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Integrating ORC systems for energy recovery in battery production: A holistic performance evaluation

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  • Ji, Jie
  • Yin, Qingyuan
  • Ji, Chenliang
  • Shi, Yuanyuan
  • Shi, Jiaming
  • Huang, Hui
  • Sun, Na
  • Peng, Tian
  • Zhang, Chu
  • Zhao, Huanyu

Abstract

Despite significant advancements in Organic Rankine Cycle (ORC) systems for waste heat recovery, existing research often lacks a comprehensive evaluation of working fluid selection, particularly in specialized industrial processes such as lithium battery anode production. This study addresses this gap by conducting an in-depth performance analysis of seven organic working fluids (R11, R113, R123, R141b, R245fa, HFO-R1233zd, and a mixture of pentafluorobutane and cyclohexane) across various operating conditions, including evaporation pressure, superheat, and subcooling. The results reveal that R141b achieves the lowest equivalent carbon dioxide emissions (ECE values) across the entire evaporation pressure range, indicating superior environmental performance. Additionally, R141b demonstrates a maximum net output power of 6.74 kW at 5 bar evaporation pressure, while R11 exhibits the highest thermal efficiency of 9.68 % at 9 bar. These findings highlight the significant impact of working fluid selection on ORC system performance and emphasize the need for a balanced approach to optimize efficiency, output power, and environmental sustainability. Future research will focus on expanding the range of working fluids and exploring intelligent control systems to further enhance ORC technology in waste heat recovery applications.

Suggested Citation

  • Ji, Jie & Yin, Qingyuan & Ji, Chenliang & Shi, Yuanyuan & Shi, Jiaming & Huang, Hui & Sun, Na & Peng, Tian & Zhang, Chu & Zhao, Huanyu, 2025. "Integrating ORC systems for energy recovery in battery production: A holistic performance evaluation," Renewable Energy, Elsevier, vol. 252(C).
    • Handle: RePEc:eee:renene:v:252:y:2025:i:c:s0960148125011991
    DOI: 10.1016/j.renene.2025.123537
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