Paper Titles
Impact of Bamboo Particles Treatments on the Physicomechanical, Thermal and Structural Properties of Polypropylene Random
p.21
Performance and Predictive Modeling of Self-Compacting Mortars Containing Fine RAP and Silica Fume
p.41
Identification of Friction Stir Welding Joint Areas in Crevices of Polyethylene Pipes
p.65
Investigation of Thermal Hydraulic Performance of Wavy Double Forward Facing Step
p.83
Parametric and Computational Fluid Dynamics Study on Improving the Design of a Degumming Reactor
p.99
Thermodynamic Optimization of an Organic Rankine Cycle for Energy Recovery from Phosphogypsum Desulfurization Waste Heat
p.117
Fluid-Structure Interaction Analysis of Load Capacity Characteristics for Main Bearing Bush in Marine Low-Speed Engine
p.129
The Effect of Clearances on the Contact Interaction Force in the Parts of a Screw Conveyor Drive
p.143
Analytical Study and Conservation Plan of Akhmerutnisut’s Tomb at Western Cemetery, Giza Plateau, Egypt
p.155

Thermodynamic Optimization of an Organic Rankine Cycle for Energy Recovery from Phosphogypsum Desulfurization Waste Heat

Article Preview

Abstract:

In heavy industrial processes, such as the treatment of phosphogypsum (a by-product of fertilizer manufacturing), a colossal amount of heat is generated and, in most cases, simply released into the atmosphere. This is a free and abundant source of energy that we are wasting. This research proposes to transform this low-temperature waste heat into usable electricity using smart technology : the Organic Rankine Cycle (ORC). Think of the ORC as a mini power plant (prototype) specially designed for low temperatures. Instead of using water, it uses a special organic fluid (similar to a refrigerant) that boils very easily, allowing it to capture the energy from the residual heat and convert it into electricity. This approach is not only environmentally friendly and economically viable, but it also makes the entire industrial process much more efficient while reducing thermal pollution released into the environment. To ensure the best performance, the investigation tested four different fluids (R245fa, R1233zd, R1234ze, and R227ea) using advanced Aspen Plus simulations. The most powerful organic fluid is R245fa, which proved to be the best performer, capable of converting 16.9% of waste heat into electricity. This study validates that integrating ORC systems into phosphogypsum processing plants is technically feasible and financially sound. It opens the door to more sustainable industrial practices and better management of our energy resources.

You might also be interested in these eBooks
International Journal of Engineering Research in Africa Vol. 79 View Preview

Info:

Periodical:

International Journal of Engineering Research in Africa (Volume 79)

Pages:

117-128

DOI:

https://doi.org/10.4028/p-tdEfg7

Citation:

Cite this paper

Online since:

June 2026

Authors:

Majdouline Alla, Omar Ghoulam, Kamal Amghar*, Mohamed Larbi El Hafyan, El Khadir Gharibi

Keywords:

AEA, Aspen Plus, Desulfurization, Electricity, Organic Rankine Cycle (ORC), Phosphogypsum (PG), Thermal Energy

Export:

RIS, BibTeX

Price:

Permissions CCC:

Request Permissions

Permissions PLS:

Request Permissions

Сopyright:

© 2026 Trans Tech Publications Ltd. All Rights Reserved

Share:

Citation:

* - Corresponding Author

References

[1] X. Li, S. Han, Z. Liu, C. He, B. Zhang & Q. Chen, Design optimization and analysis of a multi-temperature partition and multi-configuration integrated organic Rankine cycle for low temperature heat recovery, Energy Conversion and Management. 293 (2023) 117504.

DOI: 10.1016/j.enconman.2023.117504

Google Scholar

[2] E. Sun, Y. Sun, S. Feng, L. Zhang, J. Xu, & Z. Zheng Miao, Thermodynamic study of organic Rankine cycle based on extraction steam compression regeneration in the supercritical state, Energy Conversion and Management. 293 (2023) 117546.

DOI: 10.1016/j.enconman.2023.117546

Google Scholar

[3] S.Damarseckin, S.Y.J. Kane, A. Atiz, M. Karakilcik, H. Sogukpinar, & I . Bozkurt, A comparative review of ORC and R-ORC technologies in terms of energy, exergy, and economic performance, Heliyon. 10 (23) (2024), e40575.

DOI: 10.1016/j.heliyon.2024.e40575

Google Scholar

[4] S. Gürgen, & İ. Altın, Novel decision-making strategy for working fluid selection in Organic Rankine Cycle: a case study for waste heat recovery of a marine diesel engine. Energy. 286 (2024) 129541.

DOI: 10.1016/j.energy.2022.124023

Google Scholar

[5] Y. Peng, X. Lin, J. Liu, W. Su & N. Zhou (2021), Machine learning prediction of ORC performance based on properties of working fluid, Applied Thermal Engineering, 195 (2021) 117184.

DOI: 10.1016/j.applthermaleng.2021.117184

Google Scholar

[6] Y.S. Jeong, K. Park, & Y.C. Jang, Optimal working-fluid selection for organic Rankine cycle integrated into a combined cycle cogeneration plant. Journal of Mechanical Science and Technology, 38(4) (2024) 2073-2080.

DOI: 10.1007/s12206-024-0337-0

Google Scholar

[7] L.Wang et al, (2024), Multi-objective optimization of an organic Rankine cycle (ORC) for a hybrid solar-waste energy plant, Energies, 17(2024) 1810.

DOI: 10.3390/en17081810

Google Scholar

[8] P. Li, J. Xu, B. Wang, J. Liu, W. Zhao, & Z. Han, Performance analysis of a coupled system based on organic Rankine cycle and double effect absorption refrigeration for waste heat recovery in data center, Journal of Thermal Science, 33 (2024) 2043-2056.

DOI: 10.1007/s11630-024-2043-8

Google Scholar

[9] M. Alla, A. Harrou, M.A. Elhafiany, M. Azerkane, M. El Ouahabi and E. Gharibi, Reduction of phosphogypsum to calcium sulfide (CaS) using metallic iron in a hydrochloric acid medium, Phosphorus, Sulfur, and Silicon and the Related Elements, 197 (2020) 1026-1035.

DOI: 10.1080/10426507.2022.2052881

Google Scholar

[10] X. Zhang et al. (2025), Performance simulation and optimization of ship waste heat TEG-ORC combined cycle based on R1234ze and its mixed working fluids, Journal of Traffic and Transportation Engineering, 12 (2020) 147-159.

Google Scholar

[11] T.C. Hung, T.Y. Shai, S.K. Wang, (2012), A review of Organic Rankine Cycle (ORC) for the recovery of low-grade waste heat, Energy, 16 (2012) 3763-3775.

Google Scholar

[12] S. Lecompte, H. Huisseune, M. Van den Broek, B. Vanslambrouck, M. De Paepe, (2015), Review of organic Rankine cycle (ORC) architectures for waste heat recovery, Renewable and Sustainable Energy Reviews, 47 (2015) 448-461.

DOI: 10.1016/j.rser.2015.03.089

Google Scholar

[13] A. J. Grebenkov, O.V. Beliayeva, P.M. Klepatski, V.V. Saplitsa, B.D. Timofeyev, V.P. Tsurbelev, T.A. Zayats, Thermophysical Properties of R245fa, Final Report. ASHRAE Research Project 1256-RP, 2004.

Google Scholar

[14] J.M. Calm, G.C. Hourahan, Refrigerant Data Summary. Engineered Systems, 18 (2001) 74-88.

Google Scholar

[15] A. Landelle, N. Tauveron, P. Haberschill, R. Revellin, S. Colasson, (2017), Organic Rankine Cycle design and performance comparison based on experimental database, Applied Energy, 204 (2017) 1172-1187.

DOI: 10.1016/j.apenergy.2017.04.012

Google Scholar

[16] F. Molés, J. Navarro-Esbrí, B. Peris, A. Mota-Babiloni, A. Barragán-Cervera, (2014), Low GWP alternatives to HFC-245fa in Organic Rankine Cycles for low temperature heat recovery: HCFO-1233zd-E and HFO-1336mzz-Z, Applied Thermal Engineering, 71(2014) 204-212.

DOI: 10.1016/j.applthermaleng.2014.06.055

Google Scholar

[17] M.T. White, O.A. Oyewunmi, A.J. Haslam, C.N. Markides, (2018), Industrial waste-heat recovery through integrated computer-aided working-fluid and ORC system optimisation using SAFT-γ Mie, Energy Conversion and Management, 150 (2018) 851-869.

DOI: 10.1016/j.enconman.2017.03.048

Google Scholar

[18] J. Bao, L. Zhao, A review of working fluid and expander selections for organic Rankine cycle, Renewable and Sustainable Energy Reviews, 24 (2013) 325-342.

DOI: 10.1016/j.rser.2013.03.040

Google Scholar

[19] S. Quoilin, M. Orosz, H. Hemond, V. Lemort, (2011), Performance and design optimization of a low-cost solar organic Rankine cycle for remote power generation, Solar Energy, 85(2011) 955-966.

DOI: 10.1016/j.solener.2011.02.010

Google Scholar

[20] B. Peris, J. Navarro-Esbrí, F. Molés, A. Mota-Babiloni, Experimental study of an ORC (organic Rankine cycle) for low grade waste heat recovery in a ceramic industry, Energy, 85 (2015) 534-542.

DOI: 10.1016/j.energy.2015.03.065

Google Scholar

[21] J. Song, Y. Zhang, H. Li, Y. Song, B. Li, T.C. Hung, Low-grade thermal energy utilization through using organic Rankine cycle system and R1233zd(E) at different heat source temperatures, Energy, 230(Part A) (2023) 120706.

DOI: 10.1016/j.applthermaleng.2023.120706

Google Scholar

[22] H. Guo, Y. Zhang, S. Wang et al (2022), Investigation of a dual-loop ORC for the waste heat recovery of a marine main engine, Energies, 15(2022) 8365.

DOI: 10.3390/en15228365

Google Scholar

[23] H. Zhang, E. Wang, B. Fan, Heat transfer analysis of a finned-tube evaporator for engine exhaust heat recovery, Energy Conversion and Management, 65 (2013) 438-447.

DOI: 10.1016/j.enconman.2012.09.017

Google Scholar

[24] F. Campana, M. Bianchi, L. Branchini, A. De Pascale, A. Peretto, M. Baresi, A. Fermi, N. Rossetti, R. Vescovo, ORC waste heat recovery in European energy intensive industries : Energy and GHG savings, Energy Conversion and Management, 76 (2013) 244-252.

DOI: 10.1016/j.enconman.2013.07.041

Google Scholar

[25] P.C. Liu, S. Wang, S, C.Zhang, Q. Li, X. Xu, E. Huo, Experimental study of micro-scale organic Rankine cycle system based on scroll expander, Energy, 188 (2019) 115930.

DOI: 10.1016/j.energy.2019.115930

Google Scholar

[26] J. Song, Y. Song, C. W. Gu, Thermodynamic analysis and performance optimization of an Organic Rankine Cycle (ORC) waste heat recovery system for marine diesel engines, Energy, 82 (2015) 976-985.

DOI: 10.1016/j.energy.2015.01.108

Google Scholar