A novel working fluid selection and waste heat recovery by an exergoeconomic approach for a geothermally sourced ORC system

•A novel four-step approach for working fluid selection in geothermal sourced organic Rankine Cycle (ORC) systems.•R113 is proposed as new working fluid in ORCs instead of existing n-pentane.•Waste heat recovery (WHR) options from brine re-injection -where majority of the exergy destruction occurs- are examined.•Based on proposed approach at given re-injection temperature, R115 is selected as the working fluid of WHR cycle. A novel working fluid selection methodology is proposed for organic Rankine cycles (ORCs) coupled with low-grade geothermal sources by employing an existing dataset of an operating binary geothermal plant that works with n-pentane. Thermodynamic and thermoeconomic aspects of power production are combined to evaluate 29 different single-component working fluid candidates from different chemical branches in four-step elimination methodology. In terms of working fluid classification from physical point of view, results indicate that there is a direct relationship between vapor expansion ratio (VER) and net work output for dry working fluids. On the other hand, it is shown that isentropic fluids behave differently from dry fluids. Based on the proposed methodology, R113 is selected as a new working fluid for the existing plant instead of n-pentane. Results indicate that by applying the proposed methodology, it is possible to increase first and second law efficiencies of plant 0.59% and 3.18%, respectively, while reducing the levelized electrical cost (LEC) around 11% in comparison to base plant outputs with n-pentane. Furthermore, a case study is presented in addition the plant level analysis by implementing a hypothetical waste heat recovery cycle, configurated with proposed methodology, in order to reduce exergy losses originating from brine re-injection. It is shown that it may be possible to further reduce the LEC around 1% and increase the overall efficiencies 0.1% for the first law and 0.26% for the second law. However, it is necessary to be deliberate about these final results since they also demonstrate the sensitivity of LEC to the increases in second law efficiency rather than levelized capital investments.