Performance Design of an Exhaust Superheater for Waste Heat Recovery of Construction Equipment

  • Hyung Seok Heo
  • Suk Jung Bae
  • Sung Mok Hong
  • Seung Uk Park


Although fuel cost has been the largest portion of annual operating costs of construction equipment, it is possible to save the energy and reduce cost using fuel economy enhancement technology. In this study, an organic Rankine cycle is applied to an excavator in order to recover waste heat, reproduce it into electrical energy, and consequently reduce the fuel consumption by 10 %. A design process was carried out to develop an exhaust gas superheater that recovers the waste heat from exhaust gas through a composite-dimensional thermal flow analysis. A one-dimensional code was developed to perform a size design for the exhaust gas superheater. The ranges for the major design parameters were determined to satisfy the target of the heat recovery, as well as the pressure drop at both fluid sides. Performance analysis was done through onedimensional design code results, which were compared with three-dimensional CFD analysis. By utilizing a 3D commercial code, the arrangement of the tubes was selected and the working fluid pressure drop was reduced through a detailed layout design. The design procedure was verified by a performance evaluation of the prototype, which yielded only a 7 % tolerance in heat recovery.

Key Words

Excavator Construction equipment Waste heat recovery system Rankine cycle Superheater Heat recovery Spiral tube 



pressure drop, kPa


temperature difference, °C


heat, kW


temperature, °C









working fluid


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


  1. Bae, S. J., Heo, H. S. and Yoo, H. S. (2015). Cycle design for low temperature waste heat recovery of a construction equipment. KSAE Annual Conf. Proc., Korean Society of Automotive Engineers, 152–157.Google Scholar
  2. Bae, S. J., Heo, H. S., Lee, H. K., Lee, D. H., Kim, T. J., Park, J. S., Lee, H. Y. and Kim, C. J. (2011). Performance characteristics of a rankine steam cycle and boiler for engine waste heat recovery. SAE Paper No. 2011-28-0055.Google Scholar
  3. Endo, T., Kawajiri, S., Kojima, Y., Takahashi, K., Baba, T., Ibaraki, S., Takahashi, T. and Shinohara, M. (2007). Study on maximizing energy in automotive engines. SAE Paper No. 2007-01-0257.Google Scholar
  4. Freymann, R., Ringler, J., Seifert, M. and Horst, T. (2012). The second generation turbosteamer. MTZ Worldwide 73, 2, 18–28.CrossRefGoogle Scholar
  5. Heo, H. S. and Bae, S. J. (2010). Technology trends of rankine steam cycle for engine waste heat recovery. Auto Journal, Korean Society of Automotive Engineers 32, 5, 23–32.Google Scholar
  6. Ringler, J., Seifert, M., Guyotot, M. and Hubner, M. (2009). Rankine cycle for waste heat recovery of IC engines. SAE Paper No. 2009-01-0174.Google Scholar
  7. Teng, H., Regner, G. and Cowland, C. (2007). Waste heat recovery of heavy-duty diesel engines by organic rankine cycle part II: Working fluids for WHR-ORC. SAE Paper No. 2007-01-0543.Google Scholar
  8. Vicente, P. G., García, A. and Viedma. A. (2004). Experimental investigation on heat transfer and frictional characteristics of spirally corrugated tubes in turbulent flow at different Prandtl numbers. Int. J. Heat and Mass Transfer 47, 4, 671–681.CrossRefGoogle Scholar

Copyright information

© The Korean Society of Automotive Engineers and Springer-Verlag GmbH Germany, part of Springer Nature 2018

Authors and Affiliations

  • Hyung Seok Heo
    • 1
  • Suk Jung Bae
    • 1
  • Sung Mok Hong
    • 2
  • Seung Uk Park
    • 2
  1. 1.Convergence Parts Technology R&D DivisionKorea Automotive Technology InstituteChungnamKorea
  2. 2.R&D Center, Haesong Engineering Co., Ltd.ChungbukKorea

Personalised recommendations