Organic Rankine Cycle System Review: Thermodynamic Configurations, Working Fluids, and Future Challenges in Low-Temperature Power Generation.
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| Title: | Organic Rankine Cycle System Review: Thermodynamic Configurations, Working Fluids, and Future Challenges in Low-Temperature Power Generation. |
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| Authors: | Sanchez, Felix Donate1 (AUTHOR), Barba Salvador, Javier1 (AUTHOR) javier.barba@uclm.es, Mata Montes, Carmen1 (AUTHOR) |
| Source: | Energies (19961073). Dec2025, Vol. 18 Issue 24, p6561. 35p. |
| Subjects: | Rankine cycle, Working fluids, Renewable energy transition (Government policy), Heat recovery, Renewable energy sources, Heat engines, Energy conversion, System integration |
| Abstract: | In the context of the zero-carbon transition, this article provides a comprehensive review of Organic Rankine Cycle (ORC) technologies for low-grade heat recovery and conversion to power. It surveys a wide range of renewable and waste heat sources—including geothermal, solar thermal, biomass, internal combustion engine exhaust, and industrial process heat—and discusses the integration of ORC systems to enhance energy recovery and thermal efficiency. The analysis examines various configurations, from basic and regenerative cycles to advanced transcritical and supercritical designs, cascaded systems, and multi-source integration, evaluating their thermodynamic performance for different heat source profiles. A critical focus is placed on working fluid selection, where the landscape is being reshaped by stringent regulatory frameworks such as the EU F-Gas regulation, driving a shift towards low-GWP hydrofluoroolefins, natural refrigerants, and tailored zeotropic mixtures. The review benchmarks ORC against competing technologies such as the Kalina cycle, Stirling engines, and thermoelectric generators, highlighting relative performance characteristics. Furthermore, it identifies key trends, including the move beyond single-source applications toward integrated hybrid systems and the use of multi-objective optimization to balance thermodynamic, economic, and environmental criteria, despite persistent challenges related to computational cost and real-time control. Key findings confirm that ORC systems significantly improve low-grade heat utilization and overall thermal efficiency, positioning them as vital components for integrated zero-carbon power plants. The study concludes that synergistically optimizing ORC design, refrigerant choice in line with regulations, and system integration strategies is crucial for maximizing energy recovery and supporting the broader zero-carbon energy transition. [ABSTRACT FROM AUTHOR] |
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| Database: | Engineering Source |
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| Abstract: | In the context of the zero-carbon transition, this article provides a comprehensive review of Organic Rankine Cycle (ORC) technologies for low-grade heat recovery and conversion to power. It surveys a wide range of renewable and waste heat sources—including geothermal, solar thermal, biomass, internal combustion engine exhaust, and industrial process heat—and discusses the integration of ORC systems to enhance energy recovery and thermal efficiency. The analysis examines various configurations, from basic and regenerative cycles to advanced transcritical and supercritical designs, cascaded systems, and multi-source integration, evaluating their thermodynamic performance for different heat source profiles. A critical focus is placed on working fluid selection, where the landscape is being reshaped by stringent regulatory frameworks such as the EU F-Gas regulation, driving a shift towards low-GWP hydrofluoroolefins, natural refrigerants, and tailored zeotropic mixtures. The review benchmarks ORC against competing technologies such as the Kalina cycle, Stirling engines, and thermoelectric generators, highlighting relative performance characteristics. Furthermore, it identifies key trends, including the move beyond single-source applications toward integrated hybrid systems and the use of multi-objective optimization to balance thermodynamic, economic, and environmental criteria, despite persistent challenges related to computational cost and real-time control. Key findings confirm that ORC systems significantly improve low-grade heat utilization and overall thermal efficiency, positioning them as vital components for integrated zero-carbon power plants. The study concludes that synergistically optimizing ORC design, refrigerant choice in line with regulations, and system integration strategies is crucial for maximizing energy recovery and supporting the broader zero-carbon energy transition. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 19961073 |
| DOI: | 10.3390/en18246561 |
