Multi-objective optimization and exergetic analysis of a low-grade waste heat recovery ORC application on a Brazilian FPSO

•Analysis of low-grade waste heat source recovery on a Brazilian offshore platform.•Multiobjective optimization analysis of ORC application with different fluids.•ORC increased the energy and exergetic efficiency of the platform processes.•Net power generation of 2063 kW providing a 23.6% increase in exergy efficiency. This paper presents an analysis of the application of an Organic Rankine cycle (ORC) for power generation of a Brazilian FPSO (Floating Product Storage Offload). The peculiarity of this analysis is the investigation of power generation using low-temperature waste heat sources. Low-grade sources represent a significant amount of heat rejected on the platform. The primary production in the platform processes was evaluated using ASPEN-HYSYS® software v.8.6. The main sources of low-temperature residual heat were preliminarily identified, and the highest potential for energy recovery was: the heat rejected in the intercoolers and aftercoolers of the compression processes in the Main Compression Unit and the CO2 Compression Unit. For the development of this study, a computational tool was elaborated in MATLAB® to evaluate the thermodynamic performance and to predict the design of the heat exchanger of the ORC. A multi-objective optimization was conducted to verify the ORC application at the established sources. The higher net power was obtained at Main Compression Unit heat recovery, operating with R245CB2 as working fluid. This application allows to generate up to 2063 kW with a heat transfer area of 2997 m2, providing a 23.6% increase in exergy efficiency of the system. The results of this study suggest that the application of ORC cycles on FPSO platforms for heat recovery from low-temperature sources allows an essential increase in the energy and exergetic efficiency of the production processes of the platform. Although the ORC doesn’t give a substantial increase in the supply of electricity, they contribute to less gas consumption in gas turbines. In this way, contributing to a significant reduction of GHG emissions.