Optimal integration of organic Rankine cycles with industrial processes

• An optimization approach for heat integration is proposed.
• A new general superstructure for heat integration is proposed.
• Heat process streams are simultaneously integrated with an organic Rankine cycle.
• Better results can be obtained respect to other previously reported methodologies.

This paper presents a procedure for simultaneously handling the problem of optimal integration of regenerative organic Rankine cycles (ORCs) with overall processes. ORCs may allow the recovery of an important fraction of the low-temperature process excess heat (i.e., waste heat from industrial processes) in the form of mechanical energy. An integrated stagewise superstructure is proposed for representing the interconnections and interactions between the HEN and ORC for fixed data of process streams. Based on the integrated superstructure, the optimization problem is formulated as a mixed integer nonlinear programming problem to simultaneously account for the capital and operating costs including the revenue from the sale of the shaft power produced by the integrated system. The application of this method is illustrated with three example problems. Results show that the proposed procedure provides significantly better results than an earlier developed method for discovering optimal integrated systems using a sequential approach, due to the fact that it accounts simultaneously for the tradeoffs between the capital and operating costs as well as the sale of the produced energy. Also, the proposed method is an improvement over the previously reported methods for solving the synthesis problem of heat exchanger networks without the option of integration with an ORC (i.e., stand-alone heat exchanger networks).