Affordable Rankine Cycle Waste Heat Recovery for Heavy Duty Trucks
- Eaton Corporation, Menomonee Falls, WI (United States)
Nearly 30% of fuel energy is not utilized and wasted in the engine exhaust. Organic Rankine Cycle (ORC) based waste heat recovery (WHR) systems offer a promising approach on waste energy recovery and improving the efficiency of Heavy-Duty diesel engines. Major barriers in the ORC WHR system are the system cost and controversial waste heat recovery working fluids. More than 40% of the system cost is from the additional heat exchangers (recuperator, condenser and tail pipe boiler). The secondary working fluid loop designed in ORC system is either flammable or environmentally sensitive. The Eaton team investigated a novel approach to reduce the cost of implementing ORC based WHR systems to Heavy-Duty (HD) Diesel engines while utilizing safest working fluids. Affordable Rankine Cycle (ARC) concept aimed to define the next generation of waste energy recuperation with a cost optimized WHR system. ARC project used engine coolant as the working fluid. This approach reduced the need for a secondary working fluid circuit and subsequent complexity. A portion of the liquid phase engine coolant has been pressurized through a set of working fluid pumps and used to recover waste heat from the exhaust gas recirculation (EGR) and exhaust tail pipe exhaust energy. While absorbing heat, the mixture is partially vaporized but remains a wet binary mixture. The pressurized mixed-phase engine coolant mixture is then expanded through a fixed-volume ratio expander that is compatible with two-phase conditions. Heat rejection is accomplished through the engine radiator, avoiding the need for a separate condenser. The ARC system has been investigated for PACCAR’s MX-13 HD diesel engine.
- Research Organization:
- Eaton Corporation, Menomonee Falls, WI (United States)
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V)
- Contributing Organization:
- Mississippi State University, Purdue University, Kettering University, Argonne National Laboratory, AVL Powertrain Engineering, Modine Manufacturing Company, Torad Engineering, PACCAR Inc., Shell Global Solutions
- DOE Contract Number:
- EE0007286
- OSTI ID:
- 1375960
- Report Number(s):
- DOE-EATON-0007286
- Country of Publication:
- United States
- Language:
- English
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