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Thermo-economic multi-objective optimization of an innovative Rankine–organic Rankine dual-loop system integrated with a gas engine for higher energy/exergy efficiency and lower payback period

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Abstract

An innovative dual-loop heat recovery and power generation system is proposed here to increase heat recovery from the gas engine (GE) exhaust and jacket cooling water and to augment the system power output and thermal efficiency. As this proposed dual-loop heat recovery system is not studied in existing references, for comparison purpose, 18 existing single- and dual-loop systems in the literature as well as one proposed dual-loop system with six working fluids in topping and six working fluids in bottoming loop (36 cases) are investigated here (54 cases in sum). These systems are modeled in energy, exergy and economic aspects and are optimized by selecting ten design variables and two objective functions (payback period and exergy efficiency) by the use of genetic algorithm. Results show that with water as working fluid for topping loop (Rankine cycle or RC loop) and R141b for bottoming loop (organic Rankine cycle or ORC loop), which are selected in modeling and optimization procedures, the proposed above RC–ORC system has advantages among 53 other studied single- and dual-loop cases. These advantages are higher power output, thermal efficiency, exergy efficiency, annual profit as well as lower investment cost per unit of power output ($ kW−1) and payback period. It is observed that the proposed configuration of RC–ORC (with water–R141b as working fluids), which is integrated with 2 MW gas engine (as an example) generated 617 kW power output with 24% thermal efficiency, 55% exergy efficiency, 1280 $ kW−1 investment cost per unit of power output and about 3-year payback period. Furthermore, the overall thermal efficiency of integrated system (GE–RC–ORC) was about 67%. Finally, RC–ORC power output, exergy efficiency, thermal efficiency and payback period are also obtained for 1, 2 and 3 MW gas engines at various partial loads.

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Abbreviations

A:

Heat transfer surface area (m2)

\(\mathrm{AP}\) :

Annual profit ($ year−1)

\(C_{{{\text{CO}}_{2} }}\) :

CO2 penalty cost per kg ($ kg−1)

\(C_{{\text{elec,B}}}\) :

Electricity consumption price ($ kWh−1)

\(C_{{\text{elec,s}}}\) :

Electricity selling price ($ kWh−1)

\(C_{{\text{f}}}\) :

Fuel cost (S m−3)

\(C_{{\text{in,an}}}\) :

Annual investment cost ($ year−1)

\(C_{{{\text{inv}}}}\) :

Investment cost ($)

\(C_{{\text{m}}}\) :

CO2 production per (kg kWh−1)

\(C_{{\text{P}}}\) :

Specific heat capacity (kJ kg−1 K−1)

\(C_{{{\text{Penalty}}}}\) :

CO2 penalty cost ($)

\({\text{CRF}}\) :

Capital recovery factor

\(d\) :

Tube diameter (m)

\(\dot{E}\) :

Exergy rate (kW)

\(F\) :

Logarithmic mean temperature difference correction factor

\(f_{{\text{g}}}\) :

Friction factor

\(G\) :

Mass velocity (kg s−1 m−2)

\(H\) :

Annual working time (h)

\(h\) :

Specific enthalpy (kJ kg−1)

\(I_{{{\text{e}},{\text{s}}}}\) :

Income from electricity selling ($)

\(i\) :

Interest rate (%)

\(K_{{\text{m}}}\) :

Pipe material thermal conductivity (W m−1  K−1)

\({\text{LHV}}\) :

Lower heating value (Kcal m−3)

\(\dot{m}\) :

Mass flow rate (kg s−1)

\({\text{Nu}}\) :

Nusselt number

\(n\) :

System lifetime (year)

\(P\) :

Pressure (bar)

\({\text{PBP}}\) :

Payback period (year)

\({\text{PL}}\) :

Partial load (%)

\({\text{Pr}}\) :

Prandtl number

\(Q\) :

Volumetric flow rate (m3 s−1)

\(\dot{Q}\) :

Heat transfer rate (kW)

\({\text{Re}}\) :

Reynolds number

\(s\) :

Specific entropy (kJ kg−1)

\(T\) :

Temperature (°C)

\(U\) :

Overall heat transfer coefficient (Wm−2 K−1)

\({\text{V}}\) :

Water velocity (m s−1)

\(\dot{W}\) :

Work produced/consumed rate (kW)

\(x\) :

Steam quality

α :

Heat transfer coefficient (Wm−2 K−1)

\(\eta_{{{\text{thermal}}}}\) :

Thermal efficiency (%)

\(\eta_{{{\text{ex}}}}\) :

Exergy efficiency (%)

\(\gamma\) :

Isobaric to isometric specific heat capacity ratio

\(\gamma \left( {i,n} \right)\) :

Sinking fund factor

\(\Delta p_{{\text{g}}}\) :

Gas side pressure drop (kPa)

\(\rho\) :

Density (kg m−3)

μ :

Dynamic viscosity (Pa s)

\({\text{APTD}}\) :

Approach point temperature difference

\({\text{amb}}\) :

Ambient

\({\text{atm}}\) :

Atmosphere

\({\text{Cond}}\) :

Condenser

\({\text{CHP}}\) :

Combined heat and power

\({\text{Des}}\) :

Exergy destruction

\({\text{DOS}}\) :

Degree of superheat

\({\text{Eva}}\) :

Evaporator

\({\text{exp}}\) :

Expander

f:

Fuel

\({\text{GE}}\) :

Gas engine

\({\text{GWP}}\) :

Global warming potential

g:

Gas

HRSG:

Heat recovery steam generator

i :

Internal

\({\text{JCW}}\) :

Jacket cooling water

\({\text{ma}}\) :

Maintenance

\({\text{NTU}}\) :

Number of transfer units

\({\text{ODP}}\) :

Ozone depletion potential

\({\text{OP}}\) :

Operational

\({\text{ORC}}\) :

Organic Rankine cycle

\(o\) :

Outer

\({\text{PPTD}}\) :

Pinch point temperature difference

\({\text{RC}}\) :

Rankine cycle

\({\text{ST}}\) :

Steam turbine

\({\text{SV}}\) :

Salvage value

\({\text{Sat}}\) :

Saturation state

s:

Isentropic process

\({\text{st}}\) :

Steam

t:

Turbine

\({\text{Wa}}\) :

Water

\({\text{Wf}}\) :

Working fluid

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  1. Energy Systems Improvement Laboratory (ESIL), School of Mechanical Engineering, Iran University of Science and Technology (IUST), 16844, Narmak, Tehran, Iran

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Sanaye, S., Ghaffari, A. Thermo-economic multi-objective optimization of an innovative Rankine–organic Rankine dual-loop system integrated with a gas engine for higher energy/exergy efficiency and lower payback period. J Therm Anal Calorim 144, 1883–1905 (2021). https://doi.org/10.1007/s10973-021-10753-y

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