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System design and control for waste heat recovery of automotive engines based on Organic Rankine Cycle

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  • Shi, Rongqi
  • He, Tianqi
  • Peng, Jie
  • Zhang, Yangjun
  • Zhuge, Weilin

Abstract

In this study, a novel and practical design for an ORC (Organic Rankine Cycle) system is presented. It can be applied to waste heat recovery of unsteady heat sources, such as exhaust gas of automobile engines. According to the variation characteristics of exhaust gas temperature and mass flow rate, the EGMR (Exhaust Gas Mixture Recirculation) loop is designed. The exhaust gas flowing out of the evaporator is partially recovered and mixed with the real-time engine exhaust gas, and then led to recirculation in the evaporator. Moreover, an energy storage module is also introduced, which is simplified as a metal block with internal tubes. A control approach based on ADRC (Active Disturbance Rejection Control is established. It is composed of an outer sub-loop controller for the evaporating pressure, a control allocator for mass flow rate allocation of the exhaust gas, and an inner sub-loop controller for the valve openings. The system is evaluated according to the numerical simulations. The results show that it can work steadily and reliably. The control error of the evaporating pressure is lower than 0.1%, and the fluctuation of the superheating is less than 1 °C. Compared with the conventional ORC system, both the cycle and the overall energy efficiencies are increased significantly. Furthermore, since no extra thermodynamic cycle or working fluid is demanded, the system architecture is more practical and simpler than most previous designs of system improvement.

Suggested Citation

  • Shi, Rongqi & He, Tianqi & Peng, Jie & Zhang, Yangjun & Zhuge, Weilin, 2016. "System design and control for waste heat recovery of automotive engines based on Organic Rankine Cycle," Energy, Elsevier, vol. 102(C), pages 276-286.
    • Handle: RePEc:eee:energy:v:102:y:2016:i:c:p:276-286
    DOI: 10.1016/j.energy.2016.02.065
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    11. Nour Eddine, A. & Chalet, D. & Faure, X. & Aixala, L. & Chessé, P., 2018. "Effect of engine exhaust gas pulsations on the performance of a thermoelectric generator for wasted heat recovery: An experimental and analytical investigation," Energy, Elsevier, vol. 162(C), pages 715-727.
    12. Agudelo, Andrés F. & García-Contreras, Reyes & Agudelo, John R. & Armas, Octavio, 2016. "Potential for exhaust gas energy recovery in a diesel passenger car under European driving cycle," Applied Energy, Elsevier, vol. 174(C), pages 201-212.
    13. Imran, Muhammad & Pili, Roberto & Usman, Muhammad & Haglind, Fredrik, 2020. "Dynamic modeling and control strategies of organic Rankine cycle systems: Methods and challenges," Applied Energy, Elsevier, vol. 276(C).
    14. Zhou, Feng & Joshi, Shailesh N. & Rhote-Vaney, Raphael & Dede, Ercan M., 2017. "A review and future application of Rankine Cycle to passenger vehicles for waste heat recovery," Renewable and Sustainable Energy Reviews, Elsevier, vol. 75(C), pages 1008-1021.
    15. Iglesias Garcia, Steven & Ferreiro Garcia, Ramon & Carbia Carril, Jose & Iglesias Garcia, Denis, 2018. "A review of thermodynamic cycles used in low temperature recovery systems over the last two years," Renewable and Sustainable Energy Reviews, Elsevier, vol. 81(P1), pages 760-767.
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