Volume 15, Issue 5

Comparative Thermo-Economic and Environmental Evaluation of Eco-Friendly Working Fluids Across Multiple Organic Rankine Cycle Configurations for Waste Heat Recovery

Author

Ochuko Goodluck Utu, Okiemute Dickson OFUYEKPONE, Augustine Ben OKOUBULU, Oghenemaro Geraldine EDUVIERE and Yaabari NAENWI

Abstract

This study compares the thermo-economic and environmental performance of eco-friendly fluids in various Organic Rankine Cycle (ORC) configurations for waste heat recovery. Three working fluids carbon dioxide (CO2), isobutane, and a zeotropic mixture were analyzed under regenerative, transcritical, and dual-loop ORC configurations using a MATLAB-based simulation framework. Thermodynamic performance was evaluated over an evaporator temperature range of 80–160°C. Results showed that thermal efficiency increased with temperature for all fluids, with CO2 ranging from 0.50% to 0.80%, isobutane 0.54% to 0.82%, and the zeotropic mixture achieving the highest values of 0.58% to 0.84%. Similarly, exergy efficiency varied between 2.60% – 3.30% for CO2, Isobutane: 2.64% – 3.70%, and 2.62% – 3.41% for the mixture, indicating reduced irreversibility for the mixture. Net power output reflects same, with values of CO2: 20 – 90 kW, Isobutane: 25 – 112 kW, Mixture: 60 – 220 kW. Economic analysis revealed that the Levelized Cost of Electricity (LCOE) decreased with increasing performance, ranging from $0.09 – $0.17/kWh (CO2,), Isobutane $0.07 – $0.10/kWh and Mixture: $0.08 – $0.014/kWh. Environmental assessment showed that CO2 had the lowest Global Warming Potential (GWP = 1), followed by isobutane (GWP = 3) and the mixture (GWP ≈ 10), while all fluids had zero Ozone Depletion Potential (ODP = 0). While CO2 was the most environmentally friendly choice, the zeotropic mixture had the best thermo-economic performance. The study concludes that selecting the optimal Organic Rankine Cycle (ORC) working fluid depends on specific design goals and performance priorities, which are essential for creating efficient and sustainable waste heat recovery systems.

DOI Link: https://doi.org/10.62226/ijarst20262693

Google Scholar: https://scholar.google.com/Comparative-Thermo-Economic-and-Environmental-Evaluation-of-Eco-Friendly-Working-Fluids-Across-Multiple-Organic-Rankine-Cycle-Configurations-for-Waste-Heat-Recovery

Europub: https://europub.co.uk/articles/789970

Indexcopernicus :https://journals.indexcopernicus.com/search/article?articleId=4879275

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DOI

https://doi.org/10.62226/ijarst20262672

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