Affordable Rankine Cycle Waste Heat Recovery for Heavy Duty Trucks

Subramanian, Swami Nathan

doi:10.2172/1375960

Cited by 2 publications

(4 citation statements)

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“…Perhaps one of the more discerning approaches is taken by Pantaleo et al [212], and one of the most widely encompassing costing studies is by Chen et al [238]. Another important thread of study is cost reduction, for which Subramanian [170,171] explores alternative arrangements (e.g., using engine passages and an existing radiator). Relatively few studies focus on smallscale system cost in the way of Tocci et al [159].…”

Section: Costsmentioning

confidence: 99%

“…To achieve this accuracy, the only calibration that occurs is for the recuperator. Subramanian [170,171] of Eaton focuses directly on the ORC affordability challenge with a project aimed at developing a cost-effective heavy-duty engine ORC producing an efficiency improvement of ≥5%. A distinguishing element of the approach is the use of engine coolant as the ORC working fluid and the vehicle radiator as the ORC condenser, with additional heat recovery from the engine's EGR and exhaust.…”

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confidence: 99%

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Review of Organic Rankine Cycles for Internal Combustion Engine Waste Heat Recovery: Latest Decade in Review

Sprouse

2024

Sustainability

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The last decade (2013–2023) was the most prolific period of organic Rankine cycle (ORC) research in history in terms of both publications and citations. This article provides a detailed review of the broad and voluminous collection of recent internal combustion engine (ICE) waste heat recovery (WHR) studies, serving as a necessary follow-on to the author’s 2013 review. Research efforts have targeted diverse applications (e.g., vehicular, stationary, and building-based), and it spans the full gamut of engine sizes and fuels. Furthermore, cycle configurations extend far beyond basic ORC and regenerative ORC, particularly with supercritical, trilateral, and multi-loop ORCs. Significant attention has been garnered by fourth-generation refrigerants like HFOs (hydrofluoroolefins), HFEs (hydrofluoroethers), natural refrigerants, and zeotropic mixtures, as research has migrated away from the popular HFC-245fa (hydrofluorocarbon). Performance-wise, the period was marked by a growing recognition of the diminished performance of physical systems under dynamic source conditions, especially compared to steady-state simulations. Through advancements in system control, especially using improved model predictive controllers, dynamics-based losses have been significantly reduced. Regarding practically minded investigations, research efforts have ameliorated working fluid flammability risks, limited thermal degradation, and pursued cost savings. State-of-the-art system designs and operational targets have emerged through increasingly sophisticated optimization efforts, with some studies leveraging “big data” and artificial intelligence. Major programs like SuperTruck II have further established the ongoing challenges of simultaneously meeting cost, size, and performance goals; however, off-the-shelf organic Rankine cycle systems are available today for engine waste heat recovery, signaling initial market penetration. Continuing forward, next-generation engines can be designed specifically as topping cycles for an organic Rankine (bottoming) cycle, with both power sources integrated into advanced hybrid drivetrains.

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Section: Costsmentioning

confidence: 99%

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confidence: 99%

Review of Organic Rankine Cycles for Internal Combustion Engine Waste Heat Recovery: Latest Decade in Review

Sprouse

2024

Sustainability

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“…Two years later, Hino Motors [16] obtained a 7.5% improvement in fuel economy by collecting EGR, engine coolant (at an increased temperature of 105 ºC) and exhaust heat using hydro-fluoro-ether as the working fluid. Within the frame of the US Super Truck Program, intensive investigations were conducted by Cummins [17,18], Daimler [19], Volvo [18,20] and Eaton [21]. Focusing on DEs in the approximate size range of 350 kW, different heat sources, working fluids, system layouts, component types and integration methods were considered.…”

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confidence: 99%

“…Among which, road tests by Cummins [17,18] demonstrated the best absolute improvement of the engine thermal efficiency of 3.6% with an R245fa-based ORC system recovering exhaust and EGR energy. Volvo [18,20] also mounted the RC system on a truck and testing results showed 2% contribution to the fuel economy, while Daimler [19] focused on ethanol-based ORC system and Eaton [21] chose the engine coolant as the working fluid.…”

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confidence: 99%

Potential of carbon dioxide transcritical power cycle waste-heat recovery systems for heavy-duty truck engines

Tian

Zhao

et al. 2019

Applied Energy

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Carbon dioxide transcritical power cycle (CTPC) systems are considered a new and particularly interesting technology for waste-heat recovery. In heavy-duty truck engine applications, challenges arise from the highly transient nature of the available heat sources. This paper presents an integrated model of CTPC systems recovering heat from a truck diesel engine, developed in GT-SUITE software and calibrated against experimental data, considers the likely fuel consumption improvements and identifies directions for further improvement. The transient performance of four different CTPC systems is predicted over a heavy-heavy duty driving cycle with a control structure comprising a mode switch module and two PID controllers implemented to realize stable, safe and optimal operation. Three operating modes are defined: startup mode, power mode, and stop mode. The results demonstrate that CTPC systems are robust and able to operate safely even when the heat sources are highly transient, indicating a promising potential for the deployment of this technology in such applications. Furthermore, a system layout with both a preheater and a recuperator appears as the most promising, allowing a 2.3% improvement in brake thermal efficiency over the whole driving cycle by utilizing 48.9% of the exhaust and 72.8% of the coolant energy, even when the pump and turbine efficiencies are as low as 50%. Finally, factor analysis suggests that important directions aimed at improving the performance and facilitating CTPC system integration with vehicle engines are: 1) ensuring long-duration operation in power mode, e.g., by employment in long-haul trucks; and 2) enhancing pump and turbine performance.

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Affordable Rankine Cycle Waste Heat Recovery for Heavy Duty Trucks

Cited by 2 publications

References 0 publications

Review of Organic Rankine Cycles for Internal Combustion Engine Waste Heat Recovery: Latest Decade in Review

Review of Organic Rankine Cycles for Internal Combustion Engine Waste Heat Recovery: Latest Decade in Review

Potential of carbon dioxide transcritical power cycle waste-heat recovery systems for heavy-duty truck engines

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