Maximizing ORC performance with optimal match of working fluid with system design

Abstract

This article compares constrained system design to non-constrained system design for the basic Organic Rankine Cycle (ORC). The 12 working fluids studied include eight dry-type, three isentropic, and one wet-type fluids. The ORC model was developed using Aspen HYSYS® and validated with data obtained from the literature. The constrained design compared the performance of working fluids for a fixed heat exchanger and turbine configuration. A non-constrained design was studied by altering the design specifications for the heat exchangers and turbine to match the working fluid. An energy and exergy analysis was performed using first and second law efficiency. The exergy analysis was also used to study exergy destruction across the ORC components. Cost analysis was performed by comparing the levelized cost of electricity (LCOE) for each working fluid in both designs.It was observed that non-constrained design favored working fluids with higher critical temperatures. Switching from constrained to non-constrained design lowered the LCOE for higher critical temperature working fluids such as R601, R601a, R123, R245ca, R245fa, R600, and R236ea. R245ca, R601, and R236ea show 11%, 10%, and 9% decrease in LCOE, respectively. No significant change in efficiency is observed for lower critical temperature working fluids such as R236fa and R134a. Also, no increase in net power was observed for lower critical temperature working fluids, suggesting that modifying design does not affect the performance of ORC. LCOE increased for R600a, R152a, and R227ea and remained unchanged for R236fa and R134a.