Direct and Indirect Exhaust Heat Recovery from Turbocharged Heavy-Duty Engine

Di Bartolomeo, Marco; Di Battista, Davide; Fatigati, Fabio; Cau, Giorgio; Cipollone, Roberto

doi:10.4271/2023-24-0122

Cited by 3 publications

(1 citation statement)

References 48 publications

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“…In this case, the technology chosen for this component is crucial. Finned tube heat exchangers seem to have the best performances in this regard [61] and, if these pressure drops are limited (e.g., <100 mbar), the negative effect of the engine can be neglected. However, the introduction of the ORC unit is more invasive than the turbocompound and requires more space onboard.…”

Section: Engine Side Effectsmentioning

confidence: 99%

A New Generation of Hydrogen-Fueled Hybrid Propulsion Systems for the Urban Mobility of the Future

Arsie,

Battistoni,

Brancaleoni

et al. 2023

Energies

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The H2-ICE project aims at developing, through numerical simulation, a new generation of hybrid powertrains featuring a hydrogen-fueled Internal Combustion Engine (ICE) suitable for 12 m urban buses in order to provide a reliable and cost-effective solution for the abatement of both CO2 and criteria pollutant emissions. The full exploitation of the potential of such a traction system requires a substantial enhancement of the state of the art since several issues have to be addressed. In particular, the choice of a more suitable fuel injection system and the control of the combustion process are extremely challenging. Firstly, a high-fidelity 3D-CFD model will be exploited to analyze the in-cylinder H2 fuel injection through supersonic flows. Then, after the optimization of the injection and combustion process, a 1D model of the whole engine system will be built and calibrated, allowing the identification of a “sweet spot” in the ultra-lean combustion region, characterized by extremely low NOx emissions and, at the same time, high combustion efficiencies. Moreover, to further enhance the engine efficiency well above 40%, different Waste Heat Recovery (WHR) systems will be carefully scrutinized, including both Organic Rankine Cycle (ORC)-based recovery units as well as electric turbo-compounding. A Selective Catalytic Reduction (SCR) aftertreatment system will be developed to further reduce NOx emissions to near-zero levels. Finally, a dedicated torque-based control strategy for the ICE coupled with the Energy Management Systems (EMSs) of the hybrid powertrain, both optimized by exploiting Vehicle-To-Everything (V2X) connection, allows targeting H2 consumption of 0.1 kg/km. Technologies developed in the H2-ICE project will enhance the know-how necessary to design and build engines and aftertreatment systems for the efficient exploitation of H2 as a fuel, as well as for their integration into hybrid powertrains.

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Section: Engine Side Effectsmentioning

confidence: 99%

A New Generation of Hydrogen-Fueled Hybrid Propulsion Systems for the Urban Mobility of the Future

Arsie,

Battistoni,

Brancaleoni

et al. 2023

Energies

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The dynamic behaviour of ORC-based power units fed by exhaust gases of internal combustion engines in mobile applications

Fatigati,

Coletta,

Di Bartolomeo

et al. 2024

Applied Thermal Engineering

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On the Application of Joule-Cycle-Based Waste Heat Recovery to Heavy-Duty Vehicles

Turner,

Kenkoh,

Gubba

et al. 2024

SAE Technical Paper Series

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<div class="section abstract"><div class="htmlview paragraph">Internal combustion engines are becoming ever more efficient as mankind seeks to mitigate the effects of climate change while still maintaining the benefits that a mechanized society has brought to the global economy. As peak values, mass production spark-ignition engines can now achieve approximately 40% brake thermal efficiency and heavy-duty truck compression-ignition engines can approach 50%. While commendable, the unfortunate truth is that the remainder gets emitted as waste heat and is sent to the atmosphere to no useful purpose. Clearly, if one could recover some of this waste heat for beneficial use then this is likely to become important as new means of mitigating fossil CO<sub>2</sub> emissions are demanded. A previous study by the authors has identified that the closed Joule cycle (or complications of it beginning to approximate the closed Ericsson cycle) could reasonably be developed to provide a practical means of recovering exhaust heat when applied to a large ship engine. In that previous work there was a sensitivity shown between overall pressure ratio and the ratio of specific heats of the gas being used as the working fluid and, providing those variables were appropriately chosen, relatively high efficiencies and specific work outputs appeared to be achievable. While marine engines might seem to be ideal applications for this technology, in no small part due to the effectively infinite and relatively low-temperature sink available at the bottom of the cycle, their low exhaust temperatures (arising from their inherently high efficiencies) and the existing placement of scrubbers and economizers in the exhaust gas run makes the practical application of waste heat recovery (WHR) more difficult on them; nevertheless, using real exhaust gas compositions, the previous work clearly showed some significant potential in that arena, even if the exact level of upper temperature available in the cycle is still unknown.</div><div class="htmlview paragraph">Given the early indications that Joule-cycle based WHR could work in already-efficient marine applications, this paper investigates the practicality of such methods of recovering exhaust heat in another sector – heavy-duty road transport. In this application, the challenge of a more difficult rejection of heat to the atmosphere on the cold side of the cycle is offset by a hotter exhaust gas temperature. Versus light-duty applications, long-distance transport can offer the chance for more continuous operation with fewer transients to reduce average efficiency, plus a direct economic payback in the form of lower operating costs.</div><div class="htmlview paragraph">To investigate this opportunity modelling was performed using data in the literature already published for a diesel-engined truck which was then input to one of the Joule-cycle-based WHR models already developed for the initial marine-based project. These results show that this WHR concept could usefully be applied to truck use. An open Joule cycle system is then proposed and this too is investigated; here an increased benefit was predicted because, unlike for the closed Joule cycle approach, the working fluid flow rate in the system can be varied over a wider range, and the final heat exchange is avoided, giving a reduced lower cycle temperature.</div></div>

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Direct and Indirect Exhaust Heat Recovery from Turbocharged Heavy-Duty Engine

Cited by 3 publications

References 48 publications

A New Generation of Hydrogen-Fueled Hybrid Propulsion Systems for the Urban Mobility of the Future

A New Generation of Hydrogen-Fueled Hybrid Propulsion Systems for the Urban Mobility of the Future

The dynamic behaviour of ORC-based power units fed by exhaust gases of internal combustion engines in mobile applications

On the Application of Joule-Cycle-Based Waste Heat Recovery to Heavy-Duty Vehicles

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