A regenerative supercritical-subcritical dual-loop organic Rankine cycle system for energy recovery from the waste heat of internal combustion engines

Organic Rankine cycle (ORC) system is considered as a promising technology for energy recovery from the waste heat rejected by internal combustion (IC) engines. However, such waste heat is normally contained in both coolant and exhaust gases at quite different temperatures. A single ORC system is usually unable to efficiently recover energy from both of these waste heat sources. A dual loop ORC system which essentially has two cascaded ORCs to recover energy from the engine’s exhaust gases and coolant separately has been proposed to address this challenge. In this way, the overall efficiency of energy recovery can be substantially improved. This paper examines a regenerative dual loop ORC system using a pair of environmentally friendly refrigerants, R1233zd and R1234yf, as working fluids, to recover energy from the waste heat of a compressed natural gas (CNG) engine. Unlike most previous studies focusing on the ORC system only, the present research analyses the ORC system and CNG engine together as an integrated system. As such, the ORC system is analysed on the basis of real data of waste heat sources of the CNG engine under various operational conditions. A numerical model is employed to analyse the performances of the proposed dual loop cycle with four pairs of working fluids. The effects of a regenerative heat exchanger and several other key operating parameters are also analysed and discussed in detail. The performance of the integrated engine-ORC system is then analysed under actual engine operating conditions which were measured beforehand. The performance of the proposed system under off-design conditions has also been analysed. The obtained results show that the proposed dual loop ORC system could achieve better performance than other ORC systems for similar applications

Thermodynamic analysis of a dual-loop organic Rankine cycle (ORC) for waste heat recovery of a petrol engine

Huge amounts of low-grade heat energy are discharged to the environment by vehicular engines. Considering the large number of vehicles in the world, such waste energy has a great impact on our environment globally. The Organic Rankine Cycle (ORC), which uses an organic fluid with a low boiling point as the working medium, is considered to be the most promising technology to recover energy from low-grade waste heat. In this study, a dual-loop ORC is presented to simultaneously recover energy from both the exhaust gases and the coolant of a petrol engine. A high-temperature (HT) ORC loop is used to recover heat from the exhaust gases, while a low-temperature (LT) ORC loop is used to recover heat from the coolant and the condensation heat of the HT loop. Figure 1 shows the schematic of the dual-loop ORC. Differing from previous research, two more environmentally friendly working fluids are used, and the corresponding optimisation is conducted. First, the system structure and operating principle are described. Then, a mathematical model of the designed dual-loop ORC is established. Next, the performance of the dual-loop cycle is analysed over the entire engine operating region. Furthermore, the states of each point along the cycle and the heat load of each component are compared with the results of previous research. The results show that the dual-loop ORC can effectively recover the waste heat from the petrol engine, and that the effective thermal efficiency can be improved by about 20 ~ 24%, 14~20%, and 30% in the high-speed, medium-speed, and low-speed operation regions, respectively. The designed dual-loop ORC can achieve a higher system efficiency than previous ORCs of this structure. Therefore, it is a good choice for waste heat recovery from vehicle engines