This paper investigates an Organic Rankine Cycle (ORC) system for low-to-medium temperature heat recovery using comparative thermodynamic, exergoeconomic and economic modelling. A working-fluid study considering environmental and thermodynamic perspectives is conducted. A 20 kW ORC unit is tested and used as a feasibility and trend-consistency reference to support the modelling assumptions and practical operating bounds. A parametric study then examines the effects of evaporator pressure, condensation temperature, superheat, subcooling and heat-exchanger pinch-point temperature differences on net power output, first- and second-law efficiencies, total product cost and total capital investment under prescribed boundary conditions. Multi-objective optimization is applied to identify Pareto-optimal trade-offs and representative compromise solutions. Results show an intermediate evaporator pressure maximizes net power output, while lower condensation temperature generally improves efficiency; superheat has limited efficiency impact but should ensure safe operation, and a small subcooling margin (around 3 °C) mitigates cavitation risk. The best overall performance is obtained with an evaporator pinch of 3 °C and a condenser pinch of 5–9 °C; tightening pinch constraints increases required heat-transfer area and makes heat exchangers the main cost bottleneck for high-efficiency solutions.
Xie et al. (Wed,) studied this question.