Optimizing Evaporator Design in ORC Systems for Waste-to-energy Conversion Using FAST Diagram and Value Engineering.

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Title:	Optimizing Evaporator Design in ORC Systems for Waste-to-energy Conversion Using FAST Diagram and Value Engineering.
Authors:	Wibowo, R. Susalit Setya¹, Satmintareja¹, Abdurahman, Asep Duduh¹, Suyatmin¹, Darmawan¹, Gunawan, Ari¹, Budiarti, Kusumawati Dewi¹, Baddu, Nasrul¹, Pramono, Adhi¹, Faisal¹, Nugroho, Cahyono¹, Ngudiwaluyo, Suharto¹, Putra, Zico Pratama^2,3 zico.pratama.putra@brin.go.id
Source:	Journal of Engineering & Technological Sciences. Jun2026, Vol. 58 Issue 3, p348-365. 18p.
Subjects:	Evaporators, Value engineering, Waste products as fuel, Heat exchanger efficiency, Cost functions, Clean energy, Rankine cycle
Abstract:	The global waste crisis, with 2.01 billion tons of municipal solid waste generated annually, necessitates innovative solutions for sustainable energy conversion. This study addresses the critical need to optimize evaporator design in Organic Rankine Cycle (ORC) systems for waste-to-energy applications, where evaporators represent 35-40% of total system costs. We developed an integrated optimization framework combining Function Analysis System Technique (FAST) diagrams with Value Engineering (VE) principles to systematically analyze component functionality and cost structures. Applied to an 887 kW shell-and-tube evaporator, our methodology revealed that tubes, baffles, and shells account for 90% of production costs. The optimization approach achieved a 22.6% cost reduction (from Rp. 310,261,000 to Rp. 243,739,146) while simultaneously improving thermal efficiency by 15.3% (heat transfer coefficient increased from 850 to 980 W/m²·K, thermal effectiveness from 0.72 to 0.83). This challenges the conventional trade-off between cost and performance by demonstrating simultaneous optimization of both parameters. The methodology provides a replicable framework for ORC system optimization with an 8-month payback period and 12% reduction in annual operating costs, contributing to the economic viability of waste-to-energy technologies. [ABSTRACT FROM AUTHOR]
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Database:	Engineering Source

Description
Abstract:	The global waste crisis, with 2.01 billion tons of municipal solid waste generated annually, necessitates innovative solutions for sustainable energy conversion. This study addresses the critical need to optimize evaporator design in Organic Rankine Cycle (ORC) systems for waste-to-energy applications, where evaporators represent 35-40% of total system costs. We developed an integrated optimization framework combining Function Analysis System Technique (FAST) diagrams with Value Engineering (VE) principles to systematically analyze component functionality and cost structures. Applied to an 887 kW shell-and-tube evaporator, our methodology revealed that tubes, baffles, and shells account for 90% of production costs. The optimization approach achieved a 22.6% cost reduction (from Rp. 310,261,000 to Rp. 243,739,146) while simultaneously improving thermal efficiency by 15.3% (heat transfer coefficient increased from 850 to 980 W/m²·K, thermal effectiveness from 0.72 to 0.83). This challenges the conventional trade-off between cost and performance by demonstrating simultaneous optimization of both parameters. The methodology provides a replicable framework for ORC system optimization with an 8-month payback period and 12% reduction in annual operating costs, contributing to the economic viability of waste-to-energy technologies. [ABSTRACT FROM AUTHOR]
ISSN:	23375779
DOI:	10.5614/j.eng.technol.sci.2026.58.3.4