turbine × η_cycle
P_electric = m_brine × c_p × (T_h - T_exit) × η_actual

Power from Moderate Heat

Most of Earth's accessible geothermal heat exists at moderate temperatures — 80 to 180°C — too cool for conventional steam turbines but perfect for binary-cycle power plants. These plants use the organic Rankine cycle (ORC), substituting a low-boiling-point working fluid for water. Hot geothermal brine heats the working fluid through a heat exchanger; the vaporized fluid drives a turbine; and the condensed fluid is recycled. This simulator models the thermodynamic performance of a binary-cycle geothermal plant.

The Organic Rankine Cycle

In the ORC, an organic working fluid (isobutane, isopentane, or a refrigerant) undergoes four stages: pumping to high pressure, evaporation by geothermal heat, expansion through a turbine (generating electricity), and condensation. The choice of working fluid critically affects performance — its boiling point, critical temperature, and saturation curve shape must match the geothermal source temperature for optimal heat recovery.

Efficiency and Carnot Limits

Thermodynamics imposes strict limits on energy conversion. The Carnot efficiency — set by the ratio of cold and hot absolute temperatures — is modest for geothermal sources: typically 15-30%. Real-world irreversibilities (heat exchanger pinch points, turbine losses, parasitic pump loads) reduce actual thermal efficiency to 8-15%. Yet binary plants remain economic because geothermal 'fuel' is free — no combustion, no fuel costs, no emissions.

Environmental Advantages

Binary-cycle plants are arguably the cleanest electricity source available. The geothermal brine circulates in a sealed loop from well to heat exchanger and back — no gases, minerals, or fluids contact the atmosphere. The working fluid is also contained in a closed loop. Combined with small physical footprints and 95%+ capacity factors, binary plants offer reliable baseload renewable power with near-zero environmental impact.

FAQ

What is a binary-cycle geothermal plant?

A binary-cycle plant uses hot geothermal brine to vaporize a secondary (binary) working fluid with a lower boiling point — typically an organic compound like isobutane or isopentane. The vaporized working fluid drives a turbine-generator. The geothermal brine never contacts the atmosphere, making binary plants zero-emission.

What is an organic Rankine cycle (ORC)?

An ORC is a thermodynamic cycle identical in principle to the steam Rankine cycle but using an organic working fluid instead of water. Organic fluids boil at lower temperatures, enabling power generation from low-grade heat sources (80-200°C) where water-steam cycles would be impractical.

Why are binary plants important?

Binary plants dominate new geothermal installations because they can utilize lower-temperature resources (80-180°C), which are far more abundant than high-temperature hydrothermal reservoirs. They also have zero atmospheric emissions since the brine is reinjected in a closed loop.

What limits binary-cycle efficiency?

Carnot's theorem sets the theoretical maximum efficiency based on temperature ratio. With typical geothermal temperatures (100-180°C) and ambient cooling (25-40°C), Carnot efficiency is only 15-35%. Real-world irreversibilities reduce actual efficiency to 8-18%, but free fuel makes this economically viable.

Sources

Embed

<iframe src="https://homo-deus.com/lab/geothermal-energy/binary-cycle/embed" width="100%" height="400" frameborder="0"></iframe>
View source on GitHub