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Method for customizing an organic Rankine cycle to a complex heat source for efficient energy conversion, demonstrated on a Fischer Tropsch plant

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  • DiGenova, Kevin J.
  • Botros, Barbara B.
  • Brisson, J.G.

Abstract

Organic Rankine cycles (ORCs) provide an alternative to traditional steam Rankine cycles for the conversion of low grade heat sources into power, where conventional steam power cycles are known to be inefficient. A large processing plant often has multiple low temperature waste heat streams available for conversion to electricity by a low temperature cycle, resulting in a composite heat source with a complex temperature–enthalpy profile. This work presents a set of ORC design concepts: reheat stages, multiple pressure levels, and balanced recuperators; and demonstrates the use of these design concepts as building blocks to create a customized cycle that matches an available heat source. Organic fluids are modeled using a pure substance database. The pinch analysis technique of forming composite curves is applied to analyze the effect of each building block on the temperature–enthalpy profile of the ORC heat requirement. The customized cycle is demonstrated on a heat source derived from a Fischer Tropsch reactor and its associated processes. Analysis shows a steam Rankine cycle can achieve a 20.6% conversion efficiency for this heat source, whereas a simple organic Rankine cycle using hexane as the working fluid can achieve a 20.9% conversion efficiency. If the ORC building blocks are combined into a cycle targeted to match the temperature–enthalpy profile of the heat source, this customized ORC can achieve 28.5% conversion efficiency.

Suggested Citation

  • DiGenova, Kevin J. & Botros, Barbara B. & Brisson, J.G., 2013. "Method for customizing an organic Rankine cycle to a complex heat source for efficient energy conversion, demonstrated on a Fischer Tropsch plant," Applied Energy, Elsevier, vol. 102(C), pages 746-754.
    • Handle: RePEc:eee:appene:v:102:y:2013:i:c:p:746-754
    DOI: 10.1016/j.apenergy.2012.08.029
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    1. Quoilin, Sylvain & Aumann, Richard & Grill, Andreas & Schuster, Andreas & Lemort, Vincent & Spliethoff, Hartmut, 2011. "Dynamic modeling and optimal control strategy of waste heat recovery Organic Rankine Cycles," Applied Energy, Elsevier, vol. 88(6), pages 2183-2190, June.
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    1. Lecompte, S. & Huisseune, H. & van den Broek, M. & De Paepe, M., 2015. "Methodical thermodynamic analysis and regression models of organic Rankine cycle architectures for waste heat recovery," Energy, Elsevier, vol. 87(C), pages 60-76.
    2. Li, Jian & Peng, Xiayao & Yang, Zhen & Hu, Shuozhuo & Duan, Yuanyuan, 2022. "Design, improvements and applications of dual-pressure evaporation organic Rankine cycles: A review," Applied Energy, Elsevier, vol. 311(C).
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    5. Tańczuk, Mariusz & Ulbrich, Roman, 2013. "Implementation of a biomass-fired co-generation plant supplied with an ORC (Organic Rankine Cycle) as a heat source for small scale heat distribution system – A comparative analysis under Polish and G," Energy, Elsevier, vol. 62(C), pages 132-141.
    6. Zhang, Xinxin & Kobayashi, Noriyuki & He, Maogang & Wang, Jingfu, 2016. "An organic group contribution approach to radiative efficiency estimation of organic working fluid," Applied Energy, Elsevier, vol. 162(C), pages 1205-1210.
    7. Liu, Peng & Shu, Gequn & Tian, Hua, 2019. "How to approach optimal practical Organic Rankine cycle (OP-ORC) by configuration modification for diesel engine waste heat recovery," Energy, Elsevier, vol. 174(C), pages 543-552.
    8. Li, Jian & Ge, Zhong & Duan, Yuanyuan & Yang, Zhen & Liu, Qiang, 2018. "Parametric optimization and thermodynamic performance comparison of single-pressure and dual-pressure evaporation organic Rankine cycles," Applied Energy, Elsevier, vol. 217(C), pages 409-421.
    9. Yu, Haoshui & Feng, Xiao & Wang, Yufei & Biegler, Lorenz T. & Eason, John, 2016. "A systematic method to customize an efficient organic Rankine cycle (ORC) to recover waste heat in refineries," Applied Energy, Elsevier, vol. 179(C), pages 302-315.
    10. Kwak, Dong-Hun & Binns, Michael & Kim, Jin-Kuk, 2014. "Integrated design and optimization of technologies for utilizing low grade heat in process industries," Applied Energy, Elsevier, vol. 131(C), pages 307-322.
    11. Kermani, Maziar & Wallerand, Anna S. & Kantor, Ivan D. & Maréchal, François, 2018. "Generic superstructure synthesis of organic Rankine cycles for waste heat recovery in industrial processes," Applied Energy, Elsevier, vol. 212(C), pages 1203-1225.
    12. Stijepovic, Mirko Z. & Papadopoulos, Athanasios I. & Linke, Patrick & Grujic, Aleksandar S. & Seferlis, Panos, 2014. "An exergy composite curves approach for the design of optimum multi-pressure organic Rankine cycle processes," Energy, Elsevier, vol. 69(C), pages 285-298.
    13. Zhao, Li & Bao, Junjiang, 2014. "Thermodynamic analysis of organic Rankine cycle using zeotropic mixtures," Applied Energy, Elsevier, vol. 130(C), pages 748-756.
    14. Ding, Mingyue & Yang, Yong & Wu, Baoshan & Li, Yongwang & Wang, Tiejun & Ma, Longlong, 2015. "Study on reduction and carburization behaviors of iron phases for iron-based Fischer–Tropsch synthesis catalyst," Applied Energy, Elsevier, vol. 160(C), pages 982-989.
    15. Patrick Linke & Athanasios I. Papadopoulos & Panos Seferlis, 2015. "Systematic Methods for Working Fluid Selection and the Design, Integration and Control of Organic Rankine Cycles—A Review," Energies, MDPI, vol. 8(6), pages 1-47, May.
    16. Ding, Yuxing & Liu, Yurong & Wang, Meihong & Du, Wenli & Qian, Feng, 2024. "Heat integration, simultaneous structure and parameter optimisation, and techno-economic evaluation of waste heat recovery systems for petrochemical industry," Energy, Elsevier, vol. 296(C).

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