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Integrated working fluid-thermodynamic cycle design of organic Rankine cycle power systems for waste heat recovery

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  • Cignitti, Stefano
  • Andreasen, Jesper G.
  • Haglind, Fredrik
  • Woodley, John M.
  • Abildskov, Jens

Abstract

Today, some established working fluids are being phased out due to new international regulations on the use of environmentally harmful substances. With an ever-increasing cost to resources, industry wants to converge on improved sustainability through resource recovery, and in particular waste heat recovery. In this paper, an organic Rankine cycle process and its pure working fluid are designed simultaneously for waste heat recovery of the exhaust gas from a marine diesel engine. This approach can overcome design issues caused by the high sensitivity between the fluid and cycle design variables and otherwise high resource demands, which through conventional methods cannot be addressed. The global optimal design was a 1.2MW cycle with 2,2,3,3,4,4,5,5-octafluorohexane as the new fluid. The fluid has no ozone depletion potential and a global warming potential under the regulatory limit. By using the simultaneous design approach the optimum solution was found in 5.04s, while a decomposed approach found the same solution in 5.77h. However, the decomposed approach provided insights on the correlation between the fluid and cycle design variables by analyzing all possible solutions. It was shown that the high sensitivity between the fluid and cycle design variables was overcome by using the simultaneous approach. Correlation between net power output and the product of the overall heat transfer coefficient and the heat transfer area could further be addressed by employing a new solution strategy including maximum constraints for this product. The use of such constraints resulted in the design of a new fluid (5-chloro-4,5,5-trifluoro-2,3-dimethylpent-2-ene) with a 1.25MW net power output. Finally, a comparison with conventional fluids was shown where 2,2,3,3,4,4,5,5-octafluorohexane offered an improvement on net power output and economic and environmental metrics.

Suggested Citation

  • Cignitti, Stefano & Andreasen, Jesper G. & Haglind, Fredrik & Woodley, John M. & Abildskov, Jens, 2017. "Integrated working fluid-thermodynamic cycle design of organic Rankine cycle power systems for waste heat recovery," Applied Energy, Elsevier, vol. 203(C), pages 442-453.
  • Handle: RePEc:eee:appene:v:203:y:2017:i:c:p:442-453
    DOI: 10.1016/j.apenergy.2017.06.031
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    2. White, M.T. & Oyewunmi, O.A. & Chatzopoulou, M.A. & Pantaleo, A.M. & Haslam, A.J. & Markides, C.N., 2018. "Computer-aided working-fluid design, thermodynamic optimisation and thermoeconomic assessment of ORC systems for waste-heat recovery," Energy, Elsevier, vol. 161(C), pages 1181-1198.
    3. Jesper Graa Andreasen & Martin Ryhl Kærn & Fredrik Haglind, 2019. "Assessment of Methods for Performance Comparison of Pure and Zeotropic Working Fluids for Organic Rankine Cycle Power Systems," Energies, MDPI, vol. 12(9), pages 1-25, May.
    4. Li, Xiaoya & Xu, Bin & Tian, Hua & Shu, Gequn, 2021. "Towards a novel holistic design of organic Rankine cycle (ORC) systems operating under heat source fluctuations and intermittency," Renewable and Sustainable Energy Reviews, Elsevier, vol. 147(C).
    5. Wang, Enhua & Mao, Jingwen & Zhang, Bo & Wang, Yongzhen, 2023. "On the CAMD method based on PC-SAFT for working fluid design of a high-temperature organic Rankine cycle," Energy, Elsevier, vol. 263(PD).
    6. Fanxiao, Meng & Enhua, Wang & Bo, Zhang, 2021. "Possibility of optimal efficiency prediction of an organic Rankine cycle based on molecular property method for high-temperature exhaust gases," Energy, Elsevier, vol. 222(C).
    7. Zhang, Zhaoli & Alelyani, Sami M. & Zhang, Nan & Zeng, Chao & Yuan, Yanping & Phelan, Patrick E., 2018. "Thermodynamic analysis of a novel sodium hydroxide-water solution absorption refrigeration, heating and power system for low-temperature heat sources," Applied Energy, Elsevier, vol. 222(C), pages 1-12.
    8. Schilling, J. & Entrup, M. & Hopp, M. & Gross, J. & Bardow, A., 2021. "Towards optimal mixtures of working fluids: Integrated design of processes and mixtures for Organic Rankine Cycles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 135(C).
    9. Siddiqui, Muhammad Ehtisham & Almatrafi, Eydhah & Bamasag, Ahmad & Saeed, Usman, 2022. "Adoption of CO2-based binary mixture to operate transcritical Rankine cycle in warm regions," Renewable Energy, Elsevier, vol. 199(C), pages 1372-1380.
    10. Moreira, L.F. & Arrieta, F.R.P., 2019. "Thermal and economic assessment of organic Rankine cycles for waste heat recovery in cement plants," Renewable and Sustainable Energy Reviews, Elsevier, vol. 114(C), pages 1-1.
    11. Geertsma, R.D. & Visser, K. & Negenborn, R.R., 2018. "Adaptive pitch control for ships with diesel mechanical and hybrid propulsion," Applied Energy, Elsevier, vol. 228(C), pages 2490-2509.
    12. van Kleef, Luuk M.T. & Oyewunmi, Oyeniyi A. & Markides, Christos N., 2019. "Multi-objective thermo-economic optimization of organic Rankine cycle (ORC) power systems in waste-heat recovery applications using computer-aided molecular design techniques," Applied Energy, Elsevier, vol. 251(C), pages 1-1.
    13. Martin T. White & Abdulnaser I. Sayma, 2018. "A Generalised Assessment of Working Fluids and Radial Turbines for Non-Recuperated Subcritical Organic Rankine Cycles," Energies, MDPI, vol. 11(4), pages 1-26, March.
    14. Zhang, Bo & Wang, Enhua & Meng, Fanxiao & Zhang, Fujun & Zhao, Changlu, 2020. "Prediction accuracy of thermodynamic properties using PC-SAFT for high-temperature organic Rankine cycle with siloxanes," Energy, Elsevier, vol. 204(C).
    15. Yang, Can & Wang, Weiye & Xie, Hui, 2019. "An efficiency model and optimal control of the vehicular diesel exhaust heat recovery system using an organic Rankine cycle," Energy, Elsevier, vol. 171(C), pages 547-555.

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