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107 The limits of the problems were fixed as: 108 • • • The pressure ratio in the expansion machine must be lower than 25 to achieve an efficient expansion process. Initially, the proposal cycles minimum temperature difference in the heat exchange processes is fixed to 10◦C [26–28]. The working fluid in the condenser had to be cooled by the ambient. These conditions were fixed in 40◦C and 1 bar. 109 110 111 112 113 The engine used in this study was a 12 litre double-stage turbocharged HDD [29]. The maximum engine torque is 114 2100 Nm and this values is achieved at 1000 rpm and 100% load and the maximum engine power is 311 kw at 1800 115 and 100 % load. The HDD has been adapted according to the anti-pollution directive (US2007) [23].The scheme of 116 the engine is shown in Figure 2. 117 The engine is placed in a test bench with an electric brake which allows steady tests under different operational 118 conditions. The engine is also instrumented to measure torque, engine speed, fuel consumption, air mass flow in the 119 intake line, pressures and temperatures in the compressors and turbines. The blow-by effect is neglected, for this, the 120 exhaust gases mass flow is calculated as the sum of intake mass flow and fuel consumption flow. The waste power of 121 the exhaust gases is calculated using the measured temperature and the estimated mass flow. The waste power of the 122 remaining heat sources have been calculated measuring the inlet and outlet temperatures and coolant mass flow in the 123 cylinders (radiator) and the rest of heat exchangers (EGR cooler, intercooler and aftercooler). 124 Eleven steady operating points of the engine have been chosen for testing and there after, to design and simulate 125 the recovery cycle. These points represent the steady-state engine test modes with defined speed and load used by the 126 directive (US2007) for the evaluation of the emission [23]. Table 1 lists these operational points. 127 3.2. Evaluation of the heat sources 128 Analyzing the wasted power in the thermal engine to identify the main waste heat sources is the second step 129 of this methodology. These sources are located in: 1) the exhaust gases 2) the EGR coolers, 3) the intercooler, 4) 130 the aftercooler and 5) the engine cooling water. The heat power in these sources is calculated using mass flow and 131 temperature measurements. The available power between the inlet and outlet conditions (1 and 2) of each source is 132 calculated considering the gases as ideal and perfect gases, Equation (1): E = m ̇ h − h = m ̇ C T − T (1) flow flow 1 2 flow p 1 2 where Cp has been considerate 1 kJ/kgK and 1.15 kJ/kgK for fresh air and combustion gases respectively. The 134 ambient conditions are considered as the reference state. 135 The energetic levels of the waste heat sources for two different engine operative points are listed in Table 2: 1800 136 rpm-100% load and 1200 rpm-25 %. These points were selected for two reasons: 1) They are points with energetic 5 133PDF Image | Methodology to design a bottoming Rankine cycle
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