Enhanced performances of ORC-based units for low grade waste heat recovery via evaporator layout optimization.

• Medium-low grade waste heat recovery via ORC for stationary and on-board systems. • Irreversibility reduction through dual pressure heat recovery vapor generator. • Cycle optimum design for maximum energy and exergy cycle efficiency. • Heat transfer coefficients calculation and heat exchange surface assessment. • Benefit-to-cost analysis and heat exchanger cost assessment. The full exploitation of the upper thermal source is the key for enhanced energy performances of ORC-based units for medium and low-grade waste heat recovery. The adoption of a dual evaporation pressure cycle layout has the potential to reduce the heat exchange irreversibility at the evaporation section and to assure a higher net power available at the expander shaft, particularly in small scale units and in presence of upper thermal sources with a highly variable heat release characteristic. The adoption of the dual evaporation pressure technology to small scale recovery units represents a major technological breakthrough and an element of novelty, observing that, at present, the possibility to split the evaporation process in multiple pressure levels is considered mostly with reference to steam generators and boilers. The study investigates the potential energy and exergy advantage of a dual pressure heat recovery vapor generator, with respect to a base-single evaporation pressure layout, for a recovery unit with a mechanical power in the 1–15 kW range, for stationary (100 °C–150 °C hot source temperature) and on-board (350 °C–300 °C hot source temperature) applications. A dedicated optimization procedure allows the maximization of either the net power recovered or the cycle energy efficiency, dependently on the final application of the unit. The exergy efficiency of the heat recovery vapor generator is assessed and its dependence on the fluid characteristics and the main cycle variables discussed, along with the relationship between the energy and exergy gain for the enhanced heat exchange. A preliminary economic analysis provides a first indication of the financial merit of the dual evaporation pressure layout with respect to a base single evaporation pressure configuration. [ABSTRACT FROM AUTHOR]