Search Results (27)

In the context of the zero-carbon transition, this article provides a comprehensive review of Organic Rankine Cycle (ORC) technologies for low-grade heat recovery and conversion to power. It surveys a wide range of renewable and waste heat sources—including geothermal, solar thermal, biomass, internal combustion engine exhaust, and industrial process heat—and discusses the integration of ORC systems to enhance energy recovery and thermal efficiency. The analysis examines various configurations, from basic and regenerative cycles to advanced transcritical and supercritical designs, cascaded systems, and multi-source integration, evaluating their thermodynamic performance for different heat source profiles. A critical focus is placed on working fluid selection, where the landscape is being reshaped by stringent regulatory frameworks such as the EU F-Gas regulation, driving a shift towards low-GWP hydrofluoroolefins, natural refrigerants, and tailored zeotropic mixtures. The review benchmarks ORC against competing technologies such as the Kalina cycle, Stirling engines, and thermoelectric generators, highlighting relative performance characteristics. Furthermore, it identifies key trends, including the move beyond single-source applications toward integrated hybrid systems and the use of multi-objective optimization to balance thermodynamic, economic, and environmental criteria, despite persistent challenges related to computational cost and real-time control. Key findings confirm that ORC systems significantly improve low-grade heat utilization and overall thermal efficiency, positioning them as vital components for integrated zero-carbon power plants. The study concludes that synergistically optimizing ORC design, refrigerant choice in line with regulations, and system integration strategies is crucial for maximizing energy recovery and supporting the broader zero-carbon energy transition. Full article

The present paper provides a general overview of the state of the art of steam generating heat pumps (SGHPs) technology employed in the industrial field. Recommended best practices and optimization procedures for overall performance improvement of compression closed-loop-based systems are described in detail, as well as the main modifications of the thermodynamic heat pump cycle. Once the main configurations of SGHPs are described, the different concepts are compared in terms of supply temperature ranges; cases of comparison among different concepts are reviewed, and techno-economic barriers are also discussed. The working fluids (including natural refrigerants) commonly selected for these steam generating systems are presented along with their uses. Moreover, zeotropic refrigerant mixtures and new potentially usable mixtures are mentioned. After that, refrigerant selection criteria for high temperature heat pumps are also discussed. Then, using an internal heat exchanger, refrigerant injection technique and super heating in lubricated compressors are herein presented as best practices for general performance improvement. Regarding thermodynamic cycle modifications, basic auto-cascade and quasi-two-stage compression cycles are discussed along with further improvements suggested in the specialized literature. Lastly, optimization strategies useful to enhance the heat pumps’ design and based on TOPSIS method, advanced exergy analysis, exergy-based cost minimization and combined design are analyzed. Full article

The Organic Rankine Cycle (ORC) is an effective method for transforming low- and medium-grade heat into electricity that has recently gained significant attention. Several review studies in the literature are focused on working fluids, system architecture, and the individual utilization of renewable and alternative heat sources in ORCs, like solar irradiation, geothermal, biomass, and waste heat energy. However, no studies have yet investigated ORC systems driven by two of the aforementioned sources combined. This work aims to review and explore multiple aspects of hybrid ORC systems. Such systems are categorized based on source combinations and configurations, and the results regarding their thermodynamic, thermo-economic, and environmental performance are discussed. The source arrangements follow the following three main configurations: series, parallel, and heat upgrade. Most of the examined systems include solar energy as one of the sources and only four cases involve combinations of the other three sources. The reported results show that hybrid ORCs generally perform better thermodynamically compared to their respective single-source systems, exhibiting an enhancement in power production that reaches 44%. An average levelized cost of energy (LCOE) of 0.165 USD/kWh was reported for solar–geothermal plants, 0.153 USD/kWh for solar–biomass plants, and 0.100 USD/kWh for solar–waste plants. Solar–biomass plants also reported the lowest reported LCOE value of 0.098 USD/kWh. The payback periods ranged from 2.88 to 10.5 years. Further research is proposed on multiple source combinations, the in-depth analysis of the three main configurations, the integration of polygeneration systems, the incorporation of zeotropic mixture working media and experimental research on ORCs with combined sources. Full article

Composition regulation of zeotropic mixture working fluid for a thermodynamic cycle is an effective way to improve energy conversion efficiency, which offers the potential to construct efficient, flexible and intelligent cycles. Current research on cycle construction of zeotropic mixture composition regulation still heavily relies on construction methods using pure working fluids, where the characteristics of flexible composition variations fail to be utilized. In this paper, the research progress of cycle construction methods and composition regulated structures are comprehensively reviewed, aiming to clarify the potential for enhancing a thermodynamic cycle based on composition regulation. The characteristics of different cycle construction methods are firstly summarized and compared. Then, the composition-regulated structures of a physical-based method and chemical-based method are introduced, and the composition regulation performance are also concluded. Finally, a future outlook on the cycle design and structure design is provided. The review results show that the combination of 3D construction method and superstructure/intelligences construction method has the potential to maximize the cycle performance, where the improvement of each thermal process and the optimization of complex cycles can be considered simultaneously. The composition regulation based on a passive physical method has the advantage of being readily applicable; however, the composition regulation range is limited. In addition, the distillation and hydrate method have a wider regulation range through extra energy input, where the trade-off between energy consumption and cycle performance improvement should be considered in the future. This study greatly assists in the design of thermodynamic cycles involving zeotropic mixture composition regulation and the corresponding composition regulation structures. Full article

The last decade (2013–2023) was the most prolific period of organic Rankine cycle (ORC) research in history in terms of both publications and citations. This article provides a detailed review of the broad and voluminous collection of recent internal combustion engine (ICE) waste heat recovery (WHR) studies, serving as a necessary follow-on to the author’s 2013 review. Research efforts have targeted diverse applications (e.g., vehicular, stationary, and building-based), and it spans the full gamut of engine sizes and fuels. Furthermore, cycle configurations extend far beyond basic ORC and regenerative ORC, particularly with supercritical, trilateral, and multi-loop ORCs. Significant attention has been garnered by fourth-generation refrigerants like HFOs (hydrofluoroolefins), HFEs (hydrofluoroethers), natural refrigerants, and zeotropic mixtures, as research has migrated away from the popular HFC-245fa (hydrofluorocarbon). Performance-wise, the period was marked by a growing recognition of the diminished performance of physical systems under dynamic source conditions, especially compared to steady-state simulations. Through advancements in system control, especially using improved model predictive controllers, dynamics-based losses have been significantly reduced. Regarding practically minded investigations, research efforts have ameliorated working fluid flammability risks, limited thermal degradation, and pursued cost savings. State-of-the-art system designs and operational targets have emerged through increasingly sophisticated optimization efforts, with some studies leveraging “big data” and artificial intelligence. Major programs like SuperTruck II have further established the ongoing challenges of simultaneously meeting cost, size, and performance goals; however, off-the-shelf organic Rankine cycle systems are available today for engine waste heat recovery, signaling initial market penetration. Continuing forward, next-generation engines can be designed specifically as topping cycles for an organic Rankine (bottoming) cycle, with both power sources integrated into advanced hybrid drivetrains. Full article

There are various organic compounds that can be utilized in the organic Rankine cycle as working fluids. The selection of a suitable working fluid is complicated due to the large number of options and factors affecting the choice, such as thermodynamic properties, environmental impact, cost, etc. This study evaluates seven different pure organic compounds and twenty-one of their binary zeotropic mixtures as potential working fluids for the organic Rankine cycle powered by a heat source at 200 °C. The pure organic fluids show higher exergy efficiency, higher specific net power output, and lower heat exchange area requirements compared to the binary mixtures. Among the pure fluids, RE347mcc performs the best in terms of exergy efficiency, followed by neopentane, isopentane, and pentane. Cyclopentane exhibits the highest power production capacity per unit mass flow rate of the working fluid. Two mixtures, pentane/Novec 649 and cyclopentane/Novec 649, showed significantly higher exergy efficiency than their individual components, but at significantly lower specific power production capacity. The study presents an interesting trade-off between exergy efficiency and heat exchange area, indicating that a small increase in exergy efficiency can lead to a large decrease in the required heat exchange area. The outcomes of this study can help in selecting suitable working fluids for ORC operation with a heat source at 200 °C. Full article

In this study, modeling and thermodynamic analysis of the combined double flash geothermal cycle generation was conducted using zeotropic fluid as the working fluid in the Organic Rankine Cycle (ORC). The analysis was performed based on the first and second laws of thermodynamics. Hexane, cyclohexane, isohexane, R245fa, and R236ea exhibit good performance at higher temperatures. In this study, three fluids—hexane, cyclohexane, and isohexane—were used. First, the model results for the pure fluids were compared with those of previous studies. Then, the important parameters of the cycle, including the efficiency of the first law of thermodynamics, the efficiency of the second law of thermodynamics, net productive power, and the amount of exergy destruction caused by changing the mass fraction of the refrigerant for the zeotropic fluids (investigated for the whole cycle and ORC), were obtained and compared. Full article

Ocean thermal energy is a huge renewable and clean energy. For different applications of the Ocean Thermal Energy Conversion (OTEC) system, new objective functions are proposed and optimal CO₂-based binary zeotropic mixtures for each objective function are discussed. Propane, butane, isobutane, and pentane were selected as the secondary component of the mixture working fluid. Based on each objective function, some parameters of the CO₂-based binary zeotropic mixture power cycle were studied and the optimal working fluids were obtained. The results indicated that the thermal efficiency showed an upwards trend as the evaporating temperature increased from 20 to 23 °C and decreased as the molar fraction of the secondary component of the working fluid increased from 0.01 to 0.05, but the specific volumetric flow showed the opposite trend. The specific net power increased as the evaporating temperature increased, and the net power output had a greater effect on the variations in the specific net power than the molar fraction of the secondary component. When taking thermal efficiency or specific volumetric flow as the objective functions, CO₂/propane was the suitable working fluid under the considered conditions; in the case that specific net power was taken as the objective function, CO₂/butane (0.97/0.03 or 0.96/0.04 molar ratio) or CO₂/isobutane (0.97/0.03, 0.96/0.04, or 0.95/0.05 molar ratio) were suitable under the considered evaporating temperature. Full article

The present study provides an energy, exergy and economic analysis of a seawater regasification system (open loop) combining stages of simple organic Rankine cycles (ORCs) arranged in series with an open organic Rankine cycle (OC) in order to exploit the cold energy of liquefied natural gas (LNG). The proposed system, termed ORC-OC, is implemented in a Floating Storage Regasification Unit (FSRU) to achieve the objective of zero greenhouse emissions during the regasification process. Configurations of up to three stages of ORCs and the use of zeotropic mixtures of ethane/propane and n-butane/propane as working fluids are considered in the study of the novel regasification system. Only the two-stage ORC-OC (2ORC-OC) and three-stage (3ORC-OC) configurations accomplish the objective of zero emissions, attaining exergy efficiencies of 61.80% and 62.04%, respectively. The overall cost rate of the latter, however, is 20.85% greater, so the 2ORC-OC results as being more cost-effective. A comparison with conventional regasification systems installed on board shows that the 2ORC-OC yields a lower total cost rate if the LNG price exceeds 8.903 USD/MMBtu. This value could be reduced, however, if the electrical power that exceeds the FSRU’s demand is exported and if compact heat exchangers are implemented. Full article

The organic Rankine cycle (ORC) technology is an efficient way to convert low-grade heat from renewable sources or waste heat for power generation. The partial evaporating organic Rankine cycle (PEORC) can be considered as a promising alternative as it can offer a higher utilization of the heat source. An experimental investigation of a small ORC system used in full or partial evaporation mode is performed. First characterized in superheated mode, which corresponds to standard ORC behavior, a semi-empirical correlative approach involving traditional non-dimensional turbomachinery parameters (specific speed, pressure ratio) can accurately describe one-phase turbine performance. In a second step, two-phase behavior is experimentally investigated. The efficiency loss caused by the two-phase inlet condition is quantified and considered acceptable. The turbine two-phase operation allows for an increase in the amount of recovered heat source. The ability to operate in two phases provides a new degree of flexibility when designing a PEORC. The semi-empirical correlative approach is then completed to take into account the partially evaporated turbine inlet condition. The qualitative description and the quantitative correlations in the one-phase and two-phase modes were applied to different pure working fluids (Novec649^TM, HFE7000 and HFE7100) as well as to a zeotropic mixture (Novec649^TM/HFE7000). Full article

Due to its deep utilization of geobrine and its high net power output, the binary-flashing cycle (BFC) is deemed to be the future geothermal energy power generation technology. The working fluids considered in present analysis are zeotropic mixtures (R245/R600a). The system thermodynamic model is built, and the energy and conventional and advanced exergy analyses are carried out to reveal the real optimization potential. It is demonstrated that the optimal ranges of R245fa mass fraction and working fluid dryness at the evaporator outlet are 0.30~0.50 and 0.40~0.60, considering the thermodynamic performance and the flammability of the zeotropic mixtures, simultaneously. Conventional exergy analysis indicates that the maximum exergy destruction occurs in the condenser, followed by the expander, evaporator, flashing tank, preheater, high-pressure pump and low-pressure pump. Meanwhile, the advanced exergy analysis reveals that the expander should be given the first priority for optimization, followed by the condenser and evaporator. The BFC has a large potential for improvement due to higher avoidable exergy destruction, about 48.6% of the total system exergy destruction can be reduced. Moreover, the interconnections among system components are not very strong, owing to small exogenous exergy destructions. It also demonstrates the effectiveness of advanced exergy analysis, and the approach can be extended to other energy conversion systems to maximize the energy and exergy savings for sustainable development. Full article

This paper is an introduction to the cycle proposed by the authors related to research directions concerning the problems of condensation of zeotropic refrigerant mixtures. For over a hundred years, research has been conducted on the search for new working fluids in the cycles for cooling devices and heat pumps. Initially, the natural refrigerants used were replaced with homogeneous synthetic refrigerants, followed by mixtures of two or more refrigerants. Among the mixtures, there are azeotropic and zeotropic mixtures. In the case of an azeotrope mixture, a liquid solution of two or more chemical compounds is in thermodynamic equilibrium with the saturated vapor resulting from this mixture. The chemical composition of the liquid and vapor is identical. A zeotropic mixture is a liquid-vapor system in which the composition of a liquid mixture (solution) of two or more chemical compounds is always different from that of the saturated vapor generated from this liquid. This is due to the different boiling and condensation temperatures of the individual components of the mixture at the same pressure. There is a so-called temperature glide. The phase transformations of individual components do not run simultaneously, which means that the boiling or condensation phase transition temperature changes during the process being carried out. This raises a number of computational, design, and operational problems for power equipment. Today, however, zeotropic mixtures find an alternative to refrigerants with a high GWP potential. Despite the disadvantage of temperature glide, they also have advantages. These include ecological, energy, and economic indicators. As a result, they are increasingly used in the energy economy. This prompts researchers to conduct further research in the field of a detailed description of the phenomenon of boiling and condensation phase transformations of zeotropic mixtures under temperature glide, searching for new computational relationships, new design solutions, and applications. It is still an insufficiently recognized research problem. Bearing the above in mind, the authors made an attempt to review the state of knowledge in this area. Particular attention was paid to the progress in modeling the condensation phenomenon of zeotropic mixtures for application in compact heat exchangers. Miniaturization of cooling devices creates great application possibilities in this area. Full article

In the waste heat recovery of the internal combustion engine (ICE), the transcritical CO₂ power cycle still faces the high operation pressure and difficulty in condensation. To overcome these challenges, CO₂ is mixed with organic fluids to form zeotropic mixtures. Thus, in this work, five organic fluids, namely R290, R600a, R600, R601a, and R601, are mixed with CO₂. Mixture performance in the waste heat recovery of ICE is evaluated, based on two transcritical power cycles, namely the recuperative cycle and split cycle. The results show that the split cycle always has better performance than the recuperative cycle. Under design conditions, CO₂/R290(0.3/0.7) has the best performance in the split cycle. The corresponding net work and cycle efficiency are respectively 21.05 kW and 20.44%. Furthermore, effects of key parameters such as turbine inlet temperature, turbine inlet pressure, and split ratio on the cycle performance are studied. With the increase of turbine inlet temperature, the net works of the recuperative cycle and split cycle firstly increase and then decrease. There exist peak values of net work in both cycles. Meanwhile, the net work of the split cycle firstly increases and then decreases with the increase of the split ratio. Thereafter, with the target of maximizing net work, these key parameters are optimized at different mass fractions of CO₂. The optimization results show that CO₂/R600 obtains the highest net work of 27.43 kW at the CO₂ mass fraction 0.9 in the split cycle. Full article

In this paper, the performance of an organic Rankine cycle with a zeotropic mixture as a working fluid was evaluated using exergy-based methods: exergy, exergoeconomic, and exergoenvironmental analyses. The effect of system operation parameters and mixtures on the organic Rankine cycle’s performance was evaluated as well. The considered performances were the following: exergy efficiency, specific cost, and specific environmental effect of the net power generation. A multi-objective optimization approach was applied for parametric optimization. The approach was based on the particle swarm algorithm to find a set of Pareto optimal solutions. One final optimal solution was selected using a decision-making method. The optimization results indicated that the zeotropic mixture of cyclohexane/toluene had a higher thermodynamic and economic performance, while the benzene/toluene zeotropic mixture had the highest environmental performance. Finally, a comparative analysis of zeotropic mixtures and pure fluids was conducted. The organic Rankine cycle with the mixtures as working fluids showed significant improvement in energetic, economic, and environmental performances. Full article

Decarbonization of the industrial sector is one of the most important keys to reducing global warming. Energy demands and associated emissions in the industrial sector are continuously increasing. The utilization of high temperature heat pumps (HTHPs) operating with natural fluids presents an environmentally friendly solution with great potential to increase energy efficiency and reduce emissions in industrial processes. Ammonia-water absorption–compression heat pumps (ACHPs) combine the technologies of an absorption and vapor compression heat pump using a zeotropic mixture of ammonia and water as working fluid. The given characteristics, such as the ability to achieve high sink temperatures with comparably large temperature lifts and high coefficient of performance (COP) make the ACHP interesting for utilization in various industrial high temperature applications. This work reviews the state of technology and identifies existing challenges based on conducted experimental investigations. In this context, 23 references with capacities ranging from 1.4 kW to 4500 kW are evaluated, achieving sink outlet temperatures from 45 °C to 115 °C and COPs from 1.4 to 11.3. Existing challenges are identified for the compressor concerning discharge temperature and lubrication, for the absorber and desorber design for operation and liquid–vapor mixing and distribution and the choice of solution pump. Recent developments and promising solutions are then highlighted and presented in a comprehensive overview. Finally, future trends for further studies are discussed. The purpose of this study is to serve as a starting point for further research by connecting theoretical approaches, possible solutions and experimental results as a resource for further developments of ammonia-water ACHP systems at high temperature operation. Full article