Thermoeconomic analysis of configuration methods for modular Organic Rankine Cycle units in low-temperature applications

Organic Rankine Cycle (ORC) is a promising technology for the utilization of low-grade waste heat. However, due to tailor-made power plants for different heat source temperatures, specific investment costs are still too high to be profitable. This study compares two different methods to configure a modular ORC in the temperature range of 373-463 K. The first method assumes a simple adaption of the mass flow rate within the ORC (mass flow method). In the second method, simultaneous adaption of mass flow rate and working pressure (combined method) take place. The common purpose of both methods is the optimization of the net power output for heat source temperatures lower and higher than the reference plant. Analyses are carried out for common fluorinated refrigerants (R227ea and R236ea) as well as for isoalkanes (isobutane and isopentane). It is shown that within a wide range of temperatures the deviation in net power output between the simpler mass flow method and the more sophisticated combined method is below 10%. However, the deviation strongly depends on the location of the pinch point and on the choice of the working fluid. In general, it is shown that the mass flow method in combination with a working fluid, for which the pinch point is located at the beginning of the preheating, is thermodynamically favorable for plant manufacturers. Economic analyses subsequently compare both methods with respect to payback period and cash flow. Additional investment costs for the combined method are allowed to be up to 10% in order to reach higher profitability than units with mass flow method. (C) 2016 Elsevier Ltd. All rights reserved.