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Energies 2020, 13, 5914 2 of 15 Keywords: organic Rankine cycle; single-screw expander; R123; exergy analysis; experiments; ORC; exergy destruction 1. Introduction Internal combustion engines (ICEs) for decades have been the major source of power for locomotives in the world. The stringent local and international limits on the exhaust emission of pollutant gases, such as CO, NOx, CO2, particulate matter, and other hydrocarbons, have rekindled interest in the development of energy-efficient and cleaner propulsion system for vehicles [1]. Moreover, reduction of the fuel consumption and the amount of greenhouse gases whilst increasing the mechanical performance of ICEs has been the focal point of research in the automotive sector [2]. In ICEs, only about 1/3 of the input fuel energy is converted into useful power [3]; the remainder, amounting to almost 40%, is wasted from the engine exhaust [4]. The harnessing of this enormous waste heat from ICEs can lead to higher efficiencies of the vehicle as well as reductions in global warming [5]. The organic Rankine cycle (ORC) is an established power generation technology for converting low-temperature heat into power. The ORC employs organic working fluids that can be evaporated at considerably low temperatures and can produce work through expansion processes [6]. The ORC system has been widely acknowledged and offers superior performance compared with the incumbent steam or gas cycles for harnessing low-grade heat [7]. Numerous studies investigating the application of ORC in ICEs envisioned that the implementation of ORCs in heavy-duty vehicles has the potential to reduce fuel consumption by 3% to 10% [8]. The ORC is advantageous in terms of affordability, flexibility, adaptability, and low maintenance requirements. Numerous research activities have thermodynamically and experimentally investigated the performance of ORCs integrated with heavy-duty engines [9]. The studies concluded that the need for performance optimization, weight reduction and cost optimization persist for making the system economically viable [10]. The experimental investigation of ORCs for recovering waste heat aimed at studying the operational feasibility of the components while the focus of thermodynamic investigations was to optimize the cycle’s performance. Zhang et al. [9] developed a prototype ORC system with a screw expander and compact heat exchangers for the recovery of waste heat from diesel engines. Their experimental results showed the ORC system is compatible with the engine waste heat and can produce 10.38 kW of power with an efficiency of 6.48%. The nature of heat source in ICEs is transient and an improved control strategy is desired for reliable operation. Zhang et al. [11] investigated the control strategy for ORCs in vehicles and designed an improved closed-loop proportional-integral control to regulate the operation. Their results indicated that the proposed control mechanism successfully reduced the response time and improved the output power by 3.23%. Thermodynamic optimization includes the selection of an appropriate ORC working fluid and operating parameters. Bin Wan Ramli et al. [12] studied the potential of ORCs with hybrid vehicles and found out that ORCs can recover 2.02 kW of power from the waste heat with an efficiency of 5.4%. This saving resulted in a 1.2% fuel saving in a standard Worldwide Harmonized Light Vehicle Test Procedure driving cycle test. Bufi et al. [13] performed a comprehensive analysis with various organic working fluids for harnessing waste heat from a diesel engine. They found an optimum combination of operational parameters including evaporation pressure, superheat, and pinch point temperature difference that gave the best performance. Their study showed R11 gives the best efficiency of 20.8% with an evaporation pressure, superheat heat, and pinch point of 3500 kPa, 9.8 K, and 8.5 K, respectively. Yang et al. [14] also performed the optimization of ORCs for engine waste heat with respect to the expander’s operating pressure. They showed that at the optimum in and out pressure, the expander can reach up to a maximum power output of 7.13 kW. Thermodynamic performance assessment provides the optimum operational parameters to maximize the cycle’s power output and efficiency. However, the thermodynamically most optimumPDF Image | Waste Heat Recovery from Diesel Engine Exhaust ORC
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