Dynamic behavior of Rankine cycle system for waste heat recovery of heavy duty diesel engines under driving cycle

• Waste heat recovery behavior of the RCS during driving cycle was investigated.
• Four operating modes were defined to describe the operating process of the RCS under driving cycle.
• The operating mode switching is the crucial reason for on-road inefficiency.
• The dry and isentropic fluids are superior to the wet ones on the adaptability to unsteady ExGE.
• The effects of the vapor parameters on RCT-E and power mode percentage are opposite.

The RCS (Rankine cycle system) used to recover the WHE (waste heat energy) from engines has been regarded as one of the most potential ways of achieving higher efficiency. However, it is of great challenge to keep the RCS still in good performance under driving cycle. This paper tries to reveal and explain its on-road inefficiency.The operating process of the RCS under driving cycle was analyzed in advance. Afterwards, four basic operating modes were defined, including startup mode, turbine turning mode, power mode and protection mode. Then, a RCS model was established and operating performances of the RCS under an actual driving cycle were discussed based on this model. The results indicate that the on-road RCS-E (Rankine cycle system efficiency) is as low as 3.63%, which is less than half of the design RCS-E (7.77%) at the rated operating point. Despite the inevitable vapor state fluctuation, it is the operating mode switching during the driving cycle that leads to the on-road inefficiency. Further investigations indicate that the expander safety temperature and its safety margin affected by the working fluids, designed superheat degree and evaporating pressure are the main factors determining the operating mode switching. Finally, the effects of the working fluids, designed superheat degree and evaporating pressure on the operating mode switching and RC (Rankine cycle) efficiencies were profoundly investigated. The study shows that the dry and isentropic fluids are superior to the wet ones due to their less probabilities of droplets formation as a consequence of their saturated vapor characteristics. The effects of the vapor parameters on the RCT-E (Rankine cycle thermal efficiency) and operating mode switching are opposite. Therefore, in order to optimize the RCS, it would be better to take full consideration in reducing the operating mode switching, while pursuing the maximum RCT-E.