Performance study of an integrated system combining a small-scale Organic Rankine Cycle power generation unit and an air compressor for waste heat recovery

Research Article
Open access

Performance study of an integrated system combining a small-scale Organic Rankine Cycle power generation unit and an air compressor for waste heat recovery

Xiaohui Yu 1* , Yunhao Shao 2 , Shihao Li 3
  • 1 Hebei University of Technology    
  • 2 Hebei University of Technology    
  • 3 Hebei University of Technology    
  • *corresponding author 2018133@hebut.edu.cn
Published on 10 June 2025 | https://doi.org/10.54254/2977-3903/2025.23983
AEI Vol.16 Issue 6
ISSN (Print): 2977-3911
ISSN (Online): 2977-3903

Abstract

This paper proposes a waste heat recovery system that integrates a small-scale Organic Rankine Cycle (ORC) power generation unit with an air compressor using lubricating oil. An innovative design directly connects the capacitor to the scroll expander, replacing the traditional generator. Experimental results show that when the lubricating oil is at 105°C and the cooling water at 19°C, the system achieves a maximum power output of 1.754 kW and a thermal-electric efficiency of 3.91%. Once the lubricating oil flow rate exceeds a certain threshold, its impact on efficiency improvement becomes limited, whereas lowering the cooling water temperature significantly enhances efficiency (3.91% at 19°C, dropping to 2.7% at 30°C). Increasing the capacitor size allows a maximum power output of 1.667 kW and a thermal efficiency of 3.66%. This system offers an efficient solution for recovering waste heat from industrial air compressors.

Keywords:

screw air compressor, lubricating oil-based ORC power generation, energy analysis

Yu,X.;Shao,Y.;Li,S. (2025). Performance study of an integrated system combining a small-scale Organic Rankine Cycle power generation unit and an air compressor for waste heat recovery. Advances in Engineering Innovation,16(6),10-20.
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References

[1]. Chovancová, J., Petruška, I., Pata, U. K., Adamišin, P. (2025). Diverse pathways to decarbonization: Cluster-specific impacts of energy sources on CO₂ emissions in the European Union. Energy Nexus, 17.

[2]. Gao, J., Wang, H., & Sharma, M. (2024). Research progress and prospects of CO₂ fracturing for developing unconventional energy sources. Geoenergy Science and Engineering, 241.

[3]. Supaokit, A., Verma, V., Wang, W.-C., Chen, C.L., Wang, M.-S., Nugroho, R.A.-A., Duong, V.-D., Hsu, W.-H. (2025). Turning CO₂ into an alternative energy source: Study on methanation reaction optimization. Applied Catalysis A: General, 691.

[4]. Xia, C., Balsalobre-Lorente, D., & Raza Syed, Q. (2025). Electricity generation from renewable and non-renewable energy sources in China: The role of environmental policy stringency, FDI, and economic growth. Energy, 318.

[5]. Chen, X. H., Tee, K., Elnahass, M., Ahmed, R. (2023). Assessing the environmental impacts of renewable energy sources: A case study on air pollution and carbon emissions in China. Journal of Environmental Management, 345.

[6]. Srivastava, M., Sarkar, J., Sarkar, A., Maheshwari, N.K., Antony, A. (2024). Thermo-economic feasibility study to utilize ORC technology for waste heat recovery from Indian nuclear power plants. Energy, 298.

[7]. Zhang, Q., Feng, Y.-Q., Xu, K.-J., Liang, H.-J., Liu, Z.-N., Zhao, C.-Y., Wang, Y.-Z., Sapin, P., Markides, C.N. (2024). Dynamic behaviour and performance evaluation of a biomass-fired organic Rankine cycle combined heat and power (ORC-CHP) system under different control strategies. Applied Thermal Engineering, 248.

[8]. Permana, D. I., Mahardika, M. A., Rusirawan, D., Farkas, I. (2024). Utilization of small solar ORC integrated with phase change material in Indonesia condition. Journal of Energy Storage, 92.

[9]. Lei, B., Wang, J.-F., Wu, Y.-T., Ma, C.-F., Wang, W., Zhang, L., Li, J.-Y. (2016). Experimental study and theoretical analysis of a Roto-Jet pump in small scale organic Rankine cycles. Energy Conversion and Management, 111, 198–204.

[10]. Zakeralhoseini, S., & Schiffmann, J. (2023). Design, computational and experimental investigation of a small-scale turbopump for organic Rankine cycle systems. Energy Conversion and Management, 287.

[11]. Wronski, J., Imran, M., Skovrup, M. J., Haglind, F. (2019). Experimental and numerical analysis of a reciprocating piston expander with variable valve timing for small-scale organic Rankine cycle power systems. Applied Energy, 247, 403–416.

[12]. Tsai, Y.-C., Feng, Y.-Q., Shuai, Y., Lai, J.-H., Leung, M.K.H., Wei, Y., Hsu, H.-Y., Hung, T.-C. (2023). Experimental validation of a 0.3 kW ORC for the future purposes in the study of low-grade thermal to power conversion. Energy, 285.

[13]. Jiang, L., Wang, R. Q., & Roskilly, A. P. (2020). Techno-economic analysis on a small-scale organic Rankine cycle with improved thermal driven pump. Energy Conversion and Management, 217.

[14]. Xiao, M., Zhou, Y., Miao, Z., Yan, P., Zhang, M., Xu, J. (2024). Multi-condition operating characteristics and optimization of a small-scale ORC system. Energy, 290.

[15]. Colak, A. B., & Arslan, O. (2024). Numerical analysis-based performance assessment of the small-scale organic Rankine cycle turbine design for residential applications. Thermal Science and Engineering Progress, 51.

[16]. Shen, J., Li, Z., Tan, N., Xiao, Y. (2022). Design and analysis of a suction pretreatment system for the air compressor. Energy Conversion and Management, 263.

[17]. Murgia, S., Valenti, G., Colletta, D., Costanzo, I., Contaldi, G. (2017). Experimental investigation into an ORC-based low-grade energy recovery system equipped with sliding-vane expander using hot oil from an air compressor as thermal source. In Proceedings of the 4th International Seminar on ORC Power Systems (ORC) (pp. 13–15). Politecnico Milano Bovisa Campus.

[18]. Valenti, G., Valenti, A., & Staboli, S. (2019). Proposal of a thermally-driven air compressor for waste heat recovery. Energy Conversion and Management, 196, 1113–1125.


Cite this article

Yu,X.;Shao,Y.;Li,S. (2025). Performance study of an integrated system combining a small-scale Organic Rankine Cycle power generation unit and an air compressor for waste heat recovery. Advances in Engineering Innovation,16(6),10-20.

Data availability

The datasets used and/or analyzed during the current study will be available from the authors upon reasonable request.

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About volume

Journal:Advances in Engineering Innovation

Volume number: Vol.16
Issue number: Issue 6
ISSN:2977-3903(Print) / 2977-3911(Online)

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References

[1]. Chovancová, J., Petruška, I., Pata, U. K., Adamišin, P. (2025). Diverse pathways to decarbonization: Cluster-specific impacts of energy sources on CO₂ emissions in the European Union. Energy Nexus, 17.

[2]. Gao, J., Wang, H., & Sharma, M. (2024). Research progress and prospects of CO₂ fracturing for developing unconventional energy sources. Geoenergy Science and Engineering, 241.

[3]. Supaokit, A., Verma, V., Wang, W.-C., Chen, C.L., Wang, M.-S., Nugroho, R.A.-A., Duong, V.-D., Hsu, W.-H. (2025). Turning CO₂ into an alternative energy source: Study on methanation reaction optimization. Applied Catalysis A: General, 691.

[4]. Xia, C., Balsalobre-Lorente, D., & Raza Syed, Q. (2025). Electricity generation from renewable and non-renewable energy sources in China: The role of environmental policy stringency, FDI, and economic growth. Energy, 318.

[5]. Chen, X. H., Tee, K., Elnahass, M., Ahmed, R. (2023). Assessing the environmental impacts of renewable energy sources: A case study on air pollution and carbon emissions in China. Journal of Environmental Management, 345.

[6]. Srivastava, M., Sarkar, J., Sarkar, A., Maheshwari, N.K., Antony, A. (2024). Thermo-economic feasibility study to utilize ORC technology for waste heat recovery from Indian nuclear power plants. Energy, 298.

[7]. Zhang, Q., Feng, Y.-Q., Xu, K.-J., Liang, H.-J., Liu, Z.-N., Zhao, C.-Y., Wang, Y.-Z., Sapin, P., Markides, C.N. (2024). Dynamic behaviour and performance evaluation of a biomass-fired organic Rankine cycle combined heat and power (ORC-CHP) system under different control strategies. Applied Thermal Engineering, 248.

[8]. Permana, D. I., Mahardika, M. A., Rusirawan, D., Farkas, I. (2024). Utilization of small solar ORC integrated with phase change material in Indonesia condition. Journal of Energy Storage, 92.

[9]. Lei, B., Wang, J.-F., Wu, Y.-T., Ma, C.-F., Wang, W., Zhang, L., Li, J.-Y. (2016). Experimental study and theoretical analysis of a Roto-Jet pump in small scale organic Rankine cycles. Energy Conversion and Management, 111, 198–204.

[10]. Zakeralhoseini, S., & Schiffmann, J. (2023). Design, computational and experimental investigation of a small-scale turbopump for organic Rankine cycle systems. Energy Conversion and Management, 287.

[11]. Wronski, J., Imran, M., Skovrup, M. J., Haglind, F. (2019). Experimental and numerical analysis of a reciprocating piston expander with variable valve timing for small-scale organic Rankine cycle power systems. Applied Energy, 247, 403–416.

[12]. Tsai, Y.-C., Feng, Y.-Q., Shuai, Y., Lai, J.-H., Leung, M.K.H., Wei, Y., Hsu, H.-Y., Hung, T.-C. (2023). Experimental validation of a 0.3 kW ORC for the future purposes in the study of low-grade thermal to power conversion. Energy, 285.

[13]. Jiang, L., Wang, R. Q., & Roskilly, A. P. (2020). Techno-economic analysis on a small-scale organic Rankine cycle with improved thermal driven pump. Energy Conversion and Management, 217.

[14]. Xiao, M., Zhou, Y., Miao, Z., Yan, P., Zhang, M., Xu, J. (2024). Multi-condition operating characteristics and optimization of a small-scale ORC system. Energy, 290.

[15]. Colak, A. B., & Arslan, O. (2024). Numerical analysis-based performance assessment of the small-scale organic Rankine cycle turbine design for residential applications. Thermal Science and Engineering Progress, 51.

[16]. Shen, J., Li, Z., Tan, N., Xiao, Y. (2022). Design and analysis of a suction pretreatment system for the air compressor. Energy Conversion and Management, 263.

[17]. Murgia, S., Valenti, G., Colletta, D., Costanzo, I., Contaldi, G. (2017). Experimental investigation into an ORC-based low-grade energy recovery system equipped with sliding-vane expander using hot oil from an air compressor as thermal source. In Proceedings of the 4th International Seminar on ORC Power Systems (ORC) (pp. 13–15). Politecnico Milano Bovisa Campus.

[18]. Valenti, G., Valenti, A., & Staboli, S. (2019). Proposal of a thermally-driven air compressor for waste heat recovery. Energy Conversion and Management, 196, 1113–1125.