General integration method for system configuration of organic Rankine cycle based on stage-wise concept

Organic Rankine Cycle (ORC) integrated systems with heat sources consist of heat exchange processes and thermodynamic power conversion processes. Fully exploring feasible system configuration while considering fluid selection is crucial for enhancing ORC power generation and balancing economic costs. This study innovatively proposes a theoretical framework that decomposes the Rankine cycle into basic thermodynamic processes. The design of system configuration is regarded as the adjustment of the series-parallel relationships of these basic processes, aiming to achieve simultaneous optimization of the cycle structure and the HEN structure, thereby greatly expanded the search space for feasible ORC system configurations. The optimization problem is solved using a bi-level strategy, The outer layer determines the number of thermal power conversion components, operating parameters, and working fluid selection, then provides the associated stream information to the inner layer for optimizing the heat exchange scheme. Applying this method to two different case studies from the literature validated its effectiveness in optimizing scenarios with single and complex heat sources. The Pareto frontier obtained under the conditions of Case I indicates that the investment cost can be reduced by $33.04 k/yr while maintaining the same net power output. In exchange for an increase of $1.51 k/yr in investment cost, the maximum net power output can be improved by 124.74 kW. Under the conditions of Case II, the maximum net output power can increase by 9.71 %–52.5 %, and the Pareto frontier featuring outputs exceeding 50 kW is provided. By analyzing the relative positions of literature schemes and Pareto front within the solution space, the impact of system configuration improvements on the objective functions is explained. These results confirm the effectiveness of the proposed approach for designing optimal ORC energy recovery systems for heat sources. This contribution advances optimization methods for similar closed cycle configurations, which is significant for advancing the utilization of waste heat and addressing sustainability challenges.