Analysis of ORC (Organic Rankine Cycle) systems with pure hydrocarbons and mixtures of hydrocarbon and retardant for engine waste heat recovery

•ORC with zeotropic mixtures for engine waste heat recovery is discussed.•Energetic and exergetic analysis of ORC system are conducted.•Optimal mixture working fluid composition is identified.•Greater utilization of jacket water and lower irreversible loss are important.

The Organic Rankine Cycle (ORC) has been demonstrated to be a promising technology for the recovery of engine waste heat. Systems with hydrocarbons as the working fluids exhibit good thermal performance. However, the flammability of hydrocarbons limits their practical applications because of safety concerns. This paper examines the potential of using mixtures of a hydrocarbon and a retardant in an ORC system for engine waste heat recovery. Refrigerants R141b and R11 are selected as the retardants and blended with the hydrocarbons to form zeotropic mixtures. The flammability is suppressed, and in addition, zeotropic mixtures provide better temperature matches with the heat source and sink, which reduces the exergy loss within the heat exchange processes, thereby increasing the cycle efficiency. Energetic and exergetic analysis of ORC systems with pure hydrocarbons and with mixtures of a hydrocarbon and a retardant are conducted and compared. The net power output and the second law efficiency are chosen as the evaluation criteria to select the suitable working fluid compositions and to define the optimal set of thermodynamic parameters. The simulation results reveal that the ORC system with cyclohexane/R141b (0.5/0.5) is optimal for this engine waste heat recovery case, thereby increasing the net power output of the system by 13.3% compared to pure cyclohexane.