Analyzing the optimization of an organic Rankine cycle system for

recovering waste heat from a large marine engine containing a cooling

water system
Min-Hsiung Yang
a,
, Rong-Hua Yeh
b
a
Department of Naval Architecture and Ocean Engineering, National Kaohsiung Marine University, Taiwan, Republic of China
b
Department of Marine Engineering, National Kaohsiung Marine University, Taiwan, Republic of China
a r t i c l e i n f o
Article history:
Received 9 May 2014
Accepted 15 September 2014
Keywords:
ORC
Waste heat recovery
Optimal
Evaporation
Condensation
Working uid
a b s t r a c t
In this study, six working uids with zero ozone depletion potential and low global warming potential are
used in an organic Rankine cycle (ORC) system to recover waste heat from cylinder jacket water of large
marine diesel engines. Thermodynamic analysis and a nite-temperature-difference heat-transfer
method are developed to evaluate the thermal efciency, total heat-exchanger area, objective parameter,
and exergy destruction of the ORC system. The optimal evaporation and condensation temperatures for
achieving the maximal objective parameter, the ratio of net power output to the total heat-transfer area
of heat exchangers, of an ORC system are investigated.
The results show that, among the working uids, R600a performs the best in the optimal objective
parameter evaluation followed by R1234ze, R1234yf, R245fa, R245ca, and R1233zd at evaporation temper-
atures ranging from58 Cto 68 Cand condensation temperatures ranging from35 Cto 45 C. The optimal
operating temperatures and corresponding thermal efciency and exergy destruction are proposed. Fur-
thermore, the inuences of inlet temperatures on cylinder jacket water and cooling water in the ORC are
presented for recovering waste heat. The results of this work were veried with theoretical solutions
and experimental results in the literature and it was revealed that they were consistent with them.
2014 Published by Elsevier Ltd.
1. Introduction
Because of energy shortages, global warming, and environmen-
tal pollution, conserving energy and reducing carbon dioxide emis-
sions are becoming increasingly critical for efcient energy use.
Waste heat recovery has considerable potential for increasing
energy efciency and reducing fuel consumption. Although a con-
ventional steam power cycle is applied in general industrial power
plants, the performance of the Rankine cycle is insufcient for
recovering low-grade waste heat. To enhance the energy efciency
and economical use of energy sources, an organic Rankine cycle
(ORC) is used to recover low-grade waste heat and transform it
into useful power [13]. In addition, the application of the ORC sys-
tem to the cement, steel, glass, oil, and gas industries cannot only
recover the thermal energy but also reduce greenhouse gas [4,5].
Because the thermodynamic properties of working uids
substantially inuence performances of systems, assessing the
appropriateness of working uids for use in the ORC system is
essential. Several researchers investigated the suitability of organic
uids for heat recovery in ORC systems [69]. Furthermore, Xie and
Yang [10] used the Rankine cycle system to recover waste heat
energy from engines. The results displayed that dry and isentropic
uids were superior to wet uids because the probability of drop-
lets forming as a result of their saturated vapor characteristics was
reduced. Recently, the studies on converting low-temperature dis-
charged heat into electrical energy by using an ORC system for
industrial applications have been reported [11,12].
To recover waste heat efciently, thermodynamic analysis for
the optimized ORC system is crucial. Wei et al. [13] used R245fa
as the working uid to optimize the thermodynamic performance
of an ORC system. The result revealed that when the ambient tem-
perature was excessively high, the output net power and efciency
deteriorated by more than 30% from the nominal state. To recover
the waste heat, the parametric optimization of performance analy-
sis based on the ORC system were conducted numerically [14,15].
Furthermore, an economic factor was considered in the optimiza-
tion process of the ORC system. In addition, thermodynamic and
thermo-economic optimizations of the ORC system for various
waste heat source temperatures were performed to obtain the
http://dx.doi.org/10.1016/j.enconman.2014.09.044
0196-8904/ 2014 Published by Elsevier Ltd.

Corresponding author at: No. 142, Haizhuan Rd., Nanzi Dist., Kaohsiung City
81157, Taiwan, Republic of China. Tel.: +886 7 3617141x3404; fax: +886 7
3656481.
E-mail address: mhyang@webmail.nkmu.edu.tw (M.-H. Yang).
Energy Conversion and Management 88 (2014) 9991010
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maximal net power output and the minimal apparatus cost
[1619].
Employing a geothermal heat source, Shengjun et al. [20]
applied two optimization methods to various working uids in
an ORC system. They reported that through the thermodynamic
analysis, R123, R600, R245fa, R245ca, and R600a were suitable.
However, through the energy cost evaluation, R152a, R600,
R600a, R134a, R143a, R125, and R41 were favorable. In addition,
Tian et al. [21] investigated the thermal efciency and electricity
production cost of the optimized ORC system and reported that
R141b, R123, and R245fa demonstrated more suitable performance
compared with those of various working uids used for recovering
the exhaust heat of internal combustion engines. Wang et al. [22]
analyzed an ORC system operated with R134a to achieve system
optimization by maximizing the exergy efciency and minimizing
the overall apparatus cost under the waste heat source conditions.
Using R12, R123, R134a, and R717 as working uids superheated at
a constant pressure, Roy et al. [23] numerically studied an ORC sys-
tem and presented parametric optimization. They reported that
R123 exhibited maximal thermal efciency and minimal irrevers-
ibility at various turbine inlet pressures.
Moreover, the theoretical analysis and exergy evaluation of
solar thermal energy of an ORC power plant in reverse osmosis
seawater desalination technology were reported [24,25]. Sprouse
et al. [26] reviewed an ORC system for internal combustion engine
exhaust heat recovery. The results showed a potential improve-
ment in fuel economy of approximately 10% through the use of
current working uids and advancements in expander technology.
The application of a cogeneration system, which comprised an ORC
and a heat pump, was evaluated numerically [27]. The results of
the system performance evaluation revealed that, among the
working uids used in their study, R236ea and R245ca were supe-
rior. Additionally, by using a program code, thermodynamic and
techno-economic analysis of the ORC systems were conducted
numerically [2830].
The thermodynamic and transport properties of working uids
substantially affect the performance of ORC systems. Moreover, the
heat exchange cost becomes critical when the heat source temper-
ature is low (8090 C). To improve the thermal efciency of ORC
systems, suitable working uids and optimal working conditions
for the ORC must be manifest under various conditions. The ther-
modynamic and transport properties of low global warming poten-
tial (GWP) working uids must be considered when analyzing
optimal operational conditions that yield maximal performance
and minimal heat transfer cost for waste heat recovery in ORC sys-
tems. In addition, to improve the energy efciency design index
Nomenclature
A
tot
total heat-transfer area of heat exchangers, m
2
A
con
heat-transfer area of condenser, m
2
A
eva
heat-transfer area of evaporator, m
2
D diameter, m
D
h
hydraulic diameter, m
ED exergy destruction, kW
f dimensionless friction factor
g acceleration due to gravity, m s
2
h heat-transfer coefcient, kW m
2
C
1
I irreversibility, kW
i enthalpy, kJ kg
1
k thermal conductivity, kW m
1
C
1
L length of tube or pipe, m
L
t
thickness of tube wall, m
M molecular weight of working uid, g mole
1
m mass ow rate, kg s
1
N section number of each part in the heat exchangers
p pressure, kPa
P
r
Prandtl number
Q heat transfer rate, kW
q heat ux, kW m
2
Re Reynolds number
T temperature, C
T
cwi
cooling water inlet temperature, C
T
hwi
cylinder jacket water inlet temperature, C
T
hwo
cylinder jacket water outlet temperature, C
T
ri
working uid inlet temperature, C
T
ro
working uid outlet temperature, C
DT temperature difference between inlet and outlet of the
heat exchanger, C
DT
mean
logarithmic mean temperature difference, C
U overall heat-transfer coefcient of the heat exchanger
kW m
2
C
1
v specic volume, m
3
kg
1
W power of the turbine or pump, kW
Greek symbols
c ratio of W
net
to A
tot
e effectiveness
g efciency
l dynamic viscosity, Pas
q density, kg m
3
Subscripts
0 ambient
con condensation, condenser
cw cooling water
eva evaporation, evaporator
f liquid
g vapor
hw cylinder jacket water
i inside, inlet
II second law
j section
max maximal
net net
o outside, optimization
pre pre-heater
pum pump
r working uid
s isentropic
sat saturation
sup superheating
t tube
tot total
tur turbine
th thermal
ver verication
w wall, water
wp water pump
Acronyms
EEDI energy efciency design index
ODP ozone depletion potential
ORC organic Rankine cycle
GWP global warming potential
1000 M.-H. Yang, R.-H. Yeh/ Energy Conversion and Management 88 (2014) 9991010
(EEDI) and reduce greenhouse gas emissions from merchant ships,
recovering waste heat from large diesel engines is an essential
method [31]. This study investigates the maximal objective
parameters that represent the maximal ratio of net power output
to heat transfer area for an ORC system for recovering waste heat
from the cooling water system of large marine diesel engine. In
consideration of environmental protection, the criteria used to
select the working uids are zero ozone depletion potential value
and low GWP. Table 1 lists the properties of the working uids
[32]. The rst and second laws of thermodynamics and the heat
transfer theory of heat exchange are used in this study for calculat-
ing the turbine power output, thermal efciency, exergy destruc-
tion, and heat-exchanger area of the ORC system. Furthermore,
the maximal objective parameters with the corresponding optimal
condensation, evaporation temperatures, and thermal efciency
are obtained using R1233zd, R1234yf, R1234ze, R245ca, R245fa,
and R600a as working uids.
2. Thermodynamic modeling and analysis
In this study, an ORC system used for recovering waste heat
from a large marine engine is investigated. This ORC system
primarily consists of a working uid pump, evaporator, turbine,
condenser, and pre-heater, as shown in Fig. 1. It is assumed that
steady-state conditions are applied to all components. In the evap-
orator, the working uid absorbs heat transferred from cylinder
jacket water released from the engine and approaches the satura-
tion temperature. The working uid continues to be heated and
becomes saturated vapor, and then becomes superheated vapor
at the inlet of the turbine. The superheated vapor produces power
as it passes through the turbine and expands. The low-pressure
superheated vapor then enters the pre-heater and heats the liquid
working uid from the condenser outlet. Subsequently, the cooling
water cools the working uid in the condenser. After condensation,
the liquid working uid is pumped back into the pre-heater and
evaporator to complete the cycle. Moreover, to supply cylinder
jacket water and cooling water, water pumps are installed in the
ORC system. Fig. 2 presents a diagram depicting the temperature
and entropy of the ORC system. Furthermore, the temperature
variations caused by the heat transfer among the cylinder jacket
water, working uid, and cooling water are also presented.
Fig. 3 presents the relationship between the temperature and
entropy of the working uids used in the ORC system. To prevent
damage to the turbine caused by the working uid becoming sat-
urated after generating power in the turbine, working uids that
yield a saturation line with a positive or nearly vertical slope in
the Ts diagram are used in this study. Obviously, the entropy dif-
ference between the saturated liquid and vapor of R600a is the
largest among the working uids, suggesting that R600a exhibits
the largest amount of enthalpy change during phase changes that
occur in heat exchangers. In addition, the critical points of
Table 1
The properties of working uids [32].
Item R1233zd R1234yf R1234ze R245ca R245fa R600a
Molar mass (kg/kmol) 130.5 114.04 114.04 134.05 134.05 58.122
T
cri
(C) 165.6 94.7 109.36 174.42 154.01 134.66
P
cri
(kPa) 3570.9 3382.2 3634.9 3940 3651 3269
ODP 0 0 0 0 0 0
GWP 7 4 6 1030 693 20
SAFE A1 A2 A2 A1 B1 A3
Note: ODP: Ozone depletion potential, GWP: Global warming potential.
1: No ame propagation; 2: Lower ammability; 3: Higher ammability;
A: Lower toxicity; B: Higher toxicity.
Fig. 1. Schematic diagram of the ORC system.
Fig. 2. Temperature and entropy diagram of the ORC system.
M.-H. Yang, R.-H. Yeh/ Energy Conversion and Management 88 (2014) 9991010 1001
R245ca and R1234yf are the highest and lowest, respectively,
among the six working uids.
The heat ow rate and irreversibility exhibited in the evapora-
tor are calculated as
Q
eva
m
r
i
2
i
1a
1
I
eva
T
0
m
r
s
2
s
1a

i
2
i
1a
T
eva

2
The power output and irreversibility demonstrated by the
working uid in the turbine can be shown as
W
tur
m
r
i
3
i
2
=g
t
3
I
tur
T
0
m
r
s
3
s
2
4
The effectiveness and irreversibility of the pre-heater is dened
as
e
T
3
T
3a
T
3
T
1
5
I
pre
T
0
m
r
s
3
s
3a
s
1a
s
1
6
The heat ow rate and irreversibility exhibited in the condenser
are expressed as
Q
con
m
r
i
3a
i
4
7
I
con
T
0
m
r
s
4
s
3a

i
4
i
3a
T
con

8
The power consumption and irreversibility of the working uid
pump can be calculated as
W
pum
m
r
v
4
p
1
p
4
=g
pum
9
I
pum
T
0
m
r
s
1
s
4
10
The power consumption of the cylinder jacket water and cool-
ing water pumps can be dened as
W
wp

m
w
q
w
g
p
f
L
w
D
w
q
w
V
2
w
2
!
11
where f is a dimensionless friction factor, and L
w
and D
w
are the
length and inner diameter, respectively, of the cylinder jacket water
and cooling water pipes.
The net power output of the ORC system can be determined by
W
net
W
tur
W
pum
W
wp;hw
W
wp;cw
12
The net thermal efciency of the ORC system is calculated by
g
th
W
net
=Q
eva
13
The exergy destruction of the working uid in the ORC system
can be obtained by
ED I
eva
I
tur
I
con
I
pum
I
pre
T
0
m
r

i
2
i
1a
T
eva

i
4
i
3a
T
con

14
The second law efciency is calculated by
g
II
g
th
=1 T
0
=T
hw
15
3. Heat transfer analysis
A shell-and-tube heat exchanger is designed for the evaporator,
condenser, and pre-heater. To calculate the heat transfer coef-
cient for each phase of the working uid, the evaporator is divided
into three parts (the superheating, evaporating, and liquid regions)
for the simulation method, as shown in Fig. 2. Similarly, the con-
denser comprises two parts: the superheating and condensing
regions. The logarithmic mean temperature difference (LMTD) is
widely used in calculating heat transfer rate of heat exchangers.
The properties of working uids and cylinder jacket water and
cooling water vary according to the temperature during heat trans-
fer between heat exchangers. In this study, to decrease the inu-
ence of in transport properties caused by the temperature during
heat transfer and to improve the accuracy of the simulation results,
each part of the heat exchangers is subdivided into N equal sec-
tions. The variations of net power output and total heat-exchanger
area of the ORC system for six sets of N using R1234yf as working
uid are evaluated and given in Table 2. It is clearly, that the differ-
ences in net power output are insignicant for various section
numbers, N, but the deviations in total heat-exchanger area, which
are evaluated using the transport properties, are obvious. From
Table 2, the c of the ORC system becomes consistent as the section
number increases. It can be obtained that the relative error of c
between N = 20 and N = 40 is less than 0.1%. Therefore, the number
of sections in each part of the heat exchangers is set as N = 20
throughout this study.
The heat-transfer rate between the working uid and cylinder
jacket water of one section of each part in the evaporator can be
expressed as [33]
Q
j
U
j
A
j
FDT
mean;j
16
where j represents one of the sections of one part in the evaporator,
F is a correction factor for the evaporator, and DT
mean,j
is the LMTD
between the cylinder jacket water and working uids in the section
and is obtained by [33]
DT
mean;j

T
hwi;j
T
ro;j
T
hwo;j
T
ri;j

lnT
hwi;j
T
ro;j
=T
hwo;j
T
ri;j

17
where T
hwi,j
and T
hwo,j
are the inlet and outlet temperatures of the
cylinder jacket water respectively, and T
ri,j
and T
ro,j
are the inlet
and outlet temperatures of the working uid in the section, respec-
tively. The overall heat-transfer coefcient of the section is dened
by [33]
U
j

1
1=h
o;j
A
o;j
=h
w;j
A
o;j
=A
i;j
1=h
i;j

18
1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6
20
60
100
140
180
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T

(
o
C
)
s (kJ/kg-
o
C)
Fig. 3. The temperature and entropy plots of working uids.
Table 2
The effect of sections in each part of heat exchangers in calculated results for R1234yf
at DT
hw
= 10 C, DT
cw
= 8 C, T
eva
= 65 C, and T
con
= 40 C.
N 1 2 5 10 20 40
w
net
(kW) 238.12 238.27 238.39 238.44 238.43 238.44
A (m
2
) 379.26 376.36 374.45 373.81 373.83 373.83
c (kW/m
2
) 0.6284 0.6328 0.6357 0.6381 0.6384 0.6385
1002 M.-H. Yang, R.-H. Yeh/ Energy Conversion and Management 88 (2014) 9991010
where h
o,j
and h
i,j
are the heat-transfer coefcients of the working
uid and cylinder jacket water respectively, and A
o
represents the
outside surface area of the tubes in the section.
The dimensional empirical expression for nucleate boiling in
the evaporator is used to calculate the nucleate-boiling heat-
transfer coefcient of the working-uid side [34]:
h
o
55Pr
0:120:4343lnR
P

r
0:4343lnPr
r

0:55
M
0:5
q
0:67
19
where M is the molecular weight of the working uid, q is the heat
ux of the tube, and R
p
is set to 1.0 lm for the surface roughness of
the tube. The heat-transfer coefcient of the water side can be cal-
culated using the DittusBoelter correlation for 6000 < Re < 10
7
and
0.5 < Pr < 120 [33]:
h
i
0:023Re
0:8
w
Pr
n
w
D
h
k
w

20
where n = 0.4 is used for the condenser and n = 0.3 is used for the
evaporator. The corresponding heat-transfer coefcient of the tube
wall is calculated as [33]
h
w

2pk
t
L
t
lnD
o
=D
i

21
Furthermore, the correlation proposed by Zukauskas [35] is
applied to calculate the heat-transfer coefcient on the working
uid side for superheating vapor or subcooling liquid, which gives
h
o

k
r
D
o

0:71Re
0:5
r
Pr
0:36
r
Pr
r
Pr
w

n
22
where n = 0 is used for the superheating vapor and n = 0.25 is used
for the liquid. In addition, Pr
w
is evaluated at the wall temperature
of the tubes.
Similarly, Eqs. 17, 18, 20 and 21 can be applied to calculate
heat-transfer in the condenser and pre-heater. In the condenser,
for the working-uid side around the horizontal tubes, the correla-
tion of the average heat-transfer coefcient for the lm condensa-
tion is applied [36]:
h
o
0:729
gq
f
q
f
q
g
k
3
r
i
0
fg
l
f
T
sat
T
w
D
o
!
1=4
23
where q
f
and q
g
are the liquid and vapor densities of the working
uid, respectively; T
sat
represents the condensation temperature in
the condenser, andi
0
fg
is the modied latent heat of the working uid.
In the pre-heater, the liquid working uid is released from the
pump outlet by high-pressure ows in the tubes, and the vapor
working uid is released from the turbine outlet by low-pressure
ows on the shell side. The heat-transfer calculation of pre-heater
can be obtained by applying the process as mentioned previously.
Therefore, the total heat-exchanger area in the ORC system can be
obtained by
A
tot
A
eva;1
A
eva;2
A
eva;3
A
con;1
A
con;2
A
pre
24
The total cost of heat exchangers contributes largely to the total
ORC system cost in low-temperature heat source power plant and
is assumed to be representative of complete system cost [2,19,37].
Finally, the objective parameter that represents the ratio of the net
power output W
net
to total heat-transfer area A
tot
in the ORC sys-
tem is dened as [38]
c W
net
=A
tot
25
In this study, the ORC simulation is performed using a calcula-
tion program written in FORTRAN. The thermodynamic and trans-
port properties of the working uids are obtained from the
National Institute of Standards and Technology (NIST) database
REFPROP 9.0 [39]. The simulation procedure used by the program
is presented in Fig. 4.
4. Results and discussion
4.1. Verication
To evaluate the accuracy of the thermodynamic simulation
results for the ORC system, the numerical solution of the evapora-
tion and condensation pressures, power output of the turbine,
thermal efciency, and exergy destruction are veried using
R245fa at T
eva
= 106.85 C, T
eva
= 31.3 C, and a net power output
W
net
xed at 10 kW [9], as shown in Table 3. The comparison
results for the ORC thermal efciency, g
th,ver
are evaluated exclud-
ing the power consumption of the water pumps in the ORC system.
In addition, the calculated data on the R600a used in this study are
compared with the previously published results of an ORC system
that was evaluated [14] at T
eva
= 87.15 C and T
eva
= 25 C with
m
r
= 3.61 kg/s, as shown in Table 4. In this comparison, the thermo-
dynamic parameters of the working uid are analyzed in the ORC Fig. 4. Flow chart of the calculation procedures for the ORC system.
Table 3
Comparison of present calculated results with those of Ref. [9].
Parameter unit T
eva
(C) T
con
(C) W
net
(kW) P
eva
(kPa) P
con
(kPa) m
r
(kg/s) g
th,ver
(%) W
tur
(kW) ED (kW)
R245fa [9] 106.85 31.3 10 1492.3 187.4 0.4988 8.4 10.615 45.08
R245fa 106.85 31.3 10 1482.1 186.23 0.5 8.36 10.561 44.9
D (%) 0.69 0.6 0.24 0.47 0.51 0.4
Note: D represents absolute error.
M.-H. Yang, R.-H. Yeh/ Energy Conversion and Management 88 (2014) 9991010 1003
system excluding the pre-heater. Furthermore, numerical calcu-
lated solutions of this study are validated with the experimental
results of Declaye et al. [40] for a ORC system with R245fa at
T
eva
= 85.3 C and T
sup
= 10 C, as shown in Fig. 5. The corresponding
evaporation pressure, P
eva
, is maintained at 900 kPa and the con-
densation pressure, P
con
, varies with various condensation temper-
atures which results in the pressure-ratio variation from 2.6 to 5.8.
It can be observed that there is a slight deviation occurred between
the numerical results and experimental data at lower pressure
ratios, P
eva
/P
con
. This may be resulted from the constant pump
efciency assumed in the simulation. As a whole, the numerical
solutions obtained in this study are consistent with those reported
in Wang et al. [9] and Dai et al. [14], and Declaye et al. [40], as can
be clearly seen in Tables 3 and 4 and Fig. 5.
4.2. Problem description
The heat source of the ORC system used in this study is the
waste heat of the cylinder jacket water released from the cooling
water system installed in a large marine internal combustion
Table 4
Comparison of present calculated results with those of Ref. [14].
Parameter unit T
eva
(C) T
con
(C) m
r
(kg/s) P
eva
(kPa) P
con
(kPa) Q
eva
(kW) g
th,ver
(%) W
tur
(kW) ED (kW)
R600a [14] 87.15 25 3.61 1550 350 1456.85 11.52 180.91 224.13
R600a 87.15 25 3.61 1552.5 350.7 1449.8 11.63 180.27 225.41
D (%) 0.16 0.2 0.48 0.95 0.35 0.57
Note: D represents absolute error.
(a) (b)
(c) (d)
58 60 62 64 66 68
3.6
4
4.4
4.8
5.2
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
con
= 40
o
C
T
sup
= 5
o
C
T
eva
(
o
C)
(
o
/
o
)

t
h
58 60 62 64 66 68
280
320
360
400
440
480
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
A
t
o
t
(
m
2
)
T
con
= 40
o
C
T
sup
= 5
o
C
T
eva
(
o
C)
58 60 62 64 66 68
0.5
0.55
0.6
0.65
0.7
0.75
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
con
= 40
o
C
T
sup
= 5
o
C
T
eva
(
o
C)
(
k
W
/
m
2
)

Fig. 6. The effect of T

eva
on (a) g
th
, (b) A
tot
, (c) c, and (d) ED and g
II
in the ORC system.
2 3 4 5 6 7
0
2
4
6
8
10
P
eva
= 900 kPa
T
eva
= 85.3
o
C
T
sup
= 10
o
C
Declaye et al. [40]
This study
P
eva
/ P
con
t
h
(
o
/
o
)

R245fa
Fig. 5. Validation of the proposed thermal efciencies with those from experimental
work [40] of the ORC system with R245fa.
1004 M.-H. Yang, R.-H. Yeh/ Energy Conversion and Management 88 (2014) 9991010
engine. The WARTSILA RT-ex96 engine equipped with 14 cylin-
ders produces a power output of 80,080 kW to propel the large
merchant ship [41]. The ow rate of cooling water is approxi-
mately 657 m
3
/s (182.5 kg/s) and is circulated to cool the cylinder
jackets of the diesel engine at an outlet temperature of approxi-
mately 90 C. The waste heat of the cylinder jacket cooling water
system is only partially used for distilling sea water to produce
fresh water in the fresh water generator, and the left heat energy
must be removed by sea water in the central cooling system of
the marine engine. The purpose of this study is to simulate the
waste heat recovered from the cooling heat lost and increase the
energy efciency for a large marine diesel engine. It is noted that
the iterative convergence for thermodynamic analysis and heat-
transfer-area calculation are relative errors of 0.01% and 0.1%,
respectively. In the evaluation of the parametric optimization of
the ORC system, a relative error of 0.1% is specied.
In this study, the water ow rate of the heat source for the ORC
system is assumed to be approximately two-thirds that of the fresh
water in the cooling system of the large marine diesel engine. The
mass ow rate and temperature of the heat source are xed,
whereas the mass ow rates of the working uid and cooling water
are varied to obtain the optimal temperature conditions. The fol-
lowing data are given for the thermodynamic analysis and heat-
transfer evaluation:
1. Cylinder jacket water ow rate in the evaporator: 128 kg/s.
2. Cylinder jacket water inlet temperature: 85 C.
3. Cooling water inlet temperature: 25 C.
4. The degree of superheating at the evaporator outlet: 5 C.
5. Efciencies of the cylinder jacket water and cooling water
pumps and working uid pump: 0.8.
6. The length and diameter of the cylinder jacket water and cool-
ing water pipes: 10 m and 0.3 m.
7. Pre-heater effectiveness: 0.5.
8. Turbine efciency: 0.8.
9. The condenser, evaporator and pre-heater are shell-and-tube
heat exchangers and the correction factors F = 0.9.
4.3. Performance analysis
This section presents the results of parametric studies on the
various working uids used in the system. Fig. 6(ad) show the
inuence of the evaporation temperature on thermal efciency,
total heat-transfer area, the objective parameter, and total exergy
destruction in the ORC system at a condensation temperature of
T
con
= 40 C. The cylinder jacket water and cooling water tempera-
ture differences between the inlet and outlet are assumed to be
DT
hw
= 8 C and DT
cw
= 5 C for the evaporator and condenser,
respectively.
Because of an increase in evaporation temperature, the pressure
difference in the turbine becomes large and, thus, the net power
output increases. Also, because the total heat-transfer rate in the
evaporator is maintained constant, the thermal efciency of the
ORC system increases as the net power output increases, as shown
in Fig. 6(a). In the evaluation of the working uids, R1234yf exhib-
its the highest g
th
at T
eva
= 5861 C. However, the thermal ef-
ciency varies among the working uids with T
eva
. Under the
same heat-source conditions, the ORC system using R245ca and
(a) (b)
(c) (d)
35 37 39 41 43 45
3.5
4
4.5
5
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
eva
= 65
o
C
T
sup
= 5
o
C
T
con
(
o
C)

t
h
(
o
/
o
)
35 37 39 41 43 45
220
260
300
340
380
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
A
t
o
t
(
m
2
)
T
eva
= 65
o
C
T
sup
= 5
o
C
T
con
(
o
C)
35 37 39 41 43 45
0.5
0.55
0.6
0.65
0.7
0.75
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
eva
= 65
o
C
T
sup
= 5
o
C
T
con
(
o
C)
(
k
W
/
m
2
)

Fig. 7. The effect of T

con
on (a) g
th
, (b) A
tot
, (c) c, and (d) ED and g
II
in the ORC system.
M.-H. Yang, R.-H. Yeh/ Energy Conversion and Management 88 (2014) 9991010 1005
R245fa achieves excellent thermal efciency at T
eva
= 6168 C. As
shown in Fig. 6(b), the total heat-transfer area, A
tot
, gradually
increases initially and then rises steeply as the evaporation tem-
perature increases, because the temperature difference between
the cylinder jacket water and working uid decreases in the evap-
orator. In addition, Fig. 6(b) shows that the A
tot
curve of R1234zd
exhibits the highest value but the smallest value for R600a among
those of the working uids.
Fig. 6(c) shows the effects of T
eva
on the objective parameter c,
which is the ratio of net power output to the total heat-transfer
area of the ORC system. For all of the working uids, the values
of c increase initially, attain a maximal value, and nally decrease
(a) (b)
(c) (d)
(e) (f)
0.4
0.45
0.5
0.55
0.6
58
60
62
64
66
68
Teva
(
o
C
)
35
37
39
41
43
45
T
con (
o
C
)
0.640
0.629
0.618
0.608
0.597
0.586
0.575
0.565
0.554
0.553
0.552
0.543
0.532
0.522
0.511
0.500

(
k
W
/
m
2
)
R1233zd
0.4
0.45
0.5
0.55
0.6
58
60
62
64
66
68
Teva
(
o
C
)
35
37
39
41
43
45
T
con (
o
C
)
0.644
0.641
0.630
0.620
0.610
0.600
0.590
0.580
0.570
0.560
0.550
0.540
0.530
0.520
0.510
0.500

(
k
W
/
m
2
)
R1234yf
0.4
0.45
0.5
0.55
58
60
62
64
66
68
Teva
(
o
C
)
35
37
39
41
43
45
T
con (
o
C
)
0.646
0.640
0.629
0.618
0.608
0.597
0.586
0.575
0.565
0.554
0.543
0.532
0.522
0.511
0.500

(
k
W
/
m
2
)
R1234ze
0.4
0.45
0.5
0.55
0.6
58
60
62
64
66
68
Teva
(
o
C
)
35
37
39
41
43
45
T
con (
o
C
)
0.640
0.629
0.618
0.608
0.597
0.586
0.582
0.580
0.575
0.565
0.554
0.543
0.532
0.522
0.511
0.500

(
k
W
/
m
2
)
R245ca
0.4
0.45
0.5
0.55
0.6
58
60
62
64
66
68
Teva
(
o
C
)
35
37
39
41
43
45
T
con (
o
C
)
0.640
0.629
0.618
0.608
0.601
0.597
0.586
0.575
0.565
0.554
0.543
0.532
0.522
0.511
0.500

(
k
W
/
m
2
)
R245fa
0.4
0.45
0.5
0.55
0.6
58
60
62
64
66
68
Teva
(
o
C
)
35
37
39
41
43
45
T
con (
o
C
)
0.677
0.670
0.656
0.640
0.629
0.618
0.608
0.597
0.586
0.575
0.565
0.554
0.543
0.532
0.522
0.511
0.500

(
k
W
/
m
2
)
R600a
Fig. 8. Contours of c for (a) R1233zd, (b) R1234yf, (c) R1234ze, (d) R245ca, (e) R245fa, and (f) R600a.
1006 M.-H. Yang, R.-H. Yeh/ Energy Conversion and Management 88 (2014) 9991010
as the evaporation temperature increases. An optimal c, which rep-
resents the maximal net power output per unit area of the heat
exchangers, can be obtained for each working uid based on the
results. In addition, c
max
= 0.73 kW/m
2
is obtained at the corre-
sponding optimal evaporation temperature T
eva,o
= 64.2 C for
R600a. The c values of R1234yf are higher than those of R1234ze
at T
eva
= 5860.5 C; however, R1234ze yields higher c values than
R1234yf at T
eva
= 60.568 C. The c
max
of R1234yf and R1234ze are
0.7 and 0.69 at T
eva,o
= 63.5 C and 63 C, respectively. As shown in
Fig. 6(d), the exergy destruction decreases with evaporation tem-
perature whereas the second law efciency increases as the evap-
oration temperature increases when T
con
= 40 C and T
sup
= 5 C.
Among these working uids, R1234yf exhibits the lowest exergy
destruction and highest second law efciency at T
eva
= 5867 C.
Generally, working uids having high thermal efciency exhibit
low exergy destruction in the ORC system.
By contrast, high condensation temperatures decrease the ther-
mal efciency because the power output of the turbine decreases,
as shown in Fig. 7(a). The gure also indicates that R245ca and
R245fa exhibit high thermal efciency at T
con
= 3543 C and
T
eva
= 65 C. Similarly, at T
con
= 3543 C, the ORC system using
R1234yf obtains maximal thermal efciency. As shown in
Fig. 7(b), the A
tot
curves tend to decline as the condensation temper-
ature increases in the ORC system. This is because as the condensa-
tion temperature increases, the temperature difference between
the cooling water and working uid in the condenser increases,
causing a decrease in the total heat-transfer area. Based on
Figs. 6(b) and 7(b), R600a, R1234ze, and R1234yf exhibit superior
transport properties in the heat exchange process in the ORC sys-
tem. Fig. 7(c) shows the inuence of T
con
on c at T
eva
= 65 C for each
working uid. As expected, the values of c increase initially, then
approach the peak points, and nally decrease as the condensation
temperature increases. The maximal value, c
max
= 0.73, occurs at
T
con,o
= 41 C for R600a. In the objective parameter evaluation,
R600a evidently performs more satisfactorily compared with the
other working uids tested. Although R245ca and R245fa demon-
strate excellent performance in thermal efciency at high evapora-
tion and low condensation temperatures, low transport properties
yield inferior values in the objective parameter estimation. Increas-
ing the condensation temperature causes the exergy destruction of
the system to increase and the second efciency to reduce, respec-
tively, as can be observed in Fig. 7(d). This gure also indicates that
R1234ze and R1233zd demonstrate unfavorable performance in
exergy destruction and the second efciency at most condensation
Table 5
The c
max
and its corresponding DT
hw,o
, DT
cw,o
, T
eva,o
, T
con,o
, g
th,o
, ED
o
, and g
II,o
for the
ORC system at T
cwi
= 25 C and T
hwi
= 85 C.
Item R1233zd R1234yf R1234ze R245ca R245fa R600a
c
max
(kW/m
2
) 0.58 0.66 0.67 0.62 0.64 0.71
DT
hw,o
(C) 7.4 8.9 8.4 7 7.5 7.4
DT
cw,o
(C) 5.1 6 5.5 4.6 4.9 5
T
eva,o
(C) 64.2 63.2 63.7 63.9 63.9 64.6
T
con,o
(C) 38.1 40.2 39.3 37.6 38.1 39.4
g
th,o
(%) 4.46 4.08 4.2 4.56 4.48 4.38
ED
o
(kW) 413.42 519.97 484.55 387.3 418.44 418.67
g
II
,
o
(%) 30.71 30.85 30.56 31.05 30.79 30.97
(a) (b)
(c) (d)
85 87 89 91 93 95
63
65
67
69
71
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
e
v
a
,
o
(
o
C
)
T
cwi
= 25
o
C
T
hwi
(
o
C)
85 87 89 91 93 95
36
38
40
42
44
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
c
o
n
,
o
(
o
C
)
T
cwi
= 25
o
C
T
hwi
(
o
C)
85 87 89 91 93 95
0.5
0.6
0.7
0.8
0.9
1
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
cwi
= 25
o
C
T
hwi
(
o
C)

m
a
x
(
k
W
/
m
2
)
85 87 89 91 93 95
3.6
4
4.4
4.8
5.2
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
cwi
= 25
o
C
T
hwi
(
o
C)
t
h
,
o
(
o
/
o
)

Fig. 9. The inuence of T

hwi
on (a) T
eva,o
(b) T
con,o
(c) c
max
, and (d) g
th,o
at T
cwi
= 25 C.
M.-H. Yang, R.-H. Yeh/ Energy Conversion and Management 88 (2014) 9991010 1007
temperatures. According to Figs. 6(d) and 7(d), R1234yf
demonstrates satisfactory performance in exergy destruction at
low evaporation and high condensation temperatures.
4.4. Optimization
To show the optimal operating temperatures of the ORC system,
the distributions of c for various evaporationandcondensationtem-
perature ranges at DT
hw
= 8 C and DT
cw
= 5 C are plotted in
Fig. 8(af) for each working uid. As expected, the optimal evapora-
tion temperatures, T
eva,o
, and optimal condensation temperatures,
T
con,o
, canbe observedfor the maximal ratio of W
net
to A
tot
. Moreover,
these contour plots of c showthe variations in the optimal operating
temperatures among the working uids. The c
max
of R600a is the
highest among the six working uids with a corresponding T
eva,o
of 64.3 C, and T
con,o
of 41.1 C, followed by R1234ze, R1234yf,
R245fa, and R245ca. Clearly, R1233zd exhibits the lowest maximal
objective parameter, c
max
= 0.53 at T
eva,o
= 63.9 C and T
con,o
= 40 C,
among the working uids.
Furthermore, the maximal objective parameter, c
max
, and its
corresponding optimal operating conditions, DT
hw,o
, DT
cw,o
, T
eva,o
,
T
con,o
, g
th,o
, ED
o
, and g
II
for the ORC system at T
cwi
= 25 C,
T
hwi
= 85 C, and m
hw
= 128 kg/s are obtained numerically and are
shown in Table 5. Under the condition in which the cylinder jacket
water and cooling water inlet temperatures are maintained con-
stant, the optimal temperature differences between the inlet and
outlet of the cylinder jacket water and cooling water, DT
hw,o
and
DT
cw,o
, are obtained according to the maximal objective parameter
for various working uids. The DT
hw,o
and DT
cw,o
of R1234yf are
higher than those of the other working uids. A high temperature
difference between the inlet and outlet of the cylinder jacket water
indicates a large amount of heat energy added in the ORC system.
Similarly, a high temperature difference between the inlet and out-
let of the cooling water suggests that an additional cooling load is
required in the condenser of the system. Conversely, the lowest
values of DT
hw,o
, and DT
cw,o
are obtained for R245ca. Moreover,
the corresponding optimal evaporation, condensation, thermal
efciency, and exergy destruction are determined to compare the
working uids. The thermodynamic properties and transport prop-
erties affect the results for the maximal objective parameter and
optimal operating temperatures. Among the working uids,
R600a exhibits the highest objective parameter value of 0.71 kW/
m
2
. The sequence of c
max
for each working uid is listed, as men-
tioned previously. According to Table 5, the corresponding T
eva,o
and T
con,o
of c
max
vary among the working uids. Also, note that
R600a and R245ca exhibit the highest T
eva,o
and lowest T
con,o
,
respectively. The values of g
th,o
and ED
o
, which respectively repre-
sent the thermal efciency and exergy destruction, are calculated
according to the conditions of the c
max
in the ORC system. Under
the optimal conditions, R1234yf exhibits the lowest T
eva,o
and high-
est T
con,o
, resulting in inferior performance in thermodynamic ef-
ciency and exergy destruction. In addition, R245ca exhibits the
lowest exergy destruction under the optimal conditions.
4.5. Effects of cylinder jacket water and cooling water temperatures
Increasing the heat source temperature enhances the perfor-
mance of the ORC system. In this study, the cylinder jacket water
(a) (b)
(c) (d)
20 22 24 26 28 30
60
62
64
66
68
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
e
v
a
,
o
(
o
C
)
T
hwi
= 85
o
C
T
cwi
(
o
C)
20 22 24 26 28 30
32
34
36
38
40
42
44
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
c
o
n
,
o
(
o
C
)
T
hwi
= 85
o
C
T
cwi
(
o
C)
20 22 24 26 28 30
0.5
0.6
0.7
0.8
0.9
1
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
hwi
= 85
o
C
T
cwi
(
o
C)

m
a
x
(
k
W
/
m
2
)
20 22 24 26 28 30
3.6
4
4.4
4.8
5.2
R1233zd
R1234yf
R1234ze
R245ca
R245fa
R600a
T
hwi
= 85
o
C
T
cwi
(
o
C)
(
o
/
o
)

t
h
,
o
Fig. 10. The inuence of T
cwi
on (a) T
con,o
(b) T
eva,o
(c) c
max
, and (d) g
th,o
at T
hwi
= 85 C.
1008 M.-H. Yang, R.-H. Yeh/ Energy Conversion and Management 88 (2014) 9991010
temperature is considered at T
hwi
= 8595 C. To show the inu-
ence of cylinder jacket water temperature on the operating tem-
peratures and c
max
, the variations in the optimal evaporation and
condensation temperature at T
cwi
= 25 C are presented in
Fig. 9(a) and (b), respectively. Both the optimal evaporation and
condensation temperatures increase as T
hwi
increases in the ORC
system. Furthermore, the increment of T
eva,o
is more apparent than
that of T
con,o
for each working uid, suggesting that the inuence of
T
hwi
on T
eva,o
is more substantial than that on T
con,o
in the ORC sys-
tem. As previously mentioned, R1234yf exhibits the lowest T
eva,o
and highest T
con,o
at T
hwi
= 8595 C. Notably, the optimal evapora-
tion temperature of R600a under all of the conditions is the highest
than those of the other working uids. Therefore, R600a is suitable
for use at a high evaporation temperature in the ORC system. In
addition, it is observed that the T
eva,o
and T
con,o
of R245ca and
R245fa are similar. Fig. 9(c) shows the inuence of T
hwi
on the c
max
in the ORC system. Overall, the maximal objective parameters
increase as the cylinder jacket water temperature increases
because of an increase in the net power output. Remarkably, the
increase in the c
max
of R1234yf is mitigated as T
hwi
increases.
Therefore, R1234yf is suitable for use with a low-temperature heat
source. The variations in optimal thermal efciency, which are
obtained under the conditions corresponding to c
max
, at various
T
hwi
are shown in Fig. 9(d). The g
th,o
values from highest to lowest
are R245ca, R245fa, R1233zd, R600a, R1234ze, and R1234yf.
The variation of the optimal evaporation and condensation tem-
peratures in relation to the cooling water inlet temperature T
cwi
at
T
hwi
= 85 C are shown in Fig. 10(a) and (b). Similarly, the T
eva,o
and T
con,o
increase as the cooling water inlet temperature increases
for each working uid, and the inuence of T
cwi
on T
con,o
is stronger
than that on T
eva,o
in the ORC system. According to Fig. 10(a), the
T
eva,o
values of R1233zd, R245ca, and R245fa tend to be similar at
T
cwi
= 2630 C. In addition, Fig. 10(b) indicates that the T
eva,o
values
of R600a and R1234ze and those of R1233zd and R245fa are similar
at various T
cwi
. The optimal objective parameters decrease as T
cwi
decreases for each working uid, as shown in Fig. 10(c). Based on
Fig. 9(c) and (d) and Fig. 10(c) and (d), although R600a exhibits
the most favorable results in the objective parameter analysis,
R245ca exhibits the highest net thermal efciency under optimal
conditions among the working uids. The results given in Fig. 9(c)
and Fig. 10(c) show the sequence of c
max
, as mentioned previously.
Based on these results, R1233zd performs unfavorably in the object
parameter analysis, and R1234yf exhibits the lowest net thermal
efciency under optimal conditions for the ORC system.
5. Conclusions
In this study, the thermodynamic and transport properties of
the ORC working uids used to recover waste heat from a large
marine diesel engine are optimally simulated to increase the EEDI
and reduce greenhouse gas emissions from merchant ships. An
objective parameter c, which represents the ratio of net power out-
put to total heat-exchanger area, is determined to analyze the per-
formance of the ORC system in recovering waste heat. The optimal
operating temperatures of the ORC system, T
con,o
and T
eva,o
, are
obtained numerically to achieve the maximal objective parameter
c
max
at T
cwi
= 2030 C and T
hwi
= 8595 C for R1233zd, R1234yf,
R1234ze, R245ca, R245fa, and R600a. The results, which are
obtained numerically, support the following conclusions:
1. In the evaluation of the maximal objective parameter for recov-
ering waste heat from the diesel engine containing a cooling
water system, R600a performs the most satisfactorily, followed
by R1234ze, R1234yf, R245fa, and R245ca, and R1233zd
performs the least satisfactorily at T
eva
= 5868 C and
T
con
= 3545 C.
2. The working uid demonstrating superior thermodynamic
properties does not necessarily demonstrate excellent perfor-
mance in the heat-transfer process. Although R245ca, R245fa,
and R1234yf exhibit higher thermal efciency among the work-
ing uids according to thermodynamic analysis, outstanding
performance in the evaluation of objective parameters for the
ORC system is not guaranteed.
3. In the ORC system, the cylinder jacket water temperature
affects the optimal evaporation temperature more strongly than
it affects the optimal condensation temperature. By contrast,
the cooling water temperature affects the optimal condensation
temperature more substantially than it affects the optimal
evaporation temperature.
Acknowledgements
The nancial support for this research from the Engineering
Division of National Science Council, Republic of China, through
contract NSC 101-2221-E-022-004, is greatly appreciated.
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