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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 Pratama2,3 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]
Copyright of Journal of Engineering & Technological Sciences is the property of Institut Teknologi Bandung and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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  Data: Optimizing Evaporator Design in ORC Systems for Waste-to-energy Conversion Using FAST Diagram and Value Engineering.
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  Data: <searchLink fieldCode="JN" term="%22Journal+of+Engineering+%26+Technological+Sciences%22">Journal of Engineering & Technological Sciences</searchLink>. Jun2026, Vol. 58 Issue 3, p348-365. 18p.
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  Data: <searchLink fieldCode="DE" term="%22Evaporators%22">Evaporators</searchLink><br /><searchLink fieldCode="DE" term="%22Value+engineering%22">Value engineering</searchLink><br /><searchLink fieldCode="DE" term="%22Waste+products+as+fuel%22">Waste products as fuel</searchLink><br /><searchLink fieldCode="DE" term="%22Heat+exchanger+efficiency%22">Heat exchanger efficiency</searchLink><br /><searchLink fieldCode="DE" term="%22Cost+functions%22">Cost functions</searchLink><br /><searchLink fieldCode="DE" term="%22Clean+energy%22">Clean energy</searchLink><br /><searchLink fieldCode="DE" term="%22Rankine+cycle%22">Rankine cycle</searchLink>
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  Data: 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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  Data: <i>Copyright of Journal of Engineering & Technological Sciences is the property of Institut Teknologi Bandung and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.5614/j.eng.technol.sci.2026.58.3.4
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      – Code: eng
        Text: English
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        PageCount: 18
        StartPage: 348
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      – SubjectFull: Evaporators
        Type: general
      – SubjectFull: Value engineering
        Type: general
      – SubjectFull: Waste products as fuel
        Type: general
      – SubjectFull: Heat exchanger efficiency
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      – SubjectFull: Cost functions
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      – SubjectFull: Clean energy
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      – SubjectFull: Rankine cycle
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              Text: Jun2026
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