Thermodynamic potential of Rankine and flash cycles for waste heat recovery in a heavy duty Diesel engine

In heavy duty Diesel engines more than 50% of the fuel energy is not converted to brake power, but is lost as heat. One promising way to recapture a portion of this heat and convert it to power is by using thermodynamic power cycles. Using the heavy duty Diesel engine as the waste heat source, this paper evaluates and compares the thermodynamic potential of different working fluids in four power cycles: the Rankine cycle (RC), the transcritical Rankine cycle (TRC), the trilateral flash cycle (TFC) and the single flash cycle (SFC). To establish the heat input into the cycle, operating conditions from an actual heavy duty Diesel engine are used as boundary conditions for the cycle heat source. A GT-Power model of the engine was previously developed and experimentally validated for the stationary points in the European Stationary Cycle (ESC). An energy analysis of this engine revealed that it has four heat sources with the potential for waste heat recovery: the charge air cooler (CAC), the coolant flow, the exhaust gas recirculation cooler (EGRC), and the exhaust flow. Using fixed heat input conditions determined by the selected engine operating mode, the TFC performed best for the CAC with a net power increase of around 2 kW, while the RC performed best for the coolant flow, with a net power increase of 5 kW. For the EGRC, ethanol performed especially well with both the RC and TRC, leading to an 8 kW net power increase. When using the exhaust as heat source, all four cycles provided a power output of around 5 kW with some variation depending on the working fluid. This study shows that for most cases, considering the different heat sources, the choice of cycle has a larger impact on the cycle performance than the choice of working fluid.