Thermodynamic and economic analysis of a novel solar heating crude oil system in oil refinery

Li, Yang; Yang, Jin-Rong; Chen, Hong-Wei; Lin, Chang-Hua

doi:10.1590/1517-7076-rmat-2024-0018

Yang Li

Liaoning Petrochemical University, College of Petroleum Engineering. Fushun, 113001, Liaoning, China.

Jin-Rong Yang

Liaoning Petrochemical University, College of Petroleum Engineering. Fushun, 113001, Liaoning, China.

Hong-Wei Chen

Liaoning Petrochemical University, College of Petroleum Engineering. Fushun, 113001, Liaoning, China.

https://orcid.org/0000-0003-0953-3340

Chang-Hua Lin

Qiandongnan Polytechnic College. Kaili City, 556099, Guizhou, China.

Corresponding Author: Hong-Wei Chen e-mail: chenhongwei@lnpu.edu.cn, liyang@lnpu.edu.cn, 13238582547@163.com, chenhongwei@lnpu.edu.cn, linchanghua0626@163.com

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Figure 1
Process flow diagram of the proposed solar heating crude oil system.

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Figure 2
The effect of compressor pressure ratio on (a) overall energy efficiency and exergy efficiency, and (b) system net output work.

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Figure 3
The effect of crude oil flow rate on (a) overall energy efficiency and exergy efficiency, and (b) heat gain of heat exchangers.

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Figure 4
The effect of turbine inlet pressure on (a) overall energy efficiency and exergy efficiency, and (b) Rankine cycle energy efficiency and exergy efficiency.

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Figure 5
The effect of turbine inlet temperature on (a) overall energy efficiency and exergy efficiency (b) Rankine cycle energy efficiency and exergy efficiency.

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Figure 6
The effect of Rankine cycle fluid flow on (a) overall energy efficiency and exergy efficiency, and (b) Rankine cycle energy efficiency and exergy efficiency.

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Figure 7
(a) The effect of charging duration on TES energy efficiency and exergy efficiency. (b) The effect of discharging duration on TES energy efficiency and exergy efficiency.

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Figure 8
The exergy destruction rate of each component.

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Figure 9
The effect of electricity energy price on (a) annualized cost of system and levelized cost of product, and (b) net annual benefit and period of return.

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Table 1
Structural parameters of TES tank.

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Table 2
Simulation conditions of the proposed system.

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Table 3
The main parameters of the solar concentrating system [²⁰[20] WU, S.Y., XIAO, L, CAO, Y., et al., “A parabolic dish/AMTEC solar thermal power system and its performance evaluation”. Applied Energy, v. 87, n. 2, pp. 452–462, 2010. doi: https://doi.org/10.1016/j.apenergy.2009.08.041.
https://doi.org/10.1016/j.apenergy.2009.... ].

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Table 4
Validation of the thermal efficiency of the solar receiver in various average operating wall temperature in the cavity.

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Table 5
Purchased cost of components.

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Table 6
Economic parameters in annualized cost of system.

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Table 7
Data of each state point of the heating system.

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Table 8
Main findings of thermodynamic analysis.

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Table 9
Results of economic analysis of the system.

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PARAMETER	VALUE
Material	Mullite-Cordierite
Hole pattern	Hexagonal hole
Aperture	2.9 mm
Wall thickness	0.8 mm
Porosity	0.61
Density	958 kg/m³
Specific heat capacity	1000 J/(kgK)
Diameter	1.5 m
Height	4 m

PARAMETER	VALUE
Ambient temperature	25 °C
Ambient pressure	101.3 kPa
The minimum heat exchange temperature difference of the heat exchanger	15 °C
The isentropic efficiency of the pump and compressor	85%
The flow rate of crude oil	14 kg/s
The flow rate of air	40 kg/s
The initial temperature of air	20 °C
The initial temperature of crude oil	25 °C
The final temperature of crude oil	320 °C

PARAMETER	SYMBOL	VALUE
Dish concentrator aperture area	A _a	11×11 m²
Normal direct insolation (DNI) per unit of collector area	I _s	900 W/m²
Reflectivity of dish surface	ρ	0.94
Transmittance–absorptance product	τα	0.99
Intercept factor of receiver	γ	0.99
Cavity internal area of the receiver	A _w	0.0654 m²
Radiative emissivity of cavity	ε _c	0.9
Geometrical concentration ratio	C	3000
Stefan–Boltzmann constant	σ	5.672 × 10^–8 W/(m² K⁴)
Ambient temperature	T _a	25 °C

AVERAGE WALL TEMPERATURE IN THE CAVITY (°C)	THERMAL EFFICIENCY (%)
AVERAGE WALL TEMPERATURE IN THE CAVITY (°C)	THIS WORK	REF. [²⁰[20] WU, S.Y., XIAO, L, CAO, Y., et al., “A parabolic dish/AMTEC solar thermal power system and its performance evaluation”. Applied Energy, v. 87, n. 2, pp. 452–462, 2010. doi: https://doi.org/10.1016/j.apenergy.2009.08.041. https://doi.org/10.1016/j.apenergy.2009.... ]	ERROR
800	96.65	96.62	0.03
850	96.12	96.08	0.04
900	95.52	95.47	0.05
950	94.84	94.79	0.05
1000	94.08	94.03	0.05
1050	93.25	93.18	0.07
1100	92.31	92.24	0.07
1150	91.29	91.20	0.09
1200	90.14	90.04	0.10
1250	88.88	88.77	0.11
1300	87.50	87.38	0.12

COMPONENT	PURCHASED EQUIPMENT COST FUNCTIONS	REFERENCE
Heat exchanger	$C_{H X} = 85000 + 409 N_{H X}^{0.85}$	[²²[22] REYHANI, H.A., MERATIZAMAN, M., EBRAHIMI, A., et al., “Thermodynamic and economic optimization of SOFC-GT and its cogeneration opportunities using generated syngas from heavy fuel oil gasification”, Energy, v. 107, pp. 141–164, 2016. doi: https://doi.org/10.1016/j.energy.2016.04.010. https://doi.org/10.1016/j.energy.2016.04... ]
Pump	$C_{p u m p} = 705 .48 {\dot{W}}^{0.71} (1 + \frac{0.2}{1 - η_{p u m p}})$	[²³[23] GHORBANI, B., MEHRPOOYA, M., SHIMMOHAMMADI, R., et al., “A comprehensive approach toward utilizing mixed refrigerant and absorption refrigeration systems in an integrated cryogenic refrigeration process”, Journal of Cleaner Production, v. 179, pp. 495–514, 2018. doi: https://doi.org/10.1016/j.jclepro.2018.01.109. https://doi.org/10.1016/j.jclepro.2018.0... ]
Collector	$C_{C S P} = 50 N_{C S P}$	[²¹[21] MORADI, M., MEHRPOOYA, M., “Optimal design and economic analysis of a hybrid solid oxide fuel cell and parabolic solar dish collector, combined cooling, heating and power (CCHP) system used for a large commercial tower”, Energy, v. 130, pp. 530–543, 2017. doi: http://dx.doi.org/10.1016/j.energy.2017.05.001. https://doi.org/10.1016/j.energy.2017.05... ]
Compressor	$C_{c o m p r e s s o r} = \frac{39.5 \times \dot{m}}{ε_{C}} (\frac{p_{d c}}{p_{s u c}}) In (\frac{p_{d c}}{p_{s u c}})$	[²⁴[24] GALANTI, L., MASSARDO, A.F., “Micro gas turbine thermodynamic and economic analysis up to 500 kWe size”, Applied Energy, v. 88, n. 12, pp. 4795–4802, 2011. doi: http://dx.doi.org/10.1016/j.apenergy.2011.06.022. https://doi.org/10.1016/j.apenergy.2011.... ]
Turbine	$C_{t u r b i n e} = 3644.3 {\dot{W}}^{0.7} - 61.3 {\dot{W}}^{0.95}$	[²²[22] REYHANI, H.A., MERATIZAMAN, M., EBRAHIMI, A., et al., “Thermodynamic and economic optimization of SOFC-GT and its cogeneration opportunities using generated syngas from heavy fuel oil gasification”, Energy, v. 107, pp. 141–164, 2016. doi: https://doi.org/10.1016/j.energy.2016.04.010. https://doi.org/10.1016/j.energy.2016.04... ]
Boiler	$C_{b o i l e r} = (0.249 p_{b o i l e r} + 47.19) \dot{m} + 3.29 p_{b o i l e r} + 624.6$	[²⁵[25] MANESH, M.H.K., GHALAMI, H., AMIDPOUR, M., et al., “Optimal coupling of site utility steam network with MED-RO desalination through total site analysis and exergoeconomic optimization”, Desalination, v. 316, pp. 42–52, 2013. doi: https://doi.org/10.1016/j.desal.2013.01.022. https://doi.org/10.1016/j.desal.2013.01.... ]
Condenser	$C_{c o n d n s e r} = 516 .621 N_{c o n d n s e r} + 268.45$	[²²[22] REYHANI, H.A., MERATIZAMAN, M., EBRAHIMI, A., et al., “Thermodynamic and economic optimization of SOFC-GT and its cogeneration opportunities using generated syngas from heavy fuel oil gasification”, Energy, v. 107, pp. 141–164, 2016. doi: https://doi.org/10.1016/j.energy.2016.04.010. https://doi.org/10.1016/j.energy.2016.04... ]
TES tank	$C_{s t o r a g e} = 17400 + 79 W_{s t o r a g e}^{0.85}$	[²⁶[26] BENATO, A., “Performance and cost evaluation of an innovative Pumped Thermal Electricity Storage power system”, Energy, v. 138, pp. 419–436, 2017. doi: http://dx.doi.org/10.1016/j.energy.2017.07.066. https://doi.org/10.1016/j.energy.2017.07... ]
Desalter	$C_{d e s a l t e r} = 8500+409 N_{d e s a l t e r}^{0.85}$	[²²[22] REYHANI, H.A., MERATIZAMAN, M., EBRAHIMI, A., et al., “Thermodynamic and economic optimization of SOFC-GT and its cogeneration opportunities using generated syngas from heavy fuel oil gasification”, Energy, v. 107, pp. 141–164, 2016. doi: https://doi.org/10.1016/j.energy.2016.04.010. https://doi.org/10.1016/j.energy.2016.04... ]
Flash drum	$\begin{array}{l} C_{d r u m} = 1 {.218f}_{m} exp [9.1 - 0.2889 In w + 0.04576 {(In w)}^{2}] + 300 D^{0.7396} L^{0.7066} \\ f_{m} = 0 .0172, W= 10000, D = 8, L = 15 \end{array}$	[²³[23] GHORBANI, B., MEHRPOOYA, M., SHIMMOHAMMADI, R., et al., “A comprehensive approach toward utilizing mixed refrigerant and absorption refrigeration systems in an integrated cryogenic refrigeration process”, Journal of Cleaner Production, v. 179, pp. 495–514, 2018. doi: https://doi.org/10.1016/j.jclepro.2018.01.109. https://doi.org/10.1016/j.jclepro.2018.0... ]
Generator	$C_{generator} = 60 {\dot{W}}^{0.95}$	[²⁷[27] GIBSON, C.A., MEYBODI, M.A., BEHNIA, M., “Optimization and selection of a steam turbine for a large scale industrial CHP (combined heat and power) system under Australia’s carbon price”, Energy, v. 61, pp. 291–307, 2013. doi: http://dx.doi.org/10.1016/j.energy.2013.08.045. https://doi.org/10.1016/j.energy.2013.08... ]
Preheater	$C_{P R E} = 8500 + 409 N_{P R E}^{0.85}$	[²²[22] REYHANI, H.A., MERATIZAMAN, M., EBRAHIMI, A., et al., “Thermodynamic and economic optimization of SOFC-GT and its cogeneration opportunities using generated syngas from heavy fuel oil gasification”, Energy, v. 107, pp. 141–164, 2016. doi: https://doi.org/10.1016/j.energy.2016.04.010. https://doi.org/10.1016/j.energy.2016.04... ]

DEFINITION	PARAMETER	REFERENCE
Annualized cost of system	ACS = C_acap (Components) + C_arep (Components) + C_amain (Components) + C_aope (Labor cost + Insurance cost + Fule cost)	[²⁸[28] GHORBANI, B., SHIRMOHAMMADI, R., MEHRPOOYA, M., “A novel energy efficient LNG/NGL recovery process using absorption and mixed refrigerant refrigeration cycles–Economic and exergy analyses”, Applied Thermal Engineering, v. 132, pp. 283–295, 2018. doi: http://dx.doi.org/10.1016/j.applthermaleng.2017.12.099. https://doi.org/10.1016/j.applthermaleng... ]
Annualized capital cost	$\begin{array}{l} C_{a c a p} = C_{c a p} . CRF(i, y) = C_{c a p} . \frac{i {(1 + i)}^{y}}{{(1 + i)}^{y} - 1} \\ C_{c a p} = 1 .1 of total capital cost; i = \frac{z - n}{1 + n} \end{array}$	[²⁹[29] GHORBANI, B., HAMEDI, M.H., AMIDPOUR, M., et al., “Implementing absorption refrigeration cycle in lieu of DMR and C3MR cycles in the integrated NGL, LNG and NRU unit”, International Journal of Refrigeration, v. 77, pp. 20–38, 2017. doi: http://dx.doi.org/10.1016/j.ijrefrig.2017.02.030. https://doi.org/10.1016/j.ijrefrig.2017.... ]
Annualized replacement cost	$\begin{array}{l} C_{r e p} = C_{c a p} (in Base year) . (1+ i)^{y} \\ C_{a r e p} = C_{r e p} . FSF(i, y) = C_{r e p} . \frac{i}{{(1 + i)}^{y} - 1} \end{array}$	[²⁹[29] GHORBANI, B., HAMEDI, M.H., AMIDPOUR, M., et al., “Implementing absorption refrigeration cycle in lieu of DMR and C3MR cycles in the integrated NGL, LNG and NRU unit”, International Journal of Refrigeration, v. 77, pp. 20–38, 2017. doi: http://dx.doi.org/10.1016/j.ijrefrig.2017.02.030. https://doi.org/10.1016/j.ijrefrig.2017.... ]
Annualized maintenance cost	C_amain = 0.05 of total capital cost	[²⁸[28] GHORBANI, B., SHIRMOHAMMADI, R., MEHRPOOYA, M., “A novel energy efficient LNG/NGL recovery process using absorption and mixed refrigerant refrigeration cycles–Economic and exergy analyses”, Applied Thermal Engineering, v. 132, pp. 283–295, 2018. doi: http://dx.doi.org/10.1016/j.applthermaleng.2017.12.099. https://doi.org/10.1016/j.applthermaleng... ]
Annualized operating cost	C_aope = Labor cost + Insurance cost + Fule cost + Utility Number of labor = 80, Labor cost = 500 US$/month Fuel cost (Electrical energy price) = 0.15 US$/kW . h Fuel cost (Water price) = 0.18 US$/m³ Insurance cost = 0.02 of capital cost	[²⁹[29] GHORBANI, B., HAMEDI, M.H., AMIDPOUR, M., et al., “Implementing absorption refrigeration cycle in lieu of DMR and C3MR cycles in the integrated NGL, LNG and NRU unit”, International Journal of Refrigeration, v. 77, pp. 20–38, 2017. doi: http://dx.doi.org/10.1016/j.ijrefrig.2017.02.030. https://doi.org/10.1016/j.ijrefrig.2017.... ]
Net present value	$NPV = \frac{ACS}{CRF (i, y)}$	[²⁵[25] MANESH, M.H.K., GHALAMI, H., AMIDPOUR, M., et al., “Optimal coupling of site utility steam network with MED-RO desalination through total site analysis and exergoeconomic optimization”, Desalination, v. 316, pp. 42–52, 2013. doi: https://doi.org/10.1016/j.desal.2013.01.022. https://doi.org/10.1016/j.desal.2013.01.... ]
NEW ACS = ACS-I I = Solar power generation cost (US$/year)	Produced electricity price: 0.15 US$/kW . h	[²³[23] GHORBANI, B., MEHRPOOYA, M., SHIMMOHAMMADI, R., et al., “A comprehensive approach toward utilizing mixed refrigerant and absorption refrigeration systems in an integrated cryogenic refrigeration process”, Journal of Cleaner Production, v. 179, pp. 495–514, 2018. doi: https://doi.org/10.1016/j.jclepro.2018.01.109. https://doi.org/10.1016/j.jclepro.2018.0... ]
Levelized cost of product total product in one year (crude oil)	$LCP = \frac{NEW ACS}{Annual output roduct of the system}$	[²⁹[29] GHORBANI, B., HAMEDI, M.H., AMIDPOUR, M., et al., “Implementing absorption refrigeration cycle in lieu of DMR and C3MR cycles in the integrated NGL, LNG and NRU unit”, International Journal of Refrigeration, v. 77, pp. 20–38, 2017. doi: http://dx.doi.org/10.1016/j.ijrefrig.2017.02.030. https://doi.org/10.1016/j.ijrefrig.2017.... ]
Prime cost	$\begin{array}{l} VOP = Volume of product \\ PC = \frac{C_{a o p e}}{VOP} \end{array}$	[²³[23] GHORBANI, B., MEHRPOOYA, M., SHIMMOHAMMADI, R., et al., “A comprehensive approach toward utilizing mixed refrigerant and absorption refrigeration systems in an integrated cryogenic refrigeration process”, Journal of Cleaner Production, v. 179, pp. 495–514, 2018. doi: https://doi.org/10.1016/j.jclepro.2018.01.109. https://doi.org/10.1016/j.jclepro.2018.0... ]
Summary of product cost	COP = Cost of product SPC = VOP . COP	[³⁰[30] KARAGIANNIS, I.C., SOLDATOS, P.G., “Water desalination cost literature: review and assessment”, Desalination, v. 223, n. 1–3, pp. 448–456, 2008. doi: http://dx.doi.org/10.1016/j.desal.2007.02.071. https://doi.org/10.1016/j.desal.2007.02.... ]
Annual benefit	AB = SPC – C_aope	[²³[23] GHORBANI, B., MEHRPOOYA, M., SHIMMOHAMMADI, R., et al., “A comprehensive approach toward utilizing mixed refrigerant and absorption refrigeration systems in an integrated cryogenic refrigeration process”, Journal of Cleaner Production, v. 179, pp. 495–514, 2018. doi: https://doi.org/10.1016/j.jclepro.2018.01.109. https://doi.org/10.1016/j.jclepro.2018.0... ]
Net annual benefit	NAB = AB∙(1 – Tax percent),Tax = 0.1(AB)	[²³[23] GHORBANI, B., MEHRPOOYA, M., SHIMMOHAMMADI, R., et al., “A comprehensive approach toward utilizing mixed refrigerant and absorption refrigeration systems in an integrated cryogenic refrigeration process”, Journal of Cleaner Production, v. 179, pp. 495–514, 2018. doi: https://doi.org/10.1016/j.jclepro.2018.01.109. https://doi.org/10.1016/j.jclepro.2018.0... ]
Period of return	$PR = \frac{C_{c a p}}{NAB}$	[²³[23] GHORBANI, B., MEHRPOOYA, M., SHIMMOHAMMADI, R., et al., “A comprehensive approach toward utilizing mixed refrigerant and absorption refrigeration systems in an integrated cryogenic refrigeration process”, Journal of Cleaner Production, v. 179, pp. 495–514, 2018. doi: https://doi.org/10.1016/j.jclepro.2018.01.109. https://doi.org/10.1016/j.jclepro.2018.0... ]
Rate of return	$PR = \frac{NAB}{C_{c a p}}$	[²³[23] GHORBANI, B., MEHRPOOYA, M., SHIMMOHAMMADI, R., et al., “A comprehensive approach toward utilizing mixed refrigerant and absorption refrigeration systems in an integrated cryogenic refrigeration process”, Journal of Cleaner Production, v. 179, pp. 495–514, 2018. doi: https://doi.org/10.1016/j.jclepro.2018.01.109. https://doi.org/10.1016/j.jclepro.2018.0... ]
Additive value	AV = COP – PC	[²³[23] GHORBANI, B., MEHRPOOYA, M., SHIMMOHAMMADI, R., et al., “A comprehensive approach toward utilizing mixed refrigerant and absorption refrigeration systems in an integrated cryogenic refrigeration process”, Journal of Cleaner Production, v. 179, pp. 495–514, 2018. doi: https://doi.org/10.1016/j.jclepro.2018.01.109. https://doi.org/10.1016/j.jclepro.2018.0... ]

State NO.	STATE COMPOSITION	ṁ (kg/s)	T (°C)	P (kPa)	h (kJ/kg)	s (kJ/(kg. K))	ex (kJ/kg)
1	crude oil	14	25	100	–1990.86	–6.83	46.11
2	crude oil	14	25.67	150	–1990.77	–6.83	46.41
3	crude oil	14	120	150	–1761.84	–6.19	85.09
4	water	22	35	150	–15824.00	–8.92	–13162.49
5	water	22	38.91	150	–15807.70	–8.87	–13161.84
6	crude oil	14	110	150	–1787.46	–6.25	78.47
7	crude oil	14	210	150	–1516.43	–5.64	167.30
8	crude oil	13.12	200	958.27	–1575.83	–5.84	165.98
9	crude oil	0.88	200	958.29	–1676.40	–5.27	–104.87
10	crude oil	13.12	320	958.29	–1221.61	–5.19	326.79
11	air	40	25	100	–0.2219	0.0038	0
12	air	40	264.67	500	242.62	0.14	202.71
13	air	40	480.48	500	357.61	0.33	259.80
14	air	40	1000	500	1061.69	1.09	738.57
15	air	20	950	500	771.28	0.84	523.79
16	air	20	749.24	500	538.85	0.58	366.98
17	air	20	580.49	500	349.13	0.32	255.26
18	air	20	433.5	500	188.88	0.03	180.25
19	air	20	950	500	771.28	0.84	523.79
20	air	20	780.19	500	599.69	0.65	406.32
21	water	65	15	100	–15907.60	–9.2	–13162.58
22	water	65	25	100	–15868.90	–9.07	–13160.33
23	water	1	800	15000	–12391.60	–2.75	–11569.38
24	water	1	180.37	10	–13333.40	–1.12	–12999.16
25	water	1	30	10	–15845.00	–8.99	–13163.22
26	water	1	31.92	15000	–15823.5	–8.97	–13147.89
27	air	40	609.71	500	394.28	0.39	280.04
28	air	40	400	500	279.29	0.20	219.73

PARAMETER	VALUE
The number of collectors used	259
Land requirement	31339 m²
Generated thermal energy in solar collectors	28163 kW
CO₂ reduction	11724 t/y
Refining capacity	441504 t/y
Annual solar heat generation	8250 (MW . h)/y
Storage capacity of TES tan k	270.88 MJ
Heat gain at the first heat exchanger	3205.05 kW
Heat gain at the second heat exchanger	3794.31 kW
Heat gain at the third heat exchanger	4648.65 kW
Waste heat recovery efficiency	31.21%
Solar plant energy efficiency	94.56%
Solar plant exergy efficiency	11.21%
TES tan k energy efficiency	58.12%
TES tan k exergy efficiency	65.31%
Rankine cycle energy efficiency	28.01%
Rankine cycle exergy efficiency	41.59%
Overall energy efficiency	75.99%
Overall exergy efficiency	74.13%
Waste heat recovery efficiency	31.21%

PARAMETER	UNIT	VALUE
Capital cost	Million US$	2.215
Crude oil heating price	Million US$ per year	12.7008
Solar power generation cost	Million US$ per year	1.187
Summary of product cost	Million US$ per year	13.888
Prime cost of product	US$ per ton crude oil	31.334
Net annual benefit	Million US$ per year	0.591
Annualized cost of system	Million US$ per year	13.691
Net present value	Million US$ per year	212.257
Period of return	Year	4.124
Rate of return	Percent	24.252
Insurance cost	US$ per year	44305.559
Water cost	Million US$ per year	0.474
Annualized operating cost	Million US$ per year	13.265

[1] Corresponding Author: Hong-Wei Chen e-mail: chenhongwei@lnpu.edu.cn, liyang@lnpu.edu.cn, 13238582547@163.com, chenhongwei@lnpu.edu.cn, linchanghua0626@163.com

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Thermodynamic and economic analysis of a novel solar heating crude oil system in oil refinery

abstract