Design, size estimation, and thermodynamic analysis of a realizable organic Rankine cycle system for waste heat recovery in commercial truck engines

• Published in: Thermal science and engineering progress 2021-05, Vol.22, p.100849, Article 100849
• Main Authors: Thaddaeus, Julius, Unachukwu, Godwin O., Mgbemene, Chigbo A., Pesyridis, Apostolos, Usman, Muhammad, Alshammari, Fuhaid Aziz
• Format: Article
• Language: English
• Subjects: BSFC improvement; Heat recovery module; Mechanical efficiency; Module size estimation; Realizable organic Rankine cycle; Thermodynamic analysis
• ISSN: 2451-9049; 2451-9049
• DOI: 10.1016/j.tsep.2021.100849

•ORC module designed on speed mode for heat recovery in commercial trucks.•The ORC module achieved 32.3 kg/kW weight-to-power ratio.•Size estimation was based on manufacturers' cataloques from their websites.•Model achieved 2.99 kW net output, 3.27% BSFC improvement and 6.36% thermal efficiency. The application of the ORC system for WHR in truck engines is a promising tool that minimizes the rate of CO2 released by the automobile industry and reduces specific fuel consumption by the sector. This article describes the development of a high-performance energy reuse module and size estimation for application in highway truck engines. The concept was performed on GT-Suite (vs. 2019) platform using R245fa as working fluid, and the evaluation of the module size was done using details from supplier specifications. Interestingly, the ORC system simulations were all performed at vehicle speeds of 66–119 km/hr to achieve realizable vehicle speed conditions. The modelling accomplished 2.99 kW of net power output, 3.27% BSFC improvement, and 6.36% ORC system efficiency, respectively. The ORC module's total estimated weight is approximately 100 kg, roughly giving a 32.3 kg/kW weight-to-power ratio.