Thermodynamic, economic, and carbon emission evaluation of various Organic Rankine cycle configurations for maximizing waste heat recovery potential
Waste heat recovery using the Organic Rankine Cycle (ORC) enhances energy efficiency, lowers emissions, and reduces costs. This study evaluates ORC systems for high-temperature waste heat recovery (515.14 °C) using DWSIM software. Various ORC configurations, including simple ORC (sORC), series ORC (...
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Elsevier
2025-04-01
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| Series: | Energy Conversion and Management: X |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590174525000753 |
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| author | Thepparat Klamrassamee Tanatip Kittijungjit Yanin Sukjai Yossapong Laoonual |
| author_facet | Thepparat Klamrassamee Tanatip Kittijungjit Yanin Sukjai Yossapong Laoonual |
| author_sort | Thepparat Klamrassamee |
| collection | DOAJ |
| description | Waste heat recovery using the Organic Rankine Cycle (ORC) enhances energy efficiency, lowers emissions, and reduces costs. This study evaluates ORC systems for high-temperature waste heat recovery (515.14 °C) using DWSIM software. Various ORC configurations, including simple ORC (sORC), series ORC (S-ORC), single-stage regenerative ORC (SR-ORC), double-stage regenerative ORC (DR-ORC), and multi-evaporating pressure ORC (ME-ORC), were analyzed with different working fluids, including Toluene, Dodecane, Benzene, and Cyclopentane. Toluene was identified as the best working fluid, achieving a thermal efficiency of 24.33 % and a net power output of 1,839.66 kW in the sORC. The S-ORC demonstrated superior performance, delivering 3,679.32 kW of net power at the same efficiency. A parametric study examined the effects of operating pressure, exhaust gas temperature, and mass flow rate on efficiency. Results showed thermal efficiency peaked at 40.08 bar, with optimal performance at an exhaust gas temperature of 520 °C and a mass flow rate of 44.5 kg/s. Exergy analysis identified the evaporator as the main source of inefficiency, highlighting opportunities for improvement to boost overall system efficiency. Economically, the S-ORC achieved a Net Present Value (NPV) of 3.98 million EUR, a payback period of 5.75 years, and an Internal Rate of Return (IRR) of 12.66 %. It also reduced CO2 emissions by 12,971.36 metric tons annually, translating to 1.04 million EUR in revenue through carbon credit trading under the EU ETS. In summary, the S-ORC configuration offers the best balance of thermodynamic, economic, and environmental benefits for industrial waste heat recovery systems. |
| format | Article |
| id | doaj-art-b5cddccaa96e4d18815a837d4a470a1f |
| institution | Kabale University |
| issn | 2590-1745 |
| language | English |
| publishDate | 2025-04-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Energy Conversion and Management: X |
| spelling | doaj-art-b5cddccaa96e4d18815a837d4a470a1f2025-08-20T03:49:41ZengElsevierEnergy Conversion and Management: X2590-17452025-04-012610094310.1016/j.ecmx.2025.100943Thermodynamic, economic, and carbon emission evaluation of various Organic Rankine cycle configurations for maximizing waste heat recovery potentialThepparat Klamrassamee0Tanatip Kittijungjit1Yanin Sukjai2Yossapong Laoonual3Mobility & Vehicle Technology Research Center (MOVE), King Mongkut’s University of Technology Thonburi, Bangkok, ThailandDepartment of Mechanical Engineering, Faculty of Engineering, King Mongkut’s University of Technology Thonburi, Bangkok, ThailandDepartment of Mechanical Engineering, Faculty of Engineering, King Mongkut’s University of Technology Thonburi, Bangkok, Thailand; Corresponding author at: Department of Mechanical Engineering, Faculty of Engineering, King Mongkut’s University of Technology Thonburi, 126 Pracha Uthit Road, Bang Mod, Thung Khru, Bangkok 10140, Thailand.Department of Mechanical Engineering, Faculty of Engineering, King Mongkut’s University of Technology Thonburi, Bangkok, Thailand; Mobility & Vehicle Technology Research Center (MOVE), King Mongkut’s University of Technology Thonburi, Bangkok, ThailandWaste heat recovery using the Organic Rankine Cycle (ORC) enhances energy efficiency, lowers emissions, and reduces costs. This study evaluates ORC systems for high-temperature waste heat recovery (515.14 °C) using DWSIM software. Various ORC configurations, including simple ORC (sORC), series ORC (S-ORC), single-stage regenerative ORC (SR-ORC), double-stage regenerative ORC (DR-ORC), and multi-evaporating pressure ORC (ME-ORC), were analyzed with different working fluids, including Toluene, Dodecane, Benzene, and Cyclopentane. Toluene was identified as the best working fluid, achieving a thermal efficiency of 24.33 % and a net power output of 1,839.66 kW in the sORC. The S-ORC demonstrated superior performance, delivering 3,679.32 kW of net power at the same efficiency. A parametric study examined the effects of operating pressure, exhaust gas temperature, and mass flow rate on efficiency. Results showed thermal efficiency peaked at 40.08 bar, with optimal performance at an exhaust gas temperature of 520 °C and a mass flow rate of 44.5 kg/s. Exergy analysis identified the evaporator as the main source of inefficiency, highlighting opportunities for improvement to boost overall system efficiency. Economically, the S-ORC achieved a Net Present Value (NPV) of 3.98 million EUR, a payback period of 5.75 years, and an Internal Rate of Return (IRR) of 12.66 %. It also reduced CO2 emissions by 12,971.36 metric tons annually, translating to 1.04 million EUR in revenue through carbon credit trading under the EU ETS. In summary, the S-ORC configuration offers the best balance of thermodynamic, economic, and environmental benefits for industrial waste heat recovery systems.http://www.sciencedirect.com/science/article/pii/S2590174525000753Organic Rankine Cycle (ORC)Waste heat recoveryThermodynamicsEconomicsCarbon emission reduction |
| spellingShingle | Thepparat Klamrassamee Tanatip Kittijungjit Yanin Sukjai Yossapong Laoonual Thermodynamic, economic, and carbon emission evaluation of various Organic Rankine cycle configurations for maximizing waste heat recovery potential Energy Conversion and Management: X Organic Rankine Cycle (ORC) Waste heat recovery Thermodynamics Economics Carbon emission reduction |
| title | Thermodynamic, economic, and carbon emission evaluation of various Organic Rankine cycle configurations for maximizing waste heat recovery potential |
| title_full | Thermodynamic, economic, and carbon emission evaluation of various Organic Rankine cycle configurations for maximizing waste heat recovery potential |
| title_fullStr | Thermodynamic, economic, and carbon emission evaluation of various Organic Rankine cycle configurations for maximizing waste heat recovery potential |
| title_full_unstemmed | Thermodynamic, economic, and carbon emission evaluation of various Organic Rankine cycle configurations for maximizing waste heat recovery potential |
| title_short | Thermodynamic, economic, and carbon emission evaluation of various Organic Rankine cycle configurations for maximizing waste heat recovery potential |
| title_sort | thermodynamic economic and carbon emission evaluation of various organic rankine cycle configurations for maximizing waste heat recovery potential |
| topic | Organic Rankine Cycle (ORC) Waste heat recovery Thermodynamics Economics Carbon emission reduction |
| url | http://www.sciencedirect.com/science/article/pii/S2590174525000753 |
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