Environmental and life cycle assessment of organic Rankine cycle technology for industrial waste heat recovery

Abstract

Industrial waste heat recovery offers a significant opportunity to improve energy efficiency and reduce emissions, supporting carbon neutrality and sustainable development. Among various technologies, the organic Rankine cycle (ORC) stands out as a leading technology to exploit low-to-medium temperature heat sources for power generation. While the technical and economic aspects of ORC technology have been extensively studied, research on its sustainability profiles remains fragmented in the literature. This study provides a structured and comprehensive review of life cycle assessment (LCA) research on ORC systems in industrial applications. By systematically analyzing methodological choices such as functional units, system boundaries, inventory data, and impact assessment approaches, this review identifies key inconsistencies, research gaps, and sources of environmental burden across diverse industrial heat sources. The analysis reveals that component material composition, particularly of turbines and heat exchangers, and the choice of working fluids (e.g., low-GWP alternatives) significantly influence lifecycle impacts. It also emphasizes that cycle layout and system configuration can critically affect environmental outcomes. This work integrates fragmented LCA knowledge on ORC technology and proposes future research directions focused on standardized evaluation frameworks, improved data transparency, and sustainability-oriented system design. The findings offer practical guidance for researchers, policymakers, and engineers to improve the environmental and economic viability of ORC-based waste heat recovery solutions.