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engine. Custom cooling and engine oil systems were fabricated to provide adequate adjustment to achieve target coolant and oil temperatures and large enough temperature differences across the engine to reduce uncertainty. Changes to exhaust emissions were recorded using a 5-gas analyzer. The engine condition was also monitored throughout the tests by engine compression testing, oil analysis, and a complete teardown and inspection after testing was completed. The integrity of the head gasket seal proved to be a significant problem and leakage of engine coolant into the combustion chamber was detected when testing ended. The post-test teardown revealed problems with oil breakdown at locations where temperatures were highest, with accompanying component wear. The results from the experiment were then used as inputs for a WHR system model using ethanol as the working fluid, which provided estimates of system output and improvement in efficiency. Thermodynamic models were created for eight different WHR systems with coolant temperatures of 90°C, 150°C, 175°C, and 200°C and condenser temperatures of 60°C and 90°C at a single operating point of 3100 rpm and 24 N-m of torque. The models estimated that WHR output for both condenser temperatures would increase by over 100% when the coolant temperature was increased from 90°C to 200°C. This increased WHR output translated to relative efficiency gains as high as 31.0% for the 60°C condenser temperature and 24.2% for the 90°C condenser temperature over the baseline engine efficiency at 90°C. Individual heat exchanger models were created to estimate the footprint for a WHR system for each of the eight systems. When the coolant temperature increased from 90°C to 200°C, the total heat exchanger volume increased from 16.6 × 103 cm3 to 17.1 × 103 cm3 with a 60°C condenser temperature, but decreased from 15.1 × 103 cm3 to 14.2 × 103 cm3 with a 90°C condenser temperature. For all cases, increasing the coolant temperature resulted in an improvement in the efficiency gain for each cubic meter of heat iiiPDF Image | WASTE HEAT RECOVERY FROM A HIGH TEMPERATURE DIESEL ENGINE
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