An exhaust heat recovery system turns waste heat energy in exhaust gases into electric energy for batteries or mechanical energy reintroduced on the crankshaft. The technology is of increasing interest as car and heavy-duty vehicle manufacturers continue to increase efficiency, saving fuel and reducing emissions.
While technological improvements have greatly reduced the fuel consumption of internal combustion engines, the peak thermal efficiency of a 4-stroke Otto cycle engine is around 35%, which means that 65% of the energy released from the fuel is lost as heat. High speed Diesel cycle engines fare better with around 45% peak efficiency, but are still far from the maximum theoretical efficiency, with 55% of the fuel energy content rejected as heat.
Rankine cycle systems vaporize pressurised water using a steam generator located in the exhaust pipe. As a result of the heating by exhaust gases, the fluid is turned into steam. The steam then drives the expander of the Rankine engine, either a turbine or pistons. This expander can be directly tied to the crankshaft of the thermal engine or linked to an alternator to generate electricity.
UK researchers at Loughborough University and the University of Sussex concluded that waste heat from light-duty vehicle engines in a steam power cycle could deliver fuel economy advantages of 6.3% – 31.7%, depending upon drive cycle, and that high efficiencies can be achieved at practical operating pressures. [1]
A second technology, thermoelectric generators (Seebeck-, Peltier-, Thomson effects) is also an option to recover heat from the exhaust pipe, but has not been put to practical use in modern cars. [2]
Facing the new American, European, Japanese or Chinese regulation, more and more stringent concerning CO2 emissions, exhaust heat recovery sounds like one of the most efficient ways to recover a free energy, since heat is generated in many ways by the engine. Numerous companies develop systems based upon a Rankine Cycle:
The German company has been one of the first major to study exhaust heat recovery with a Rankine system called Turbosteamer. [3]
The 2016 Chevrolet Malibu Hybrid car features an Exhaust gas Heat Recovery (EGHR) system to accelerate coolant heat up time. This gives faster heat up of the engine coolant which in turn heats up the engine faster. Less fuel is used giving reduced emissions. This will also quicken cabin heating warm up for passenger comfort and window defrosting. For hybrid applications, it also can warm the battery pack. The cooling system is connected to a heat exchanger placed in the exhaust gas transferring the thermal energy from the exhaust gas to the cooling system. When the engine is warmed up the exhaust gas is diverted to a by-pass pipe. [4]
Honda also develops a module based on a Rankine Cycle to improve overall efficiency of hybrid vehicles, by recovering the heat of the engine and turning it into electricity for the battery pack. In the US highway cycle, the Rankine cycle system regenerated three times as much energy as the vehicle's regenerative braking system.
A French company, Exoès is specialized in designing and manufacturing exhaust heat recovery systems based on Rankine Cycles. The system EVE, Energy Via Exhaust, leads to fuel savings from 5 up to 15%. [5]
Barber-Nichols Inc. develops Rankine technologies for vehicles. [6]
The German consortium unites the majority of internal combustion engine manufacturers across the world. Two task forces are currently studying exhaust heat recovery systems on passenger cars.
Renault Trucks: As a part of the All For Fuel Eco Initiative, Renault Trucks studies a Rankine system for long distance vehicles that could lead to 10% fuel savings. [7] The goal is to produce enough energy to feed the components and electronic auxiliaries with electricity and reduce the fuel consumption by reducing the load on the alternator. [8]
Double Arrow Engineerings' WildFire Heat Recovery System (WFHRS) is under development and utilizes wasted heat from both coolant and exhaust. This system mechanically adds power back to the drive-line, utilizing a Rankine engine as the energy conversion method. The WFHRS is designed for a variety of different applications, both fixed and variable RPM, aftermarket and OEM applications, but generally geared toward larger equipment such as large on-highway trucks, diesel generators, large buses and motor-homes, marine vessels, medium duty trucks, etc. [9]
IFPEN, Enogia and Alstom are developing a system called Trenergy dedicated to improve train fuel efficiency. [10]
Fuel efficiency, reduction of CO2 emissions, reliability, and costs are necessary parts of Formula 1 manufacturers’ strategies. Automobile sport is also a good place to trial and assess technologies that, once made reliable, and with costs reduced by experience in production, can be adapted to private cars. Formula 1 constructors produced one of the first exhaust heat recovery systems,[ citation needed ] and nowadays these devices are essential parts of embedded technologies on F1. Heat recovery was scheduled to become mandatory in the 2014 F1 Championship.[ citation needed ]
An engine or motor is a machine designed to convert one or more forms of energy into mechanical energy.
A gas turbine, also called a combustion turbine, is a type of continuous flow internal combustion engine. The main parts common to all gas turbine engines form the power-producing part and are, in the direction of flow:
A hybrid vehicle is one that uses two or more distinct types of power, such as submarines that use diesel when surfaced and batteries when submerged. Other means to store energy include pressurized fluid in hydraulic hybrids.
A four-strokeengine is an internal combustion (IC) engine in which the piston completes four separate strokes while turning the crankshaft. A stroke refers to the full travel of the piston along the cylinder, in either direction. The four separate strokes are termed:
Fuel efficiency is a form of thermal efficiency, meaning the ratio of effort to result of a process that converts chemical potential energy contained in a carrier (fuel) into kinetic energy or work. Overall fuel efficiency may vary per device, which in turn may vary per application, and this spectrum of variance is often illustrated as a continuous energy profile. Non-transportation applications, such as industry, benefit from increased fuel efficiency, especially fossil fuel power plants or industries dealing with combustion, such as ammonia production during the Haber process.
A combined cycle power plant is an assembly of heat engines that work in tandem from the same source of heat, converting it into mechanical energy. On land, when used to make electricity the most common type is called a combined cycle gas turbine (CCGT) plant. The same principle is also used for marine propulsion, where it is called a combined gas and steam (COGAS) plant. Combining two or more thermodynamic cycles improves overall efficiency, which reduces fuel costs.
Internal combustion engine cooling uses either air or liquid to remove the waste heat from an internal combustion engine. For small or special purpose engines, cooling using air from the atmosphere makes for a lightweight and relatively simple system. Watercraft can use water directly from the surrounding environment to cool their engines. For water-cooled engines on aircraft and surface vehicles, waste heat is transferred from a closed loop of water pumped through the engine to the surrounding atmosphere by a radiator.
Cogeneration or combined heat and power (CHP) is the use of a heat engine or power station to generate electricity and useful heat at the same time.
A turbosteamer is a term used by BMW to describe a combined cycle engine. Waste heat energy from the internal combustion engine would be used to generate steam for a steam engine which would create supplemental power for the vehicle. The turbosteamer device is affixed to the exhaust and cooling system. It salvages the heat wasted in the exhaust and radiator and uses a steam piston or turbine to relay that power to the crankshaft. The steam circuit produces 14 hp (10 kW) and 15 ft⋅lbf (20 N⋅m) of torque at peak, yielding an estimated 15% gain in fuel efficiency. Unlike gasoline-electric hybrids, these gains increase at higher, steadier speeds.
A condensing steam locomotive is a type of locomotive designed to recover exhaust steam, either in order to improve range between taking on boiler water, or to reduce emission of steam inside enclosed spaces. The apparatus takes the exhaust steam that would normally be used to produce a draft for the firebox, and routes it through a heat exchanger, into the boiler water tanks. Installations vary depending on the purpose, design and the type of locomotive to which it is fitted. It differs from the usual closed cycle condensing steam engine, in that the function of the condenser is primarily either to recover water, or to avoid excessive emissions to the atmosphere, rather than maintaining a vacuum to improve both efficiency and power.
Waste heat is heat that is produced by a machine, or other process that uses energy, as a byproduct of doing work. All such processes give off some waste heat as a fundamental result of the laws of thermodynamics. Waste heat has lower utility than the original energy source. Sources of waste heat include all manner of human activities, natural systems, and all organisms, for example, incandescent light bulbs get hot, a refrigerator warms the room air, a building gets hot during peak hours, an internal combustion engine generates high-temperature exhaust gases, and electronic components get warm when in operation.
Energy recovery includes any technique or method of minimizing the input of energy to an overall system by the exchange of energy from one sub-system of the overall system with another. The energy can be in any form in either subsystem, but most energy recovery systems exchange thermal energy in either sensible or latent form.
Hybrid vehicle drivetrains transmit power to the driving wheels for hybrid vehicles. A hybrid vehicle has multiple forms of motive power.
The Organic Rankine Cycle (ORC) is named for its use of an organic, high molecular mass fluid with a liquid-vapor phase change, or boiling point, occurring at a lower temperature than the water-steam phase change. The fluid allows Rankine cycle heat recovery from lower temperature sources such as biomass combustion, industrial waste heat, geothermal heat, solar ponds etc. The low-temperature heat is converted into useful work, that can itself be converted into electricity.
An automotive thermoelectric generator (ATEG) is a device that converts some of the waste heat of an internal combustion engine (IC) into electricity using the Seebeck Effect. A typical ATEG consists of four main elements: A hot-side heat exchanger, a cold-side heat exchanger, thermoelectric materials, and a compression assembly system. ATEGs can convert waste heat from an engine's coolant or exhaust into electricity. By reclaiming this otherwise lost energy, ATEGs decrease fuel consumed by the electric generator load on the engine. However, the cost of the unit and the extra fuel consumed due to its weight must be also considered.
A waste heat recovery unit (WHRU) is an energy recovery heat exchanger that transfers heat from process outputs at high temperature to another part of the process for some purpose, usually increased efficiency. The WHRU is a tool involved in cogeneration. Waste heat may be extracted from sources such as hot flue gases from a diesel generator, steam from cooling towers, or even waste water from cooling processes such as in steel cooling.
A liquid nitrogen vehicle is powered by liquid nitrogen, which is stored in a tank. Traditional nitrogen engine designs work by heating the liquid nitrogen in a heat exchanger, extracting heat from the ambient air and using the resulting pressurized gas to operate a piston or rotary motor. Vehicles propelled by liquid nitrogen have been demonstrated, but are not used commercially. One such vehicle, Liquid Air, was demonstrated in 1902.
A thermal wheel, also known as a rotary heat exchanger, or rotary air-to-air enthalpy wheel, energy recovery wheel, or heat recovery wheel, is a type of energy recovery heat exchanger positioned within the supply and exhaust air streams of air-handling units or rooftop units or in the exhaust gases of an industrial process, in order to recover the heat energy. Other variants include enthalpy wheels and desiccant wheels. A cooling-specific thermal wheel is sometimes referred to as a Kyoto wheel.
An internal combustion engine is a heat engine in which the combustion of a fuel occurs with an oxidizer in a combustion chamber that is an integral part of the working fluid flow circuit. In an internal combustion engine, the expansion of the high-temperature and high-pressure gases produced by combustion applies direct force to some component of the engine. The force is typically applied to pistons, turbine blades, a rotor, or a nozzle. This force moves the component over a distance, transforming chemical energy into kinetic energy which is used to propel, move or power whatever the engine is attached to. This replaced the external combustion engine for applications where the weight or size of an engine was more important.
Exoès is a French company based in the city of Gradignan in the region of Bordeaux. Exoès was founded by Arnaud Desrentes, Rémi Daccord, and Thiébaut Kientz. It targets renewable energy and energy efficiency. It specializes in the transformation of heat into power, such as mechanical or electric energy via the Rankine cycles. The company is supported by BPI France, ADEME, the European funds (FEDER), the French Ministry of Higher Education and Research, and the Aquitaine and Poitou-Charentes regions.