Abstract
The non-linear multifactorial impacts on fuel-saving potential constrain the practical performance of the vehicular waste heat recovery system (WHRS). This study proposed a four-dimensional interaction-based appraisal approach to interpreting these impacts for enhancing WHRS’s in-vehicle performance. The interaction incorporates a heat exchanger, configuration, engine, and vehicle. The proposed approach comprises two successive steps, emphasizing evaluation under the rated (Step 1) and off-design (Step 2) heat source conditions. A case study of waste heat recovery from a passenger vehicle was conducted to evaluate the in-vehicle performance of a novel co-split system and two single-split ones (with/without a regenerator) through this approach. The novel system theoretically modifies vehicular performance but remains ambiguous concerning real-world behaviour, which is assessed and verified by the proposed approach. Two key factors determining vehicular performance were identified by Step 1, namely, net power output and engine backpressure. As the co-split system modified both factors, its fuel-saving potential could be increased by up to 20.3% compared with single-split systems. Also, the limiting factor for off-design performance was pinpointed by Step 2, namely, the mismatch between the heat source and working fluid, which led to the solution, i.e., the synergistic split regulation of the working fluid and heat source. An up to 8.8% improvement in net power output was achieved by the co-split system at off-design heat sources compared with fixed split ratios. Consequently, the approach enables holistic performance improvement of the vehicular WHRS under design/off-design heat source conditions.
Similar content being viewed by others
References
Tian H, Liu P, Shu G. Challenges and opportunities of Rankine cycle for waste heat recovery from internal combustion engine. Prog Energy Combust Sci, 2021, 84: 100906
Zhou F, Joshi S N, Rhote-Vaney R, et al. A review and future application of Rankine cycle to passenger vehicles for waste heat recovery. Renew Sustain Energy Rev, 2017, 75: 1008–1021
Horst T A, Tegethoff W, Eilts P, et al. Prediction of dynamic Rankine Cycle waste heat recovery performance and fuel saving potential in passenger car applications considering interactions with vehicles’ energy management. Energy Convers Manage, 2014, 78: 438–451
Yang F B, Yang F F, Li J, et al. Analysis of the thermodynamic performance limits of the organic Rankine cycle in low and medium temperature heat source applications. Sci China Tech Sci, 2021, 64: 1624–1640
Yang C, Xie H, Zhou S K. Overall optimization of Rankine cycle system for waste heat recovery of heavy-duty vehicle diesel engines considering the cooling power consumption. Sci China Tech Sci, 2016, 59: 309–321
Wang X, Wang R, Shu G Q, et al. Energy management strategy for hybrid electric vehicle integrated with waste heat recovery system based on deep reinforcement learning. Sci China Tech Sci, 2022, 65: 713–725
Li L, Tian H, Liu P, et al. Optimization of CO2 transcritical power cycle (CTPC) for engine waste heat recovery based on split concept. Energy, 2021, 229: 120718
Shu G, Shi L, Tian H, et al. An improved CO2-based transcritical Rankine cycle (CTRC) used for engine waste heat recovery. Appl Energy, 2016, 176: 171–182
Kim Y M, Shin D G, Kim C G, et al. Single-loop organic Rankine cycles for engine waste heat recovery using both low- and high-temperature heat sources. Energy, 2016, 96: 482–494
Ping X, Yao B, Zhang H, et al. Thermodynamic analysis and high-dimensional evolutionary many-objective optimization of dual loop organic Rankine cycle (DORC) for CNG engine waste heat recovery. Energy, 2021, 236: 121508
Wang X, Shu G, Tian H, et al. Dynamic analysis of the dual-loop organic Rankine cycle for waste heat recovery of a natural gas engine. Energy Convers Manage, 2017, 148: 724–736
Surendran A, Seshadri S. Design and performance analysis of a novel transcritical regenerative series two stage organic Rankine cycle for dual source waste heat recovery. Energy, 2020, 203: 117800
Surendran A, Seshadri S. Performance investigation of two stage organic Rankine cycle (ORC) architectures using induction turbine layouts in dual source waste heat recovery. Energy Convers Manage-X, 2020, 6: 100029
Sohrabi A, Behbahaninia A, Sayadi S. Thermodynamic optimization and comparative economic analysis of four organic Rankine cycle configurations with a zeotropic mixture. Energy Convers Manage, 2021, 250: 114872
Wang Q, Wang J, Li T, et al. Techno-economic performance of two-stage series evaporation organic Rankine cycle with dual-level heat sources. Appl Thermal Eng, 2020, 171: 115078
Li X, Xu B, Tian H, et al. Towards a novel holistic design of organic Rankine cycle (ORC) systems operating under heat source fluctuations and intermittency. Renew Sustain Energy Rev, 2021, 147: 111207
Shu G, Li X, Tian H, et al. Design condition and operating strategy analysis of CO2 transcritical waste heat recovery system for engine with variable operating conditions. Energy Convers Manage, 2017, 142: 188–199
Li L, Tian H, Shi L, et al. Adaptive flow assignment for CO2 tran-scritical power cycle (CTPC): An engine operational profile-based offdesign study. Energy, 2021, 225: 120262
Liu J, Yu A, Lin X, et al. Performances of transcritical power cycles with CO2-based mixtures for the waste heat recovery of ICE. Entropy, 2021, 23: 1551
Li X, Shu G, Tian H. Integrating off-design performance in designing CO2 power cycle systems for engine waste heat recovery. Energy Convers Manage, 2019, 201: 112146
Shi X, Wang X, Cai J, et al. A novel design method of organic Rankine cycle system harvesting waste heat of heavy-duty trucks based on off-design performance. Energy Sci Eng, 2021, 9: 172–188
Luo X, Wei Y, Qiu G, et al. Simultaneous design and off-design operation optimization of a waste heat-driven organic Rankine cycle using a multi-period mathematical programming method. Energy, 2020, 213: 118793
Li L, Tian H, Shi L, et al. Reducing the operational fluctuation via splitting CO2 transcritical power cycle in engine waste heat recovery. Energy, 2022, 252: 123994
Li X, Song J, Yu G, et al. Organic Rankine cycle systems for engine waste-heat recovery: Heat exchanger design in space-constrained applications. Energy Convers Manage, 2019, 199: 111968
Michos C N, Lion S, Vlaskos I, et al. Analysis of the backpressure effect of an organic Rankine cycle (ORC) evaporator on the exhaust line of a turbocharged heavy duty diesel power generator for marine applications. Energy Convers Manage, 2017, 132: 347–360
Baldasso E, Mondejar M E, Andreasen J G, et al. Design of organic Rankine cycle power systems for maritime applications accounting for engine backpressure effects. Appl Thermal Eng, 2020, 178: 115527
Di Battista D, Mauriello M, Cipollone R. Waste heat recovery of an ORC-based power unit in a turbocharged diesel engine propelling a light duty vehicle. Appl Energy, 2015, 152: 109–120
Shi L, Shu G, Tian H, et al. Assessment of waste heat recovery system for automotive engine with weight effect. Energy, 2020, 193: 116663
Wang M, Zhang J, Zhao S, et al. Performance investigation of tran-scritical and dual-pressure organic Rankine cycles from the aspect of thermal match. Energy Convers Manage, 2019, 197: 111850
Soffiato M, Frangopoulos C A, Manente G, et al. Design optimization of ORC systems for waste heat recovery on board a LNG carrier. Energy Convers Manage, 2015, 92: 523–534
Zhang X, Wang X, Cai J, et al. Experimental study on operating parameters matching characteristic of the organic Rankine cycle for engine waste heat recovery. Energy, 2022, 244: 122681
Lim T W, Choi Y S, Hwang D H. Optimal working fluids and economic estimation for both double stage organic Rankine cycle and added double stage organic Rankine cycle used for waste heat recovery from liquefied natural gas fueled ships. Energy Convers Manage, 2021, 242: 114323
Civgin M G, Deniz C. Analyzing the dual-loop organic rankine cycle for waste heat recovery of container vessel. Appl Thermal Eng, 2021, 199: 117512
Liu P, Shu G, Tian H. How to approach optimal practical organic Rankine cycle (OP-ORC) by configuration modification for diesel engine waste heat recovery. Energy, 2019, 174: 543–552
Li L, Tian H, Shi L, et al. Experimental investigation of a splitting CO2 transcritical power cycle in engine waste heat recovery. Energy, 2022, 244: 123126
Shu G, Liu P, Tian H, et al. Operational profile based thermal-economic analysis on an organic Rankine cycle using for harvesting marine engine’s exhaust waste heat. Energy Convers Manage, 2017, 146: 107–123
Lion S, Michos C N, Vlaskos I, et al. A review of waste heat recovery and organic Rankine cycles (ORC) in on-off highway vehicle heavy duty diesel engine applications. Renew Sustain Energy Rev, 2017, 79: 691–708
Koppauer H, Kemmetmüller W, Kugi A. Modeling and optimal steady-state operating points of an ORC waste heat recovery system for diesel engines. Appl Energy, 2017, 206: 329–345
Grelet V, Reiche T, Lemort V, et al. Transient performance evaluation of waste heat recovery rankine cycle based system for heavy duty trucks. Appl Energy, 2016, 165: 878–892
Glover S, Douglas R, De Rosa M, et al. Simulation of a multiple heat source supercritical ORC (organic Rankine cycle) for vehicle waste heat recovery. Energy, 2015, 93: 1568–1580
Stanzel N, Streule T, Preißinger M, et al. Comparison of cooling system designs for an exhaust heat recovery system using an organic rankine cycle on a heavy duty truck. Energies, 2016, 9: 928
Xu B, Yebi A, Onori S, et al. Transient power optimization of an organic rankine cycle waste heat recovery system for heavy-duty diesel engine applications. SAE Int J Alt Power, 2017, 6: 25–33
Li L, Ge Y T, Luo X, et al. Experimental investigations into power generation with low grade waste heat and R245fa organic Rankine cycles (ORCs). Appl Thermal Eng, 2017, 115: 815–824
Mahmoudzadeh Andwari A, Pesiridis A, Karvountzis-Kontakiotis A, et al. Hybrid electric vehicle performance with organic rankine cycle waste heat recovery system. Appl Sci, 2017, 7: 437
Boretti A. Recovery of exhaust and coolant heat with R245fa organic Rankine cycles in a hybrid passenger car with a naturally aspirated gasoline engine. Appl Thermal Eng, 2012, 36: 73–77
Zhi L H, Hu P, Chen L X, et al. Multiple parametric analysis, optimization and efficiency prediction of transcritical organic Rankine cycle using trans-1,3,3,3-tetrafluoropropene (R1234ze(E)) for low grade waste heat recovery. Energy Convers Manage, 2019, 180: 44–59
Shu G, Yu G, Tian H, et al. A multi-approach evaluation system (MAES) of organic Rankine cycles (ORC) used in waste heat utilization. Appl Energy, 2014, 132: 325–338
Yan C S, Xu J L, Zhu B G, et al. Numerical study on convective heat transfer of supercritical CO2 in vertically upward and downward tubes. Sci China Tech Sci, 2021, 64: 995–1006
Tian H, Shu G, Wei H, et al. Fluids and parameters optimization for the organic Rankine cycles (ORCs) used in exhaust heat recovery of internal combustion engine (ICE). Energy, 2012, 47: 125–136
Lion S, Vlaskos I, Taccani R. A review of emissions reduction technologies for low and medium speed marine diesel engines and their potential for waste heat recovery. Energy Convers Manage, 2020, 207: 112553
Wang R, Shu G, Wang X, et al. Dynamic performance and control strategy of CO2-mixture transcritical power cycle for heavy-duty diesel engine waste-heat recovery. Energy Convers Manage, 2020, 205: 112389
Fan G, Du Y, Li H, et al. Off-design behavior investigation of the combined supercritical CO2 and organic Rankine cycle. Energy, 2021, 237: 121529
Cao Y, Dai Y. Comparative analysis on off-design performance of a gas turbine and ORC combined cycle under different operation approaches. Energy Convers Manage, 2017, 135: 84–100
Shu G, Wang X, Tian H, et al. Scan of working fluids based on dynamic response characters for organic Rankine cycle using for engine waste heat recovery. Energy, 2017, 133: 609–620
Author information
Authors and Affiliations
Corresponding authors
Additional information
This work was supported by the National Natural Science Foundation of China (Grant No. 51906237), the Research Funds of the Double First-Class Initiative of University of Science and Technology of China (Grant No. YD2090002008), the Fundamental Research Funds for the Central Universities (Grant No. WK2090000032), the Youth Innovation Promotion Association of Chinese Academy of Sciences (Grant No. 2022463), and the Research Center for Multi-Energy Complementation and Conversion.
Supporting Information
The supporting information is available online at tech.scichina.com and link.springer.com. The supporting materials are published as submitted, without typesetting or editing. The responsibility for scientific accuracy and content remains entirely with the authors.
Electronic supplementary material
Rights and permissions
About this article
Cite this article
Lu, B., Shi, L., Tian, H. et al. A four-dimensional interaction-based appraisal approach towards the performance enhancement of a vehicular waste heat recovery system. Sci. China Technol. Sci. 65, 2921–2941 (2022). https://doi.org/10.1007/s11431-022-2153-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11431-022-2153-5