FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10; rule 13)
TITLE OF THE INVENTION
“TURBO-GENERATOR SYSTEM AND METHOD THEREOF FOR WASTE RECOVERY BY GENERATING POWER”
APPLICANT
ENRECOVER ENERGY RECOVERY SOLUTIONS PRIVATE LIMITED
of House No. 471/1, A/p Naigaon, Tal- Haveli, Dist- Pune, Haveli, Pune, Pune 412202, Maharashtra, India; Nationality: Indian
The following specification particularly describes the invention and the manner in
which it is to be performed

TURBO-GENERATOR SYSTEM AND METHOD THEREOF FOR WASTE RECOVERY BY GENERATING POWER
FIELD OF INVENTION
[0001] The present invention relates to a turbo-generator system, and more specifically related to a turbo-generator system and method thereof for generating power based on industry waste.
BACKGROUND OF INVENTION
[0002] In general, around 58% low grade heat gets wasted in India. Globally energy that is wasted through waste heat amounts to around 800,000,000 ton/year of carbon emission rates. This emission is partially responsible for global warming and environment pollution. One industry where this is prevalent is in steel industry. Various conventional machines are proposed to generate electricity from the waste but the conventional machines produce millions of tons of toxic emissions into the Earth's atmosphere each year. The low grade heat is also wasted to atmosphere through various process due to the inefficiencies of equipment’s or equipment’s working on principle of thermal cycle based on temperature difference between source and sink.
[0003] Thus, it is desired to address the above mentioned disadvantages or other shortcomings or at least provide a useful alternative.
OBJECT OF INVENTION
[0004] The principal object of the embodiments herein is to provide a turbo-generator system and method thereof for generating power based on industry waste. In order to efficiently utilize the low grade waste heat generated from different sources, the turbo generator system is produced which utilizes the low-grade waste heat to generate electricity.
[0005] Another object of the embodiments herein is to design of a high-speed direct coupled 3 phase permanent magnet generator provided with a passive front end & integration with solar PV grid connected inverter topology for low waste heat recovery application in a steel manufacturing industry.

[0006] Yet another object of the embodiments provide a method for a cycle control strategy for low grade waste heat to power generation using the permanent magnet generator.
[0007] Yet another object of the embodiments herein is to a design of a cycle control method that is used for low grade waste heat to power generation using a high RPM permanent magnet generator.
SUMMARY
[0008] In one aspect the object is satisfied by providing a turbo-generator system for generating power. The turbo-generator system includes a storage tank comprising liquid, an evaporator and heater system, a phase change unit connected to the storage tank and the evaporator and heater system, a turbo charger connected to the phase change unit and a phase retainer unit connected to the turbo charger and a condenser. The phase change unit receive waste from a waste source, extract heat from the waste using the evaporator and heater system, receive the liquid from the storage tank, and convert the liquid into a high pressure vapor based on the extracted heat from the waste evaporator and heater system. The turbo charger receives the high pressure vapor from the phase change unit and generates the electricity from the high pressure vapor. The phase retainer unit convert the high pressure vapor received from the turbo charger back to the liquid and store the converted liquid in the storage tank using the condenser.
[0009] In an embodiment, generate the electricity from the high pressure vapor includes extract kinetic and potential energy from the high pressure vapor received from the phase change unit, and generate the electricity based on the extracted kinetic and potential energy.
[0010] In an embodiment, convert the high pressure vapor back to the liquid includes convert the high pressure vapor into a low pressure vapor, and convert the low pressure vapor back to the liquid by exchanging heat between a cooling source and the low pressure vapor.

[0011] In an embodiment, the evaporator and heater system converts the liquid
from a liquid phase to a vapor phase using a heat available in the liquid flowing
through the evaporator.
[0012] In an embodiment, the phase retainer unit comprises four channels in
which a first channel take a low temperature input in form of air or water, a
second channel takes input from the first channel, a third channel takes hot liquid
as input from the turbo charger, and a fourth channel provide an output of the
phase retainer unit for cooled liquid in liquid state.
[0013] In an embodiment, the phase change unit comprises four channels in
which a first channel takes input waste from the waste heat source, a second
channel takes input from the first channel, a third channel takes input for liquid
from the storage tank, and a fourth channel provide an output of the phase change
unit to the turbo charger as prime mover.
[0014] In an embodiment, the turbo charger includes a volute casing, an
impeller, a rubber gasket, a stator, a Teflon gasket, a generator shaft, and a
generator connected to the turbine using the generator shaft. The volute casing,
impeller, and rubber gasket forms the turbine. The liquid is accelerated through
the volute casing to reach the highest velocity and through the stator the high
velocity liquid. The generator rotates to extracts kinetic and potential energy
from the high pressure vapor received from the evaporator and heater system
and generates the electricity.
[0015] In an embodiment, the turbine is connected to the generator using a set
of shaft seal, a bearing, and a bearing end cover.
[0016] In an embodiment, the generator is a radial flux permanent magnet
rotating at 16800 rotations per minute (rpm).
[0017] In an embodiment, the turbo-generator system comprises an AC-DC
converter connected to the generator to receive a high frequency AC power
generated by the generator and convert the high frequency AC power into a DC
power, and a solar grid tie inverter to feed the DC power back to a grid of a waste
heat recovery application.

[0018] In an embodiment, the liquid has a boiling point of 34 degree Celsius at
1 bar pressure and 90 degree boiling point at 4.5 to 5.5 bar pressure.
[0019] In an embodiment the liquid from the storage tank is pumped at a high
pressure with a vertical multistage pump with 9 stages to pressurize the liquid to
the 4.5 to 5.5 bar pressure.
[0020] In an embodiment, the phase change unit is connected a hot source inlet
to receive the waste from the waste source and a hot source outlet to provide an
output from the evaporator and heater system.
[0021] In an embodiment, the phase retainer unit is connected to a cooling source
inlet to receive a coolant from a cooling source and a cooling source outlet to
provide an output from the evaporator.
[0022] In yet another aspect the object is satisfied by providing a turbo charger
for generating power. The turbo charger includes a volute casing, an impeller, a
rubber gasket, a stator, a teflon gasket, a generator shaft, and a generator
connected to the turbine using the generator shaft. The turbine is connected to
the generator using a set of shaft seal, a bearing, and a bearing end cover. The
volute casing, impeller, and rubber gasket forms a turbine. The liquid is
accelerated through the volute casing to reach the highest velocity and through
the stator the high velocity liquid. The generator receives a high pressure vapor
from a turbo-generator system, and rotates the generator shaft to extracts kinetic
and potential energy from the high pressure vapor received to generate the
electricity.
[0023] In yet another aspect the object is satisfied by providing a method for
generating power by a turbo-generator system. The method includes receiving,
by a phase change unit, waste from a waste source. The phase change unit (4) is
connected to a storage tank and an evaporator and heater system and a phase
retainer unit is connected to the turbo charger and a condenser. The method
includes extracting by the phase change unit heat from the waste using the
evaporator and heater system, receiving by the phase change unit the liquid from
the storage tank, converting by the phase change unit the liquid into a high
pressure vapor based on the extracted heat from the waste evaporator and heater

system, receiving by a turbo charger the high pressure vapor from the phase change unit, generating by the turbo charger the electricity from the high pressure vapor, converting by a phase retainer unit the high pressure vapor received from the turbo charger back to the liquid, and storing by the phase retainer unit the converted liquid in the storage tank using the condenser. [0024] In an embodiment, generating the electricity from the high pressure vapor comprises extracting kinetic and potential energy from the high pressure vapor received from the phase change unit, and generating the electricity based on the extracted kinetic and potential energy.
[0025] In an embodiment, converting the high pressure vapor back to the liquid comprises converting the high pressure vapor into a low pressure vapor, and converting the low pressure vapor back to the liquid by exchanging heat between a cooling source and the low pressure vapor.
[0026] In yet another aspect the object is satisfied by providing a method for generating electricity using a turbo charger. The method includes providing a volute casing, providing an impeller, providing a rubber gasket, wherein the volute casing, impeller, and rubber gasket forms the turbine, providing a stator, providing a teflon gasket, providing a generator shaft, and connecting a generator to the turbine using the generator shaft. The liquid is accelerated through the volute casing to reach the highest velocity and through the stator the high velocity liquid. The generator receives a high pressure vapor from a turbo-generator system, and rotates the generator shaft to extracts kinetic and potential energy from the high pressure vapor received to generate the electricity. The turbine is connected to the generator using a set of shaft seal, a bearing, and a bearing end cover. The generator is a radial flux permanent magnet rotating at 16800 rotations per minute (rpm).
[0027] In yet another aspect the object is satisfied by providing a radial inflow turbine based turbo-generator system for generating electricity. The turbo-generator system incudes a generator, an AC-DC converter connected to the generator, and a solar grid tie connected to a grid of a waste heat recovery application. The generator receives a high pressure vapor from the turbo-

generator system, and rotates a generator shaft to extracts kinetic and potential energy from the high pressure vapor received to generate a high frequency AC power. The AC-DC converter receive the high frequency AC power generated by the generator and convert the high frequency AC power into a DC power. The solar grid tie inverter feeds the DC power back to the grid of the waste heat recovery application.
[0028] In an embodiment, the turbo-generator system includes a LC filter connected between the AC-DC converter and the solar grid tie inverter. The LC filter receives the DC power from the AC-DC converter to cut or pass specific frequency bands of an electric signal.
[0029] In an embodiment, the turbo-generator system includes a power control limiter to limit control an output power.
[0030] In an embodiment, the high frequency AC power is generating by: determining whether electrical parameters is in a predefined range; determining that a Hot Source Temperature (H_T), a Flow rate (H_F), a Cold Source Temperature (C_T), & a Cold Source flow rate (C_F) is in a specified range in response to determining that the electrical parameters is in the predefined range; turning a feed pump (726) on by sending a command; detecting that a PID loop is settled & Temperature, Pressure of circulating fluid is achieved by pump; switching off a Bypass valve & switching on a turbine valve to rotate the turbine which in turn rotates the generator resulting in generation of the high frequency AC power.
[0031] In yet another aspect the object is satisfied by providing method for generating electricity using radial inflow turbine based turbo-generator system. The method includes receiving, by a generator, a high pressure vapor from the turbo-generator system, generating by the generator a high frequency AC power by rotating a generator shaft to extracts kinetic and potential energy from the high pressure vapor, receiving by a AC-DC converter the high frequency AC power generated by the generator and converting the high frequency AC power into a DC power, and feeding by a solar grid tie inverter DC power back to a grid of a waste heat recovery application.

[0032] Further, the method includes receiving, by a LC filter to cut or pass specific frequency bands of an electric signal and comprises controlling an output power by implementing a power control limiter.
[0033] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF FIGURES
[0034] The proposed turbo-generator system is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0035] FIG. 1 illustrates a perspective view of a turbo-generator system, according to embodiments as disclosed herein;
[0036] FIG. 2 illustrates an exploded view of a turbo-charger, according to embodiments as disclosed herein;
[0037] FIG. 3 is a flow chart illustrating a method for a cycle control strategy for low grade waste heat to power generation using the permanent magnet generator, according to embodiments as disclosed herein;
[0038] FIG. 4 illustrates a block diagram of a radial flux permanent magnet generator for low waste heat recovery application in a steel manufacturing industry, according to embodiments as disclosed herein;
[0039] FIG. 5 illustrates a 3D view of the turbine, according to embodiments as disclosed herein;

[0040] FIG. 6 is a flow chart illustrating a method for generating electricity in
an organic Rankine cycle engine, according to embodiments as disclosed herein;
and
[0041] FIG. 7 is a block diagram of an example organic Rankine cycle engine,
according to embodiments as disclosed herein.
DETAILED DESCRIPTION OF INVENTION
[0042] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. Also, the various embodiments described herein are not necessarily mutually exclusive, as some embodiments can be combined with one or more other embodiments to form new embodiments. The term “or” as used herein, refers to a non-exclusive or, unless otherwise indicated. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein can be practiced and to further enable those skilled in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0043] Referring now to the drawings, and more particularly to FIGS. 1 through 7, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0044] FIG. 1 illustrates a perspective view of a turbo-generator system (1), according to embodiments as disclosed herein. The turbo-generator system (1) includes a storage tank (2), an evaporator and heater system (3), a phase change unit (4), a turbo charger (5), a phase retainer unit (6), and a condenser (7). [0045] The storage tank (2) includes fluid or liquid such as water. The liquid has a boiling point of 34 degree Celsius at 1 bar pressure and 90 degree boiling point at 4.5 to 5.5 bar pressure. In an embodiment, the liquid from the storage tank (2)

is pumped at a high pressure with a vertical multistage pump with 9 stages to pressurize the liquid to the 4.5 to 5.5 bar pressure.
[0046] The evaporator and heater system (3) is connected to the storage tank (2). The evaporator acts as plate type heat exchangers for efficient heat transfer. [0047] The phase change unit (4) is connected to the storage tank (2) and the evaporator and heater system (3). The phase change unit (4) captures low grade waste heat from industry. This act as a primary input of waste heat from industry. The phase change unit (4) is connected to a hot source inlet (8) to receive the waste from the waste source and a hot source outlet (9) to provide an output from the evaporator and heater system (3). The inlet and outlet pipes (8 and 9) acts as entry and exit positions of the waste source. The phase change unit (4) converts the liquid from a liquid phase to a vapor phase using heat available in the liquid flowing through the evaporator and heater system (3). The phase change unit (4) includes four channels in which a first channel takes input waste from the waste heat source, a second channel takes input from the first channel, a third channel takes input for liquid from the storage tank (2), and a fourth channel provide an output of the phase change unit (4) to the turbo charger (5) as prime mover. The phase change unit (4) receives waste from a waste source, extract heat from the waste using the evaporator and heater system (3), receives the liquid from the storage tank (2), and converts the liquid into a high pressure vapor based on the extracted heat from the waste using the evaporator and heater system (3). [0048] The turbo charger (5) is connected to the phase change unit (4). The turbo charger (5) is basically combination of turbine & generator (see FIG. 2). The turbo charger (5) receives the high pressure vapor from the phase change unit (4) and generates the electricity from the high pressure vapor. In an embodiment, the turbo charger (5) extracts kinetic and potential energy from the high pressure vapor received from the phase change unit (4), and generates the electricity based on the extracted kinetic and potential energy.
[0049] For example, when fluid extracts the heat from waste input at higher pressure, it evaporates. Then the high pressure evaporated steam act as prime mover for turbine & it rotates directly coupled generator. The direct coupled

generator is then produces electricity. This is direct driven turbine & generator at almost 17000 RPM. The detailed structure of the turbo charger (5) is described in conjunction with the FIG. 2.
[0050] The phase retainer unit (6) connected to the turbo charger (5) and a condenser (7). The phase retainer unit (6) is used to collect cold input from industry & bring back the evaporated fluid to liquid state. The phase retainer unit (6) is used to bring back the evaporated liquid to the liquid state. The phase retainer unit (6) is connected to a cooling source inlet (10) to receive a coolant from a cooling source and a cooling source outlet (11) to provide an output from the evaporator. The phase retainer unit (6) includes four channels in which a first channel take a low temperature input in form of air or water, a second channel takes input from the first channel, a third channel takes hot liquid as input from the turbo charger (5), and a fourth channel provide an output of the phase retainer unit (6) for cooled liquid in liquid state. The phase retainer unit (6) converts the high pressure vapor received from the turbo charger (5) back to the liquid using the condenser (7) and store the converted liquid in the storage tank (2). In an embodiment, the phase retainer unit (6) converts the high pressure vapor into a low pressure vapor, and converts the low pressure vapor back to the liquid by exchanging heat between a cooling source and the low pressure vapor. [0051] The low pressure liquid is stored in the storage tank (2) placed below the condenser (7). Both, the condenser (7) and evaporator (3) are plate type heat exchangers for efficient heat transfer.
[0052] Design of Assembly is taken into consideration of multiple factors. Location of the storage tank (2) & Pump inlet piping is arranged with design consideration of “NET POSITIVE SUCTION HEAD” of pump & other cavitation issues. Location of the turbine inlet is kept in straight line/top of exit of the evaporator. The turbine outlet is kept at top of condenser inlet. This consideration will allow vapor coming from the turbine exit to free fall in condenser.
[0053] FIG. 2 illustrates an exploded view of a turbo-charger (5), according to embodiments as disclosed herein. The turbo-charger (5) includes a volute casing

(12), an impeller (13), a rubber gasket (14), a stator (15), a Teflon gasket (16), a generator shaft (17), and a generator (18) connected to the Teflon gasket (16). The turbine (12, 13, and 14) is connected to the generator (18) using a set of shaft seal (19), a bearing (20), and a bearing end cover (21).
[0054] The volute casing (12) is the housing of turbo-charger (5) (also referred as expander) in which the working liquid is accelerated to reach the highest velocity and through the stator (15) the high velocity fluid is impinged on the turbo expander blades. The expander extracts enthalpy from the working liquid. Here the rpm of turbo-charger (5) is 16800 rpm. At this high rpm, the overall dimensions of the turbine reduces and the adiabatic efficiency increases. The generator is a permanent magnet rotating at 16800 rpm. In order to avoid the liquid leakage which is the most critical part of the cycle, the turbine is directly coupled to the generator shaft (17). The volute acts as an accelerator where the acceleration of liquid is increased at a very faster rate which increases the impact of working liquid on stator and rotor blades. Due to the initial acceleration of liquid in volute domain, the stator (15) exit velocity increases. The exit velocity of liquid is kept close to Mach 0.9 to avoid the chocking.
[0055] Unlike the conventional machines, the proposed invention works on a closed loop cycle for low to medium temperature heat recovery. The heat which is wasted to atmosphere through various processes due to the inefficiencies of equipment and process and conversion into electrical energy using the proposed turbo-generator system (1) through the innovative high rpm and compact turbo generator as described in the FIG. 2.
[0056] Application of a thermal cycle which operates on a principle of temperature difference between Source and Sink. The heat is absorbed by the system from high temperature source particularly greater than 80 degree centigrade and part of heat energy is transferred to the novel working fluid which evaporates at high pressure and thus releases its energy to a high-speed turbo-generator which in turn produces power. As the energy of working fluid is extracted by the proposed turbo-generator, the low temperature and low-pressure working fluid at the exit of turbine is cooled by the low temperature sink and

converted back into liquid phase. The cycle operates in a closed loop. Here, as the low-pressure working fluid is condensed back into liquid phase, the heat of condensation is extracted by the sink which may be either water or air. As the temperature of sink fluid is raised, this can also be used for heating application which increases the overall efficiency of the cycle. In an embodiment, the working principle is based on the Rankine Cycle (as described in FIGS. 6-7), but instead of water as a working fluid a novel working fluid is being used which has a high molecular weight which reduces the erosion of turbine blades, increases bearing life and is a self-lubricating fluid.
[0057] FIG. 3 is a flow chart illustrating a method for a cycle control strategy for low grade waste heat to power generation using the permanent magnet (PM) generator (18), according to embodiments as disclosed herein. At S1, the PM generator (18) read RPM (n). At S2, the PM generator (18) determines that RPM (n) =RPM (rated). At S3, the PM generator (18) identifies that Pset(n)=0.01*P total (Grid export starts) via MODBUS command. At S4, the PM generator (18) reads the RPM and the system detects that ∆ RPM=RPM(n-1) -RPM(n). At S5, the PM generator (18) determines that ∆ RPM> 50 or X. If the ∆ RPM is not greater than 50 or X then at S6, the PM generator (18) identifies that Pset(n)=1.01*Pset(n-1). If ∆ RPM> 50 = true then this Pset will go back to previous state of set power & if false Pset will get incremented till total rated power. At S7, the PM generator (18) determines that Change of RPM condition. If the Pset (n) =P Total then, at 316, the system identifies that Pset=P Total. [0058] FIG. 4 illustrates a block diagram of the radial flux permanent magnet generator (18) for low waste heat recovery application in a steel manufacturing industry, according to embodiments as disclosed herein. The turbo-generator system (1) includes an Alternating Current-Direct Current (AC-DC) converter (22), a LC filter (25), a solar grid tie inverter (23), a solid state relay (26) and a grid (24), a modbus Rs485 controller (27) and a power control limiter (28)/ power controller.
[0059] The AC-DC converter (22) is connected to the generator (18) to receive a high frequency AC power generated by the generator (18) and convert the high

frequency AC power into a DC power. The LC filter (25) receives the DC power from the AC-DC converter (22) to cut or pass specific frequency bands of an electric signal. The LC filter (25) is a combination of inductors (L) and capacitors (C) to cut or pass specific frequency bands of an electric signal. The solar grid tie inverter (23) receives the electrical signal from the LC filter (25) and fed to the DC power back to grid (24) of a waste heat recovery application. The solar grid tie inverter (23) is integrated into waste heat recovery application. [0060] In an embodiment, the turbine is directly coupled with a radial flux permanent magnet generator (18) at 16,800 RPM. A high RPM direct coupled system increases the overall efficiency & reduces the size due to lower torque requirement. The smaller size results in reduction in manufacturing cost for turbine. The proposed invention results in 3-4% of efficiency improvement of overall cycle. Number of poles & winding pattern in axial generator has been selected with respect to turbine speed. This generated energy of the PM generator (18) is fed into the passive front end where the high frequency AC power is converter into DC power at the AC-DC converter (18). This DC power is then fed back to the grid (24) with help of the solar grid tie inverter (23). In an embodiment, the solar grid tie inverter (23) is a hysteresis current control based MPPT solar inverter is used in this power converter to feed the power into the grid (24). This continuously senses available RPM & Torque at the turbine and set power output limit using the power control limiter (28). Further, a close loop control is implemented to control an output power by deploying the Modbus Rs485 controller (27) and the power control limiter (28).
[0061] A source for power is mechanical input i.e., torque sensor & RPM sensor. Both these quantity are sensed & computation operation done to get available instantaneous power. This power is then used to set a current reference point for actual electric power limit which is fed into the grid (24). The proposed turbo-generator system (1) starts with heat input from steel plant for getting heat input and the liquid flows with the phase change unit (4) & results into rotation of the turbine. The main solid state relay (26) is used to isolate the grid (24) from turbo-generator system (1) output. Once the turbine RPM reaches to rated RPM, the

solid state relay (24) is operated and the solar PV inverter (23) is synchronized with the grid (24).
[0062] FIG. 5 illustrates a 3D view of the turbine, according to embodiments as disclosed herein. Example Volatile Organic Compounds (VOC) reading of the PM generator (18) recorded in the lab is indicated in the table 1 below.

S. No. RPM Voc-AC-RMS
1 0 0
2 497 13.14
3 1003 25.18
4 1497 36.7
5 2000 51
6 2500 63
7 3000 76
8 3500 89
9 4200 103
10 8400 208
11 12600 311
12 16800 415
Table 1
[0063] FIG. 6 is a flow chart illustrating a method for generating electricity in
an organic Rankine cycle engine, according to embodiments as disclosed herein.
[0064] The method starts at 602. Once the system started, electrical parameters
are being checked for 2 mins, such as Line voltage, Line frequency & Unbalance
voltage are within prescribed limits or not. For example, at start it is checked
whether Valve V1, V2=OFF, Valve V3=ON. If everything is in specified range
then at 604, Hot Source Temperature (H_T) & Flow rate (H_F) & Cold Source
Temperature (C_T) & Cold Source flow rate (C_F). These four parameters are
being verified. For example, the four parameters are being verified to check
whether C_T<= 25 & H_T>=92 & C_F>=18m3/hr & H_F>=11m3/hr.
[0065] The turbo-generator system (1) checks this
condition for 2 minutes & if satisfied, turns VFD on as shown at 606. Once these

the four parameters are satisfied, Turn ON command is given to feed pump via
controller. The pump is controlled with variable frequency drive & speed is
controlled by a PID loop with mathematically derived reference point.
[0066] At 608 and 610, the turbo-generator system (1) starts a PI loop for VFD
with respect to flow, i.e. VFD frequency should be adjusted with reference to
settled flow of 2.2m3/hr (Flow_SP), where set point is settled 2.2m3/hr & Actual
flow is sensed from flow_SP meter.
[0067] At 612, Switch between Valves >IF difference between (Settled flow –
Actual flow) is <=0.1 then the control system turns ON Valve V1, V2 & turns
OFF Valve V3.
[0068] At 614, PID for V2 >Once V2 is fully on, the engine puts V2 in PID loop,
position of V2 will be changed with respect to pressure of set
point 1.2 Bar. This is mentioned as P3. i.e. % opening position of valve should
be controlled in a PID with set pressure of 1.2 bar.
[0069] At 616, Turn on Power Relay >Once error between (Pressure set point –
Actual pressure) <=0.1 Bar & RPM reached to 16500 RPM
& CN_O_T (temperature) <=30 deg & P<=1.1 bar. Check this for 2 mins. If
satisfied, turn on Relay (DO) as shown at 618.
[0070] Once PID loop is settled & Temperature, Pressure of circulating fluid is
achieved by pump, set points are mainly settled to achieve superheating &
ensuring 100% vapor state. The valves are switched here. For example, bypass
valve is closed & turbine main valve is opened, turbine starts rotation by this
time & hence generator also rotates resulting in voltage generation. Once Valve
switching is done, Pressure control valve is operated in PID loop to control back
pressure of turbine as per inlet flow rate turbine is expected to reach 16800 RPM
which is rated RPM @ 440VAC. Once the system achieves rated RPM, power
contactor is turned on & generated voltage is fed to AC/DC converter & inverter
control system for power export.
[0071] If any of above condition not met system should be OFF, i.e. VFD Input
DO should be OFF. If RPM recorded above 17000 RPM, system Power Relay
DO should be OFF.

[0072] FIG. 7 is a block diagram of an example organic Rankine cycle engine, according to embodiments as disclosed herein. Example application of the proposed turbo-generator system (1) using organic Rankine cycle engine. [0073] The organic Rankine cycle engine (700) includes a radial inflow turbine (702), a radial flux permanent magnet generator (704), a cooling tower (706), a condenser (708), a storage tank (710), a gate valve (712), a drain valve (714), an ORC feed pump (716), a ball valve (718), and an evaporator (720). In another embodiment, in the Rankine cycle engine (700), a radial inflow turbine (702) is directly coupled with a radial flux permanent magnet generator (704) at 16,800 RPM. The high RPM direct coupled system increases the overall efficiency & reduces the size due to lower torque requirement. The smaller size results in reduction in manufacturing cost for the turbine (702). The proposed invention results in considerable amount of efficiency improvement of overall cycle. Above mentioned is overall control strategy for presently invented system. The overall cycle operation is carried with Programmable logic controller, this system starts with auto sensing of all parameters from the various sensors such as Pressure, Temperature, & flow meter. The design of the cycle control strategy for low grade waste heat is used in the power generation using a high RPM permanent magnet generator.
[0074] The ORC feed pump (716) pumps the ORC fluid from a low pressure to a high pressure at required flow rate with the help of VFD. The evaporator (720) converts the high pressure liquid ORC fluid to high pressure vapour with the help of high temperature waste heat source. The high pressure vapour drives the turbine (702) coupled to the generator (704), so as to produce an electrical power output. The condenser (708) condenses the low pressure vapour from the turbine (702) to liquid phase by exchanging the heat with the cooling water supply from the cooling tower (706). The storage tank (710) stores the ORC fluid in liquid phase at low temperature. The range and unit of the flow meter (F1-F3), pressure sensor (P1-P4), RPM sensor (RS), temperature sensor (T1-T7) and Level transducer (LT) indicated in the below table 2:

INST Range Unit
F1 0-20 M3/hr
F2 0-20 M3/hr
F3 0-10 M3/hr
P1 0-6 bar
P2 0-6 bar
P3 0-6 bar
P4 0-6 bar
RS 0-20000 RPM
T1 0-150 Degree Celsius
T2 0-150 Degree Celsius
T3 0-100 Degree Celsius
T4 0-150 Degree Celsius
T5 0-150 Degree Celsius
T6 0-150 Degree Celsius
T7 0-150 Degree Celsius
LT Level tra nsducer
Table 2
[0075] The embodiments disclosed herein can be implemented through at least one software program running on at least one hardware device and performing network management functions to control the elements.
[0076] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of

preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
[0077] List to reference numerals:

Sr. No. Description
1 turbo-generator system
2 storage tank
3 evaporator and heater system
4 phase change unit
5 turbo charger
6 phase retainer unit
7 condenser
8 hot source inlet
9 hot source outlet
10 cooling source inlet
11 cooling source outlet
12 volute casing
13 impeller
14 rubber gasket
15 stator
16 teflon gasket
17 generator shaft
18 generator
19 shaft seal
20 bearing
21 bearing end cover
22 AC-DC converter
23 solar grid tie inverter
24 grid
25 LC filter

26 solid state relay
27 modbus Rs485 controller
28 power control limiter
700 organic Rankine cycle engine
702 radial inflow turbine
704 radial flux permanent magnet generator
706 cooling tower
708 condenser
710 storage tank
712 gate valve
714 drain valve
716 ORC feed pump
718 ball valve
720 evaporator

We Claim:
1. A turbo-generator system (1) for generating power, wherein the turbo-generator
system (1) comprises:
a storage tank (2) comprising liquid;
an evaporator and heater system (3);
a phase change unit (4) connected to the storage tank (2) and the evaporator and heater system (3), wherein the phase change unit (4) receive waste from a waste source, extract heat from the waste using the evaporator and heater system (3), receive the liquid from the storage tank (2), and convert the liquid into a high pressure vapor based on the extracted heat from the waste evaporator and heater system (3);
a turbo charger (5) connected to the phase change unit (4), wherein the turbo charger (5) receives the high-pressure vapor from the phase change unit (4) and generates the electricity from the high-pressure vapor; and
a phase retainer unit (6) connected to the turbo charger (5) and a condenser (7), wherein the phase retainer unit (6) convert the high pressure vapor received from the turbo charger (5) back to the liquid and store the converted liquid in the storage tank (2) using the condenser (7).
2. The turbo-generator system (1) as claimed in claim 1, wherein said turbo¬
generator system configured to generate the electricity from the high-pressure
vapor comprises:
extract kinetic and potential energy from the high-pressure vapor received from the phase change unit (4), and
generate the electricity based on the extracted kinetic and potential energy.
3. The turbo-generator system (1) as claimed in claim 1, wherein the phase change
unit (4) comprises four channels in which a first channel takes input waste from
the waste heat source, a second channel takes input from the first channel, a third
channel takes input for liquid from the storage tank (2), and a fourth channel
provide an output of the phase change unit (4) to the turbo charger (5) as prime
mover.

4. The turbo-generator system (1) as claimed in claim 1, wherein the turbo
generator (5) comprises:
a volute casing (12),
an impeller (13),
a rubber gasket (14), wherein the volute casing (12), impeller (13), and rubber gasket (14) forms the turbine,
a stator (15), wherein the liquid is accelerated through the volute casing (12) to reach the highest velocity and through the stator (15) the high velocity liquid;
a teflon gasket (16),
a generator shaft (17),
a generator (18) connected to the turbine using the generator shaft (17), wherein the generator (18) rotates the generator shaft (17) to extracts kinetic and potential energy from the high pressure vapor received from the evaporator and heater system (3) and generates the electricity.
5. The turbo-generator system (1) as claimed in claim 1, wherein the turbo¬
generator system (1) comprises:
integration of a solar grid tie inverter (23) for waste heat to electricity is applied with modified control mechanism for generating electricity and feeding to grid, an AC-DC converter (22) connected to the generator (18) to receive a high frequency AC power generated by the generator (18) and convert the high frequency AC power into a DC power; and
a solar grid tie inverter (23) is controlled with reference to waste heat to feed the DC power back to a grid (24) of a waste heat recovery application.
6. The turbo-generator system (1) as claimed in claim 1, wherein the liquid has a boiling point of 34 degree Celsius at 1 bar pressure and 90-degree boiling point at 4.55 bar (G) pressure.
7. A turbo generator (5) for generating power, wherein the turbo generator (5) comprises:

a volute casing (12),
an impeller (13),
a rubber gasket (14), wherein the volute casing (12), impeller (13), and rubber gasket (14) forms a turbine,
a stator (15), wherein the liquid is accelerated through the volute casing (12) to reach the highest velocity and through the stator (15) the high velocity liquid;
a Teflon gasket (16),
a generator shaft (17),
a generator (18) connected to the turbine using the generator shaft (17), wherein the generator (18) receives a high pressure vapor from a turbo-generator system (1), and rotates the generator shaft (17) to extracts kinetic and potential energy from the high pressure vapor received to generate the electricity.
8. The turbo charger (5) as claimed in claim 7, wherein the generator (18) is a radial flux permanent magnet rotating at 16800 rotations per minute (rpm).
9. A method for generating power by a turbo-generator system (1), wherein the method comprises:
receiving, by a phase change unit (4), waste from a waste source, wherein the phase change unit (4) is connected to a storage tank (2) and an evaporator and heater system (3);
extracting, by the phase change unit (4), heat from the waste using the evaporator and heater system (3);
receiving, by the phase change unit (4), the liquid from the storage tank (2);
converting, by the phase change unit (4), the liquid into a high-pressure vapor based on the extracted heat from the waste evaporator and heater system (3);
receiving, by a turbo charger (5), the high-pressure vapor from the phase change unit (4);
generating, by the turbo charger (5), the electricity from the high-pressure vapor;

converting, by a phase retainer unit (6), the high-pressure vapor received from the turbo charger (5) back to the liquid, wherein the phase retainer unit (6) is connected to the turbo charger (5) and a condenser (7); and
storing, by the phase retainer unit (6), the converted liquid in the storage tank (2) using the condenser (7).
10. The method as claimed in claim 9, wherein generating the electricity from the
high-pressure vapor comprises:
extracting kinetic and potential energy from the high-pressure vapor received from the phase change unit (4), and
generating the electricity based on the extracted kinetic and potential energy.
11. The method as claimed in claim 9, wherein the turbo charger (5) is formed by:
providing a volute casing (12),
providing an impeller (13),
providing a rubber gasket (14), wherein the volute casing (12), impeller (13), and rubber gasket (14) forms the turbine,
providing a stator (15), wherein the liquid is accelerated through the volute casing (12) to reach the highest velocity and through the stator (15) the high velocity liquid,
providing a Teflon gasket (16),
providing a generator shaft (17),
connecting a generator (18) to the turbine using the generator shaft (17), wherein the generator (18) rotates the generator shaft (17) to extracts kinetic and potential energy from the high pressure vapor received from the evaporator and heater system (3) and generates the electricity.
12. The method as claimed in claim 9, wherein the method comprises:
integration of a solar grid tie inverter (23) for waste heat to electricity is applied with modified control mechanism for generating electricity and feeding to grid, an AC-DC converter (22), a high frequency AC power generated by the

generator (18), wherein the AC-DC converter (22) is connected to the generator (18);
converting, by the AC-DC converter (22), the high frequency AC power into a DC power; and
feeding, by a solar grid tie inverter (23), the DC power back to a grid (24) of a waste heat recovery application.
13. The method as claimed in claim 9, wherein the liquid has a boiling point of 34 degree Celsius at 1 bar pressure and 90-degree boiling point at 4.55 Bar(G) Pressure.
14. A method for generating electricity using a turbo charger (5), wherein the method comprises:
providing a volute casing (12);
providing an impeller (13);
providing a rubber gasket (14), wherein the volute casing (12), impeller (13), and rubber gasket (14) forms the turbine;
providing a stator (15), wherein the liquid is accelerated through the volute casing (12) to reach the highest velocity and through the stator (15) the high velocity liquid;
providing a teflon gasket (16);
providing a generator shaft (17); and
connecting a generator (18) to the turbine using the generator shaft (17), wherein the generator (18) receives a high pressure vapor from a turbo-generator system (1), and rotates the generator shaft (17) to extracts kinetic and potential energy from the high pressure vapor received to generate the electricity.
15. The method as claimed in claim 14, wherein the generator (18) is a radial flux permanent magnet rotating at 16800 rotations per minute (rpm).
16. The method as claimed in claim 14, wherein the method comprises:

receiving, by an AC-DC converter (22), a high frequency AC power generated by the generator (18), wherein the AC-DC converter (22) is connected to the generator (18);
converting, by the AC-DC converter (22), the high frequency AC power into a DC power; and
feeding, by a solar grid tie inverter (23), the DC power back to a grid (24) of a waste heat recovery application.
17. A radial inflow turbine-based turbo-generator system (1) for generating
electricity, wherein the turbo-generator system (1) comprises:
a generator (18) receives a high pressure vapor from the turbo-generator system (1), and rotates a generator shaft (17) to extracts kinetic and potential energy from the high pressure vapor received to generate a high frequency AC power;
a AC-DC converter (22), connected to the generator (18), to receive the high frequency AC power generated by the generator (18) and convert the high frequency AC power into a DC power; and
a solar grid tie inverter (23) to feed the DC power back to a grid (24) of a waste heat recovery application.
18. The turbo-generator system (1) as claimed in claim 17, comprises a LC filter (25), connected between the AC-DC converter (22) and the solar grid tie inverter (23), to receives the DC power from the AC-DC converter (22) to cut or pass specific frequency bands of an electric signal.
19. The turbo-generator system (1) as claimed in claim 17, comprises a power controller (28) to limit control an output power, said power Controller works on Feedback loop by taking RPM as reference point and control output power of solar grid connected inverter as per maximum power available.
20. The turbo-generator system (1) as claimed in claim 17, wherein the high frequency AC power is generating by:

determining whether electrical parameters is in a predefined range; determining that a Hot Source Temperature (H_T), a Flow rate (H_F), a Cold Source Temperature (C_T = T3), & a Cold Source flow rate (C_F = F2) is in a specified range in response to determining that the electrical parameters is in the predefined range;
turning a feed pump (726) on by sending a command;
detecting that a PID loop is settled & Temperature, Pressure of circulating fluid is achieved by pump;
switching off a Bypass valve & switching on a turbine valve to rotate the turbine which in turn rotates the generator (18) resulting in generation of the high frequency AC power.
21. A method for generating electricity using radial inflow turbine-based turbo¬
generator system (1), wherein the method comprises:
receiving, by a generator (18), a high pressure vapor from the turbo¬generator system (1);
generating, by the generator (18), a high frequency AC power by rotating a generator shaft (17) to extracts kinetic and potential energy from the high-pressure vapor;
receiving, by a AC-DC converter (22) connected to the generator (18), the high frequency AC power generated by the generator (18) and converting the high frequency AC power into a DC power; and
feeding, by a solar grid tie inverter (23), DC power back to a grid (24) of a waste heat recovery application.
22. The method as claimed in claim 21, comprises receiving, by a LC filter (25) connected between the AC-DC converter (22) and the solar grid tie inverter (23), the DC power from the AC-DC converter (22) to cut or pass specific frequency bands of an electric signal.
23. The method as claimed in claim 21, The turbo-generator system (1) as claimed in claim 37, comprises a power control limiter (28) to limit control an output

power. This Power Controller works on Feedback loop by taking RPM as reference point & control output power of solar grid connected inverter as per maximum power available.
24. The method as claimed in claim 21, wherein generating the high frequency AC power comprises:
determining whether electrical parameters is in a predefined range; determining that a Hot Source Temperature (H_T), a Flow rate (H_F), a Cold Source Temperature (C_T), & a Cold Source flow rate (C_F) is in a specified range in response to determining that the electrical parameters is in the predefined range;
turning a feed pump (726) on by sending a command;
detecting that a PID loop is settled & Temperature, Pressure of circulating fluid is achieved by pump;
switching off a Bypass valve & switching on a turbine valve to rotate the turbine which in turn rotates the generator (18) resulting in generation of the high frequency AC power.