2014 Springer-Verlag Berlin Heidelberg. This paper proposes a systematic approach for energy integration involving waste heat recovery through an organic Rankine cycle (ORC). The proposed approach is based on a two-stage procedure. In the first stage, heating and cooling targets are determined through heat integration. This enables the identification of the excess process heat available for use in the ORC. The optimization of the operating conditions and design of the cogeneration system are carried out in the second stage using genetic algorithms. A modular sequential simulation approach is proposed including several correlations to determine the properties for the streams in the ORC. The proposed approach is applied to a case study which addresses the tradeoffs among the different forms of energy and associated costs. The results show that the optimal selection of the operating conditions and working fluid is very important to reduce the costs associated to the process.
