Optimizing Evaporator Design in ORC Systems for Waste-to-Energy Conversion Using FAST Diagram and Value Engineering

R. Susalit Setya Wibowo; Satmintareja Satmintareja; Asep Duduh Abdurahman; Suyatmin Suyatmin; Darmawan Darmawan; Ari Gunawan; Kusumawati Dewi Budiarti; Nasrul Baddu; Adhi Pramono; Faisal Faisal; Cahyono Nugroho; Suharto Ngudiwaluyo; Zico Pratama Putra

doi:10.5614/j.eng.technol.sci.2026.58.3.4

Optimizing Evaporator Design in ORC Systems for Waste-to-Energy Conversion Using FAST Diagram and Value Engineering

Published: 2026-01-01 | DOI: 10.5614/j.eng.technol.sci.2026.58.3.4 | Vol 58, Issue 3 (2026)

Authors

R. Susalit Setya Wibowo

OpenAlex: A5126974922

Satmintareja Satmintareja

OpenAlex: A5126969763

Asep Duduh Abdurahman

OpenAlex: A5126966554

Suyatmin Suyatmin

OpenAlex: A5126968708

Darmawan Darmawan

OpenAlex: A5126962252

Ari Gunawan

OpenAlex: A5126971297

Kusumawati Dewi Budiarti

OpenAlex: A5093029729

Nasrul Baddu

OpenAlex: A5120775077

Adhi Pramono

OpenAlex: A5126958906

Faisal Faisal

OpenAlex: A5126957259

Cahyono Nugroho

OpenAlex: A5126965377

Suharto Ngudiwaluyo

OpenAlex: A5126971625

Zico Pratama Putra

OpenAlex: A5126970899

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Abstract

The global waste crisis necessitates innovative solutions for sustainable energy conversion. This study presents a comprehensive optimization framework for evaporator design in Organic Rankine Cycle (ORC) systems utilized in waste-to-energy conversion. This research integrates the Function Analysis System Technique (FAST) diagram with Value Engineering (VE) principles to assess the logical hierarchy and cost analysis components of system effectiveness. Evaluation of the 887 kW shell-and-tube evaporator showed tubes, baffles, and shells account for 90% of production costs and are the most thermally efficient components. Further strategic redesign under VE principles resulted in 23% cost reduction with 15% efficiency improvements, demonstrating resource expenditure without performance compromise. The proposed approach offers a foundational methodology for advancing enduring ORC system design while harnessing high waste-to-value electrical energy conversion at low expenses, fostering the circular economy.

Keywords

energy efficiency; evaporator optimization; FAST diagram; organic rankine cycle; value engineering; waste management

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Research Intelligence

Data from OpenAlex ↗

Metrics

0.00

FWCIfield-weighted

11th

Percentilevs same year + field

Article

Work type

GOLD

Open Access

Topics

Thermodynamic and Exergetic Analyses of Power and Cooling Systems Primary

0.92

Mechanical Engineering › Engineering › Physical Sciences

Integrated Energy Systems Optimization

0.01

Adsorption and Cooling Systems

0.00

Semantic Profile AI-classified research signals

Core Domains

Process engineering 0.67

level 1

Resource efficiency 0.53

level 2

Engineering 0.53

level 0

Secondary Topics

Function (biology) 0.42 Efficient energy use 0.42 Reduction (mathematics) 0.41 Energy transformation 0.41 Resource (disambiguation) 0.40 Manufacturing engineering 0.40 Mechanical engineering 0.38 Energy consumption 0.38 Systems engineering 0.38 Production (economics) 0.37 Industrial engineering 0.37 Systems design 0.36 Diagram 0.35 Energy (signal processing) 0.32 Degree Rankine 0.31 Control engineering 0.30 Computer science 0.30 Value engineering 0.30 Multi-objective optimization 0.29 Cost reduction 0.28 Design cycle 0.28 Engineering design process 0.27 Hierarchy 0.27 Value (mathematics) 0.27 Process systems 0.27 Minification 0.26

Institution Network

National Nuclear Energy Agency of Indonesia ID
R. Susalit Setya Wibowo · Satmintareja Satmintareja · Asep Duduh Abdurahman · Suyatmin Suyatmin · Darmawan Darmawan · Ari Gunawan · Kusumawati Dewi Budiarti · Nasrul Baddu · Adhi Pramono · Faisal Faisal · Suharto Ngudiwaluyo
National Research and Innovation Agency ID
Cahyono Nugroho
Nuclear Energy Agency FR
Zico Pratama Putra

References

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An, C. S., Guardi, A., Purnama, H., Herbandono, K., Hermawan, H., Harmadi, R., Setyowati, L. A., & Winarso, D. (2024). Optimization and Analysis of Excess Heat Utilization from an Exhaust Outlet in a Waste Incinerator Plant - Case Study of The Hydro Drive Incinerator, West Java, Indonesia. Evergreen, 11(3), 2659–2667. https://doi.org/10.5109/7236905 DOI: 10.5109/7236905
Arslan, O., & Arslan, A. E. (2022). Pareto principle-based advanced exergetic evaluation of geothermal district heating system: Simav case study. Journal of Building Engineering, 58, 105035. https://doi.org/10.1016/j.jobe.2022.105035 DOI: 10.1016/j.jobe.2022.105035
Arumsari, P., & Tanachi, R. (2018). Value engineering application in a high rise building (a case study in Bali). IOP Conference Series: Earth and Environmental Science, 195(1), Article 012015. https://doi.org/10.1088/1755-1315/195/1/012015 DOI: 10.1088/1755-1315/195/1/012015
Cao, J., Zheng, L., Zheng, Z., Peng, J., Hu, M., Wang, Q., & Leung, M. K. H. (2023). Recent progress in organic Rankine cycle targeting utilisation of ultra-low-temperature heat towards carbon neutrality. Applied Thermal Engineering, 231, 120903. https://doi.org/10.1016/j.applthermaleng.2023.120903 DOI: 10.1016/j.applthermaleng.2023.120903
Chen, W. T., Merrett, H. C., Liu, S. S., Fauzia, N., & Liem, F. N. (2022). A Decade of Value Engineering in Construction Projects. Advances in Civil Engineering, 2022, 2324277. https://doi.org/10.1155/2022/2324277 DOI: 10.1155/2022/2324277
Dell’Isola, A. J. (1997). Value Engineering: Practical Applications...for Design, Construction, Maintenance and Operations. R.S. Means Co., Kingston, MA.
I Gede Angga Diputera. (2022). Application of Function Analysis using Function Analysis System Technique (FAST) Diagram on Taman Sari Apartment Construction Project. Journal of Applied Science, Engineering, Technology, and Education, 4(1), 39–44. https://doi.org/10.35877/454ri.asci847 DOI: 10.35877/454ri.asci847
Imron, A., & Husin, A. E. (2021). Value engineering and lifecycle cost analysis to improve cost performance in green hospital project. Archives of Civil Engineering, 67(4), 497–510. https://doi.org/10.24425/ace.2021.138514 DOI: 10.24425/ace.2021.138514
Jum’a, L., & Basheer, M. E. (2023). Analysis of Warehouse Value-Added Services Using Pareto as a Quality Tool: A Case Study of Third-Party Logistics Service Provider. Administrative Sciences, 13(2). Article 51. https://doi.org/10.3390/admsci13020051 DOI: 10.3390/admsci13020051
Le, C., Jeong, H. D., Damnjanovic, I., & Bukkapatnam, S. (2022). Pareto Principle in Scoping-Phase Cost Estimating: A Multiobjective Optimization Approach for Selecting and Applying Optimal Major Work Items. Journal of Construction Engineering and Management, 148(8), Article 04022056. https://doi.org/10.1061/(asce)co.1943-7862.0002349 DOI: 10.1061/(asce
Lecompte, S., Huisseune, H., van den Broek, M., Vanslambrouck, B., & De Paepe, M. (2015). Review of organic Rankine cycle (ORC) architectures for waste heat recovery. Renewable and Sustainable Energy Reviews, 47, 448–461. https://doi.org/10.1016/j.rser.2015.03.089 DOI: 10.1016/j.rser.2015.03.089
Ola, K. K., Waluyo, J., Cahyadi, & Agustina, L. (2025). Thermodynamic Perfomance Comparison of Working Fluids Based on Organic Rankine Cycle in Waste Power Plants. E3S Web of Conferences, 605, Article 01001. https://doi.org/10.1051/e3sconf/202560501001 DOI: 10.1051/e3sconf/202560501001
Pethurajan, V., Sivan, S., & Joy, G. C. (2018). Issues, comparisons, turbine selections and applications – An overview in organic Rankine cycle. In Energy Conversion and Management, 166, 474–488. Elsevier Ltd. https://doi.org/10.1016/j.enconman.2018.04.058 DOI: 10.1016/j.enconman.2018.04.058
Rahbar, K., Mahmoud, S., Al-Dadah, R. K., & Moazami, N. (2015). Parametric analysis and optimization of a small-scale radial turbine for Organic Rankine Cycle. Energy, 83, 696–711. https://doi.org/10.1016/j.energy.2015.02.079 DOI: 10.1016/j.energy.2015.02.079
World Bank Group. (2021). Plastic Waste Discharges from Rivers and Coastlines in Indonesia (Vol. 1 of 2). Marine Plastics Series, East Asia and Pacific Region. Washington DC.

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[ref-1] Alvi, J. Z., Guan, Z., & Imran, M. (2024). Thermoeconomic Evaluation and Sustainability Insights of Hybrid Solar–Biomass Powered Organic Rankine Cycle Systems: A Comprehensive Review. Biomass, 4(4), 1092–1121. https://doi.org/10.3390/biomass4040061 DOI: 10.3390/biomass4040061

[ref-2] An, C. S., Guardi, A., Purnama, H., Herbandono, K., Hermawan, H., Harmadi, R., Setyowati, L. A., & Winarso, D. (2024). Optimization and Analysis of Excess Heat Utilization from an Exhaust Outlet in a Waste Incinerator Plant - Case Study of The Hydro Drive Incinerator, West Java, Indonesia. Evergreen, 11(3), 2659–2667. https://doi.org/10.5109/7236905 DOI: 10.5109/7236905

[ref-3] Arslan, O., & Arslan, A. E. (2022). Pareto principle-based advanced exergetic evaluation of geothermal district heating system: Simav case study. Journal of Building Engineering, 58, 105035. https://doi.org/10.1016/j.jobe.2022.105035 DOI: 10.1016/j.jobe.2022.105035

[ref-4] Arumsari, P., & Tanachi, R. (2018). Value engineering application in a high rise building (a case study in Bali). IOP Conference Series: Earth and Environmental Science, 195(1), Article 012015. https://doi.org/10.1088/1755-1315/195/1/012015 DOI: 10.1088/1755-1315/195/1/012015

[ref-5] Cao, J., Zheng, L., Zheng, Z., Peng, J., Hu, M., Wang, Q., & Leung, M. K. H. (2023). Recent progress in organic Rankine cycle targeting utilisation of ultra-low-temperature heat towards carbon neutrality. Applied Thermal Engineering, 231, 120903. https://doi.org/10.1016/j.applthermaleng.2023.120903 DOI: 10.1016/j.applthermaleng.2023.120903

[ref-6] Chen, W. T., Merrett, H. C., Liu, S. S., Fauzia, N., & Liem, F. N. (2022). A Decade of Value Engineering in Construction Projects. Advances in Civil Engineering, 2022, 2324277. https://doi.org/10.1155/2022/2324277 DOI: 10.1155/2022/2324277

[ref-7] Dell’Isola, A. J. (1997). Value Engineering: Practical Applications...for Design, Construction, Maintenance and Operations. R.S. Means Co., Kingston, MA.

[ref-8] I Gede Angga Diputera. (2022). Application of Function Analysis using Function Analysis System Technique (FAST) Diagram on Taman Sari Apartment Construction Project. Journal of Applied Science, Engineering, Technology, and Education, 4(1), 39–44. https://doi.org/10.35877/454ri.asci847 DOI: 10.35877/454ri.asci847

[ref-9] Imron, A., & Husin, A. E. (2021). Value engineering and lifecycle cost analysis to improve cost performance in green hospital project. Archives of Civil Engineering, 67(4), 497–510. https://doi.org/10.24425/ace.2021.138514 DOI: 10.24425/ace.2021.138514

[ref-10] Jum’a, L., & Basheer, M. E. (2023). Analysis of Warehouse Value-Added Services Using Pareto as a Quality Tool: A Case Study of Third-Party Logistics Service Provider. Administrative Sciences, 13(2). Article 51. https://doi.org/10.3390/admsci13020051 DOI: 10.3390/admsci13020051

[ref-11] Le, C., Jeong, H. D., Damnjanovic, I., & Bukkapatnam, S. (2022). Pareto Principle in Scoping-Phase Cost Estimating: A Multiobjective Optimization Approach for Selecting and Applying Optimal Major Work Items. Journal of Construction Engineering and Management, 148(8), Article 04022056. https://doi.org/10.1061/(asce)co.1943-7862.0002349 DOI: 10.1061/(asce

[ref-12] Lecompte, S., Huisseune, H., van den Broek, M., Vanslambrouck, B., & De Paepe, M. (2015). Review of organic Rankine cycle (ORC) architectures for waste heat recovery. Renewable and Sustainable Energy Reviews, 47, 448–461. https://doi.org/10.1016/j.rser.2015.03.089 DOI: 10.1016/j.rser.2015.03.089

[ref-13] Ola, K. K., Waluyo, J., Cahyadi, & Agustina, L. (2025). Thermodynamic Perfomance Comparison of Working Fluids Based on Organic Rankine Cycle in Waste Power Plants. E3S Web of Conferences, 605, Article 01001. https://doi.org/10.1051/e3sconf/202560501001 DOI: 10.1051/e3sconf/202560501001

[ref-14] Pethurajan, V., Sivan, S., & Joy, G. C. (2018). Issues, comparisons, turbine selections and applications – An overview in organic Rankine cycle. In Energy Conversion and Management, 166, 474–488. Elsevier Ltd. https://doi.org/10.1016/j.enconman.2018.04.058 DOI: 10.1016/j.enconman.2018.04.058

[ref-15] Rahbar, K., Mahmoud, S., Al-Dadah, R. K., & Moazami, N. (2015). Parametric analysis and optimization of a small-scale radial turbine for Organic Rankine Cycle. Energy, 83, 696–711. https://doi.org/10.1016/j.energy.2015.02.079 DOI: 10.1016/j.energy.2015.02.079

[ref-16] World Bank Group. (2021). Plastic Waste Discharges from Rivers and Coastlines in Indonesia (Vol. 1 of 2). Marine Plastics Series, East Asia and Pacific Region. Washington DC.