Method for customizing an organic Rankine cycle to a complex heat source for efficient energy conversion, demonstrated on a Fischer Tropsch plant

Organic Rankine cycles (ORCs) provide an alternative to traditional steam Rankine cycles for the conversion of low grade heat sources into power, where conventional steam power cycles are known to be inefficient. A large processing plant often has multiple low temperature waste heat streams available for conversion to electricity by a low temperature cycle, resulting in a composite heat source with a complex temperature–enthalpy profile. This work presents a set of ORC design concepts: reheat stages, multiple pressure levels, and balanced recuperators; and demonstrates the use of these design concepts as building blocks to create a customized cycle that matches an available heat source. Organic fluids are modeled using a pure substance database. The pinch analysis technique of forming composite curves is applied to analyze the effect of each building block on the temperature–enthalpy profile of the ORC heat requirement. The customized cycle is demonstrated on a heat source derived from a Fischer Tropsch reactor and its associated processes. Analysis shows a steam Rankine cycle can achieve a 20.6% conversion efficiency for this heat source, whereas a simple organic Rankine cycle using hexane as the working fluid can achieve a 20.9% conversion efficiency. If the ORC building blocks are combined into a cycle targeted to match the temperature–enthalpy profile of the heat source, this customized ORC can achieve 28.5% conversion efficiency.