Simulation and Optimization of Waste Heat to Electricity through Organic Rankine Cycles (ORCs): a Case Study in an Oil Refinery

Energy efficiency has become a global problem that is detrimental to the chemical industries technically, economically and to the environment. Organic Rankine Cycle (ORC) is a promising technology that can solve this problem by recovering heat from low-grade waste heat sources by using organic working fluids. The heat source for the ORC system used in this article is air leaving air coolers in an oil refinery with a temperature of 140o C. The heat exchanger data for this refinery was used in the simulation of a basic cycle and a regenerative cycle using ASPEN HYSYS V.10. These ORC systems were simulated using hydrocarbons, refrigerants, and alternative refrigerants as the working fluids to compare their performance at three different condensation temperatures which are 15o C, 35o C, and 50o C. The system was optimized using the HYSYS optimizer to reach the optimum conditions for each working fluid. Results of this study have proven that the alternative working fluids R1234ze (Z) and R1224yd (Z) perform very well when compared to hydrocarbon working fluids and outperform the regular refrigerants. For the basic cycle which yielded the optimum results, R1234ze (Z) produced 1258.90 kW of turbine work and has a thermal efficiency of 11.31%. Hence, they are promising working fluids and are highly recommended to be used in the future since they perform highly economically in addition to being environmentally friendly