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Organic Rankine cycle (ORC) engines in waste-heat recovery applications experience variable heat-source conditions (i.e. temperature and mass flow-rate variations). Maximising ORC system performance while accounting for off-design operation in response to such variations is of crucial importance for the financial viability and wider adoption of this technology. In this paper, the off-design performance of an ORC engine is investigated in a heat-recovery application from a stationary internal combustion engine (ICE), employing a screw expander and two heat exchanger (HEX) architectures. Unlike previous studies where the ORC expander and HEX performance are assumed fixed during off-design operation, here we consider explicitly the time-varying characteristics of these system components. Nominal system sizing results indicate that the screw expander isentropic efficiency exceeds 80%, and that the heat transfer area requirements of plate HEXs (PHEXs) are 50% lower than those of double-pipe HEXs (DPHEX). Following nominal system design, the ORC engine operation is optimised at conditions relating to part-load (PL) operation of the ICE. Although, the heat transfer coefficients in the evaporator decrease by 30% at PL, the HEX effectiveness increases by up to 20% due to higher temperature differences between the working fluid and the heat source, and the performance of the PHEX appears less sensitive to off-design operation conditions. The optimum PL screw expander efficiency maps reveal only a minor reduction of the expander efficiency (by 2%) relative to the design conditions. Optimum off-design maps indicate that the power output of the ORC engine reduces to 72% of full-load for an ICE at 60% of full-load, and that ORC engines with PHEXs generate slightly more power for the same heat-source conditions. Overall, the tool developed predicts ORC performance over an operating envelope and allows the selection of optimal HEX and expander designs. The findings can be used by ORC plant operators to optimise the ORC engine power output given varying on-site heat-source conditions, and by ORC vendors to inform HEX and expander design decisions.

Organic Rankine cycle (ORC) engines often operate under variable heat-source conditions, so maximising performance at both nominal and off-design operation is crucial for the wider adoption of this technology. In this work, an off-design optimisation tool is developed and used to predict the impact of varying heat-source conditions on ORC operation. Unlike previous efforts where the performance of ORC engine components is assumed fixed, here we consider explicitly the time-varying operational characteristics of these components. A bottoming ORC system is first optimised for maximum power output when recovering heat from the exhaust gases of an internal-combustion engine (ICE) running at full load. A double-pipe heat exchanger (HEX) model is used for sizing the ORC evaporator and condenser, and a piston-expander model for sizing the expander. The ICE is then run at part-load, thus varying the temperature and mass flow rate of the exhaust gases. The tool predicts the new off-design heat transfer coefficients in the heat exchangers, and the new optimum expander operating points. Results reveal that the ORC engine power output is underestimated by up to 17% when the off-design operational characteristics of these components are not considered. In particular, the piston-expander isentropic efficiency increases at off-design operation by 10–16%, due to the reduced pressure ratio and flow rate in the system, while the evaporator effectiveness improves by up to 15%, due to the higher temperature difference across the HEX and a higher proportion of heat transfer taking place in the two-phase evaporating zone. As the ICE operates further away from its nominal point, the off-design ORC engine power output reduces by a lesser extent than that of the ICE. At an ICE part-load operation of 60% (by electrical power), the optimised ORC engine with fluids such as R1233zd operates at 77% of its nominal capacity. ORC off-design performance maps are generated, for characterising and predicting system performance, which can be used, along with the optimisation tool, by ORC system designers, manufacturers and plant operators to identify optimum performance under real operating conditions.

The wider adoption of organic Rankine cycle (ORC) technology for power generation or cogeneration from renewable or recovered waste-heat in many applications can be facilitated by improved thermodynamic performance, but also reduced investment costs. In this context, it is suggested that the further development of ORC power systems should be guided by combined thermoeconomic assessments that can capture directly the trade-offs between performace and cost with the aim of proposing solutions with high resource-use efficiency and, importantly, improved economic viability. This paper couples, for the first time, the computer-aided molecular design (CAMD) of the ORC working-fluid based on the statistical associating fluid theory (SAFT)-γ Mie equation of state with thermodynamic modelling and optimisation, in addition to heat-exchanger sizing models, component cost correlations and thermoeconomic assessments. The resulting CAMD-ORC framework presents a novel and powerful approach with extended capabilities that allows the thermodynamic optimisation of the ORC system and working fluid to be performed in a single step, thus removing subjective and pre-emptive screening criteria that exist in conventional approaches, while also extending to include cost considerations relating to the resulting optimal systems. Following validation, the proposed framework is used to identify optimal cycles and working fluids over a wide range of conditions characterised by three different heat-source cases with temperatures of 150 °C, 250 °C and 350 °C, corresponding to small- to medium-scale applications. In each case, the optimal combination of ORC system design and working fluid is identified, and the corresponding capital costs are evaluated. It is found that fluids with low specific-investment costs (SIC) are different to those that maximise the power output. The fluids with the lowest SIC are isoheptane, 2-pentene and 2-heptene, with SICs of £5620, £2760 and £2070 per kW respectively, and corresponding power outputs of 32.9 kW, 136.6 kW and 213.9 kW.

The successful commercialisation of organic Rankine cycle (ORC) systems across a range of power outputs and heat-source temperatures demands step-changes in both improved thermodynamic performance and reduced investment costs. The former can be achieved through high-performance components and optimised system architectures operating with novel working-fluids, whilst the latter requires careful component-technology selection, economies of scale, learning curves and a proper selection of materials and cycle configurations. In this context, thermoeconomic optimisation of the whole power-system should be completed aimed at maximising profitability. This paper couples the computer-aided molecular design (CAMD) of the working-fluid with ORC thermodynamic models, including recuperated and other alternative (e.g., partial evaporation or trilateral) cycles, and a thermoeconomic system assessment. The developed CAMD-ORC framework integrates an advanced molecular-based group-contribution equation of state, SAFT-γ Mie, with a thermodynamic description of the system, and is capable of simultaneously optimising the working-fluid structure, and the thermodynamic system. The advantage of the proposed CAMD-ORC methodology is that it removes subjective and pre-emptive screening criteria that would otherwise exist in conventional working-fluid selection studies. The framework is used to optimise hydrocarbon working-fluids for three different heat sources (150, 250 and 350 °C, each with mcp = 4.2 kW/K). In each case, the optimal combination of working-fluid and ORC system architecture is identified, and system investment costs are evaluated through component sizing models. It is observed that optimal working fluids that minimise the specific investment cost (SIC) are not the same as those that maximise power output. For the three heat sources the optimal working-fluids that minimise the SIC are isobutane, 2-pentene and 2-heptene, with SICs of 4.03, 2.22 and 1.84 £/W respectively.

Energy security, pollution and sustainability are major challenges presently facing the international community, in response to which increasing quantities of renewable energy are to be generated in the urban environment. Consequently, recent years have seen a strong increase in the uptake of solar technologies in the building sector. In this work, the potential of a solar combined heat and power (CHP) system based on an organic Rankine cycle (ORC) engine is investigated in a domestic setting. Unlike previous studies that focus on the optimisation of the ORC subsystem, this study performs a complete system optimisation considering both the design parameters of the solar collector array and the ORC engine simultaneously. Firstly, we present thermodynamic models of different collectors, including flat-plate and evacuated-tube designs, coupled to a non-recuperative sub-critical ORC architecture that delivers power and hot water by using thermal energy rejected from the engine. Optimisation of the complete system is first conducted, aimed at identifying operating conditions for which the power output is maximised. Then, hourly dynamic simulations of the optimised system configurations are performed to complete the system sizing. Results are presented of: (i) dynamic 3-D simulations of the solar collectors together with a thermal energy storage tank, and (ii) of an optimisation analysis to identify the most suitable working fluids for the ORC engine, in which the configuration and operational constraints of the collector array are considered. The best performing working fluids (R245fa and R1233zd) are then chosen for a whole-system annual simulation in a southern European climate. The system configuration combining an evacuated-tube collector array and an ORC engine is found to be best-suited for electricity prioritisation, delivering an electrical output of 3,605¿kWh/year from a 60¿m2 collector array. In addition, the system supplies 13,175¿kWh/year in the form of domestic hot water, which is equivalent to more than 6 times the average annual household demand. A brief cost analysis and comparison with photovoltaic (PV) systems is also performed, where despite the lower PV investment cost per kWel, the levelised energy costs of the different systems are found to be similar if the economic value of the thermal output is taken into account. Finally, a discussion of the modelled solar-CHP systems results shows how these could be used for real applications and extended to other locations

For buildings with low heat-to-power demand ratios, the installation of internal combustion engines (ICEs) for the onsite provision of combined heat and power (CHP) results in large amounts of surplus heat. In the UK, such installations risk being ineligible for the CHP Quality Assurance (CHPQA) programme, thereby incurring additional levies. In this work, a technoeconomic optimisation of small-scale organic Rankine cycle (ORC) engines is performed, in which the ORC engines recover heat from the ICE exhaust gases in order to increase the overall efficiency of this combined solution and meet the CHPQA requirements. Two competing system configurations are assessed. In the first, the ORC engine also recovers heat from the CHP-ICE jacket water to generate additional power. In the second, the ORC engine operates at a higher condensing temperature, which prohibits jacket-water heat recovery but allows heat from the condenser to be delivered to the building. When optimised for minimum specific investment cost, the first configuration is initially found to deliver 20% more power (25.8 kW) at design conditions, and a minimum specific investment cost (1600 £/kW) that is 8% lower than the second configuration. However, the first configuration leads to less heat from the CHP-ICE being supplied to the building, increasing the cost of meeting the heat demand. By establishing part-load performance curves for both the CHP-ICE and ORC engines, the economic benefits from realistic operation can be evaluated. The present study goes beyond previous work by testing the configurations against a comprehensive database of real historical electricity and heating demand for thirty energy-intensive buildings at half-hour resolution. The discounted payback period for the second configuration is found to lie between 3.5 and 7.5 years for all of the buildings considered, while the first configuration is seen to recoup capital investment costs for only 23% of the buildings. The broad applicability of the second configuration offers attractive opportunities to increase manufacturing volumes and reduce unit costs. The findings are relevant to a range of buildings with heat-to-power demand ratios from 20% to 100%.

Organic Rankine cycle (ORC) engines often operate under variable heat-source conditions, so maximising performance at both nominal and off-design operation is crucial for the wider adoption of this technology. In this work, an off-design optimisation tool is developed and used to predict the impact of varying heat-source conditions on ORC operation. Unlike previous efforts where the performance of ORC engine components is assumed fixed, here we consider explicitly the time-varying operational characteristics of these components. A bottoming ORC system is first optimised for maximum power output when recovering heat from the exhaust gases of an internal-combustion engine (ICE) running at full load. A double-pipe heat exchanger (HEX) model is used for sizing the ORC evaporator and condenser, and a piston-expander model for sizing the expander. The ICE is then run at part-load, thus varying the temperature and mass flow rate of the exhaust gases. The tool predicts the new off-design heat transfer coefficients in the heat exchangers, and the new optimum expander operating points. Results reveal that the ORC engine power output is underestimated by up to 17% when the off-design operational characteristics of these components are not considered. In particular, the piston-expander isentropic efficiency increases at off-design operation by 10–16%, due to the reduced pressure ratio and flow rate in the system, while the evaporator effectiveness improves by up to 15%, due to the higher temperature difference across the HEX and a higher proportion of heat transfer taking place in the two-phase evaporating zone. As the ICE operates further away from its nominal point, the off-design ORC engine power output reduces by a lesser extent than that of the ICE. At an ICE part-load operation of 60% (by electrical power), the optimised ORC engine with fluids such as R1233zd operates at 77% of its nominal capacity. ORC off-design performance maps are generated, for characterising and predicting system performance, which can be used, along with the optimisation tool, by ORC system designers, manufacturers and plant operators to identify optimum performance under real operating conditions.