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The present paper focuses both on the thermodynamic and on the economic optimization of a small scale ORC in waste heat recovery application. A sizing model of the ORC is proposed, capable of predicting the cycle performance with different working fluids and different components sizes. The working fluids considered are R245fa, R123, n-butane, n-pentane and R1234yf and Solkatherm. Results indicate that, for the same fluid, the objective functions(economics profitability, thermodynamic efficiency) lead to different optimal working conditions in terms of evaporating temperature: the operating point for maximum power doesn't correspond to that of the minimum specific investment cost: The economical optimum is obtained for nbutane with a specific cost of 2136 €/kW, a net output power of 4.2 kW, and an overall efficiency of 4.47%, while the thermodynamic optimum is obtained for the same fluid with an overall efficiency of 5.22%. It is also noted that the two optimizations can even lead to the selection of a different working fluid. This is mainly due to additional fluid properties that are not taken into account in the thermodynamic optimization, such as the fluid density: a lower density leads to the selection of bigger components which increases the cost and decreases the economical profitability.

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This paper presents the results of an experimental study carried out on a prototype of a hermetic scroll expander, integrated into a gas cycle test rig, whose working fluid is HFC-245fa. This system is designed to test only the performance of the expander. It is made up mainly of a scroll compressor, a scroll expander, a heat exchanger, and a by-pass valve. The latter is used to adjust the pressure ratio imposed to the expander. The expander was originally a compressor designed for heat pump applications and is characterized by a nominal power input of 2.5 kWe. Performance of the expander is evaluated in terms of isentropic effectiveness and filling factor as functions of the main operating conditions. The study also investigates the impact of oil mass fraction on the expander performance. Maximum overall isentropic effectiveness of 71.03 per cent is measured, which is partly explained by the good volumetric performance of the machine. Using the experimental data, parameters of a semi-empirical simulation model of the expander are identified. This model is used to analyse the measured performance of the expander. Finally, a polynomial empirical model of the expander is proposed for fast and robust simulations of organic Rankine cycle systems.

The Organic Rankine Cycle (ORC) appears progressively as a promising solution to recover waste heat energy from thermal processes for electricity generation. A prototype of small-scale ORC has been built and successfully tested at the University of Lie`ge. It uses R-245fa and R-123 as working fluid, and an oil-free scroll compressor adapted to run in expander mode. Thermodynamic model of the system was derived and validated for performance prediction. The validated thermodynamic model is used to optimize the operation of the small ORC in waste heat recovery application (ORC-WHR). For exhaust gases at 180 °C and a mass flow rate of 0.21 kg/s, a maximum net power output of 2 kWe is obtained for an evaporator pressure of 11.84 bar. The cycle thermal efficiency is 8.23 and the recuperation efficiency, 66.32%. Based on the aforementioned conditions, the economic assessment of small scale ORC-WHR was carried out using economic criteria such as levelized electricity cost (LEC), Net present value (NPV) and depreciated payback period (DPP). For a 2kWe ORC-WHR, the specific installed cost is 5775 €/kW with a LEC of 13.27 c€/kWh while for a 50 kWe, the specific installed cost is about 3034 €/kW and the LEC, 7c€/kWh. For an electricity unit price of 20 c€/kWh, the payback period of a 2 kWe system is 6 years while it is 2.5 years for a 50 kWe system. It is concluded from the study that recovering the waste heat by way of ORCs is technically and economically feasible. As recycled energy, waste heat has the same advantages as renewable energy and should benefit from the same legislative conditions (Feed-in-Laws).