The “UGK-Energetika” Group develops, manufactures, and supplies containerized ORC (Organic Rankine Cycle) power plants under the “Neutron-ORC” brand of Russian production.

The production of ORC turbines, with power ranging from 1000 kW to 100 MW, ensures electricity generation from various heat sources using the following types of fuel: natural and associated petroleum gas, gas condensate, landfill gas, liquid fuel, organic fuel, low-calorie coal (coal dust), biomass, heat from industrial processes, as well as geothermal sources and other fuel types.

“Neutron-ORC” power plants come in two types:

Low-temperature ORC modules for utilizing heat carriers with temperatures from 80°C to 250°C, with power from 1000 to 2500 kW.
High-temperature ORC turbines for working with heat carriers from 260°C to 350°C, with power from 1.5 to 25* MW.

* Stationary ORC installations with power up to 100 MW consist of high-temperature ORC turbines installed in cascade.

3D overview of “Neutron-ORC” power plant:

Technical characteristics of “Neutron-ORC” power plant

“Neutron-ORC” power plants operate on the Organic Rankine Cycle (ORC) principle and use a two-circuit system, including a heat pump using R600a refrigerant and a turbine circuit with SF6 (sulfur hexafluoride) as the working fluid. This design eliminates the need for heat discharge into the atmosphere through internal condensation of the working fluid, which increases process efficiency. The torque created by the turbine is transmitted to the asynchronous generator shaft through a coupling.

The power plants are supplied as ready-made modules, including a turbogenerator based on ORC, control system, automatic circuit breaker for parallel operation with other units or the grid, and heat exchangers with circulation pumps. The entire complex is controlled by an industrial controller, ensuring coordinated operation of all elements. The amount of heat required for the installation’s operation is regulated by an electronic pump controlling the supply of warm water to the heat exchanger.

“Neutron-ORC” ORC installations are widely used in various industries, including strategic facilities, industry, agriculture, oil and gas sector, telecommunications, and municipal services. These power plants are distinguished by their high environmental friendliness, efficiency, and economy, making them competitive compared to traditional gas piston and gas turbine generators. The ability to use various types of fuel increases their versatility and reliability in electricity production.

Parameters of “Neutron-ORC” ORC power plant:

No.	Power Plant Modification	Neutron-ORC
1	Nominal electrical power at generator terminals, kW	1000 — 25000
2	Electrical power control range, kW	5% — 100%
3	Average fuel efficiency of the installation, %	48.6
4	Nominal generator rotor speed, rpm	1 500
5	Exhaust gas flow rate (average), kg/s	by calculation
6	Exhaust gas temperature, °С	by calculation
7	Generator type	Synchronous or asynchronous, four-pole
8	Current type	alternating
9	Nominal voltage, kV	0.4; 6.3 and 10.5
10	Nominal current frequency, Hz	50
11	Operational indicators of equipment, including:
	— time between maintenance, hours	8 000
	— resource until major overhaul, hours	40 000
	— service life, hours	200 000
	— service life, years	25
	— availability factor	0.98
12	Operating temperature range	— 40…+60°С
13	Seismic impact intensity in MSK-64 scale	not less than 7

“Neutron-ORC” ORC power plants are designed to generate three-phase AC power with voltages of 0.4, 6, and 10.5 kV at 50 Hz frequency. They provide primary switching, allowing the installation to connect to consumer loads and use it as an autonomous power supply source.

“Neutron-ORC” ORC power plants are equipped with TDPS* generators, which ensure high reliability and stable operation. TDPS generators are characterized by high efficiency, compact size, and adaptability to various operating conditions. They can operate with a wide range of loads, maintaining stable voltage and output frequency, making them an ideal choice for autonomous and backup power supply systems.

* The “Neutron-ORC” power plant can be modified and adapted for use with generators of domestic and foreign production.

The versatility of “Neutron-ORC” installations allows reliable startup and stable operation in various climatic and geographical conditions. The installation is adapted for operation in a wide temperature range and has high resistance to external factors, making it an effective solution for autonomous and backup power supply in various regions.

Fig. 1 — Neutron-ORC 2.5 MW

Economic indicators of “Neutron-ORC” 1 MW ORC power plant:

Indicator	Value
Energy output per 1 cubic meter of gas	6 kW
Average natural gas cost	7.2 rubles including 20% VAT
Specific cost of 1 kW of electrical energy	1.2 rubles including 20% VAT
Installation resource until major overhaul	40,000 hours (or 5 years)
Energy generation for 40,000 hours	40,000,000 kWh
Annual service maintenance costs	1,987,700 rubles including 20% VAT
Service maintenance costs for 5 years	9,938,500 rubles including 20% VAT
Major overhaul cost	18,700,000 rubles including 20% VAT
TOTAL operational costs until major overhaul	28,638,500 rubles including 20% VAT
Production cost of 1 kW of electrical energy	0.7 rubles including 20% VAT
Total cost of 1 kW of electrical energy	1.9 rubles including 20% VAT (including gas and operation costs)
Electricity selling price to consumers	from 3.2 rubles including 20% VAT

Comparison table of GTU, GPU, and “NEUTRON-ORC” power plants:

Parameter	GTU (Gas Turbine Unit)	GPU (Gas Piston Unit)	ORC (Neutron-ORC)
Electrical power	1.0 MW	1.0 MW	1.0 MW
Electrical efficiency	25.5%	42.5%	48.6%
Total gas consumption	500 m³/hour	250 m³/hour	166 m³/hour
Exhaust gas temperature	463°C	–	200°C
Time between maintenance	4000 hours	750 hours	8000 hours
Resource until major overhaul	35,000 hours	40,000 hours	40,000 hours
Designated resource	25 years	15-20 years	20-25 years
Load regulation capability	No	Yes (50% to 110%)	Yes (5% to 100%)
Power turbine rotation speed	1,500 rpm	–	1,500 rpm
Annual maintenance costs (including consumables)	3.5-4 million rubles	7.5-7.9 million rubles	1.5-1.9 million rubles
Cost of 1 kW including gas	4.3 rubles	3.3 rubles	1.9 rubles
Scheduled maintenance frequency	Once every 5 months	Once every 3 weeks	Once every 12 months
Major overhaul	after 4 years	after 5 years	after 5 years
Major overhaul cost	~35 million rubles	~33 million rubles	~19 million rubles
Additional capabilities	Cannot regulate fuel consumption	Can regulate power and consumption	Can regulate power and consumption

ORC power plants (Neutron-ORC) with an electrical capacity of 1 MW prove to be the most economical option due to their high efficiency (48.6%), low gas consumption (166 cubic meters/hour), and minimum cost of 1 kW of electricity (1.9 rubles). The installation also requires lower annual maintenance costs compared to GTU and GPU. The ability to adjust power and fuel consumption makes it more flexible and versatile. While GTU and GPU lag behind in terms of economy, ORC stands out for its high environmental friendliness and durability.

Energy sources for “NEUTRON-ORC” power plants:

Energy Source	Description
Natural and associated petroleum gas, gas condensate	Combustion for power generation
Liquid and solid organic fuels (MSW, SHW)	Combustion of various waste and organic fuels
Coal fuel, biomass, wood waste	Combustion of coal, wood, sunflower husks, and other types
Exhaust gas heat	Heat utilization from gas piston and gas turbine stations
Waste heat	Use of steam, hot water, oil from industrial processes
Residual heat from boiler houses	Heat utilization from industrial boiler operations
Thermal energy from condensate	Use of condensate heat from boiler houses and power plants
Geothermal sources, underground waters	Use of geothermal energy
Heat from “UPG-Neutron” plasma reactor	Combustion of various waste and organic fuels (MSW, SHW)

Comparison of ORC technology with classic steam turbines:

ORC turbines with organic Rankine cycle and classic steam turbines (back-pressure, condensing, cogeneration) differ mainly in working media, operating conditions, and efficiency in different temperature ranges. Let’s compare their main characteristics and highlight the advantages of ORC turbines.ORC turbines with organic Rankine cycle and classic steam turbines (back-pressure, condensing, cogeneration) differ mainly in working media, operating conditions, and efficiency in different temperature ranges. Let’s compare their main characteristics and highlight the advantages of ORC turbines.

Working Media:

Classic steam turbines use water as a working medium, which turns into steam to operate the turbine. Water has a high boiling point and requires significant temperature differentials for efficient operation.
ORC turbines use organic working fluids (SF6, etc.), which have a lower boiling point compared to water. This allows them to operate at lower temperatures.

Operating Temperature Range:

Classic steam turbines are efficient at high temperatures (typically above 300°C), such as in thermal power plants or large industrial facilities.
ORC turbines work efficiently in low and medium temperature ranges (80-300°C). This makes them suitable for use with low-potential heat sources, such as waste heat from industrial processes, geothermal sources, etc.

Efficiency:

Classic steam turbines have high efficiency at high temperatures, especially when using condensing schemes.
ORC turbines are efficient at converting low-potential heat into electricity, where classic turbines show low efficiency or cannot be used at all.

Technical Complexity and Equipment Requirements:

Classic steam turbines require complex and expensive infrastructure, including high-temperature boilers, water supply systems, and steam condensation systems. This makes them complex to operate and maintain.
ORC turbines can use simpler equipment as they operate at lower pressures and temperatures. This simplifies their operation and reduces capital and operating costs.

Environmental Friendliness and Application Flexibility:

Classic steam turbines depend on large energy sources and usually require fuel combustion, which can lead to carbon dioxide and other pollutant emissions.
ORC turbines are more environmentally friendly as they can use renewable energy sources and secondary heat, reducing fuel consumption and emissions.

Size and Scalability:

Classic steam turbines are usually used in large power plants. They require significant steam volumes and large facilities.
ORC turbines are scalable and can be used in more compact systems, making them ideal for distributed energy systems and small-scale projects.

Advantages of “Neutron-ORC”:

Investment payback on average 1-3 years, project profitability over 30%, electricity generation cost lower than grid tariffs ~ from 1.2 rubles per 1 kW (depending on heat source or gas cost).
Maximum efficiency coefficient of 48.6% achieved through two circuits: Heat pump circuit using R600a refrigerant and ORC turbine circuit (Working fluid – SF6). This design eliminates the need for working fluid cooling through heat discharge into the atmosphere, as working fluid condensation occurs inside a special condensing turbine.
Service maintenance required no more than once every 8000 hours, resource until major overhaul – 40,000 hours.
Average power plant commissioning time from 4 months, depending on power capacity, from the moment of advance payment and contract conclusion.
Compact and environmentally clean containerized power plants requiring minimal maintenance and providing high-quality electricity.
Possibility of use for primary, additional, or backup power supply, both in autonomous mode and parallel with the grid.
Ability to combine multiple units into a single complex to increase power supply reliability.
Wide range of usable fuels, including waste heat and various carbon sources, reducing electricity production costs.

Fig. 2 — 3D model of “Neutron-ORC” ORC turbine

Small and medium-scale power generation today is a relevant, profitable, and in-demand business direction that will help maximize protection and multiply your investments for years to come.

If you are interested in our offer, we are ready to provide all necessary information and discuss all possible cooperation options.

To submit an application for a mini-CHP (TPP) — ORC using ORC technology or ORC Turbines, you need to fill out the online questionnaire form.

For all questions, please contact our engineers:

Yekaterinburg	Russia, CIS	E-mail;
+7 (343) 272-31-80, +7(912) 222- 44-02	8 (800) 201-71-60	ka@urgk.ru
+7 (343) 272-31-82		info@urgk.ru; office@urgk.ru

Mini-CHP Power Plants Based on ORC Turbines or ORC Technology