Parametric analysis of a dual loop Organic Rankine Cycle (ORC) system for engine waste heat recovery

This paper presents a dual loop Organic Rankine Cycle (ORC) system consisting of a high temperature (HT) loop and a low temperature (LT) loop for engine waste heat recovery. The HT loop recovers the waste heat of the engine exhaust gas, and the LT loop recovers that of the jacket cooling water in addition to the residual heat of the HT loop. The two loops are coupled via a shared heat exchanger, which means that the condenser of the HT loop is the evaporator of the LT loop as well. Cyclohexane, benzene and toluene are selected as the working fluids of the HT loop. Different condensation temperatures of the HT loop are set to maintain the condensation pressure slightly higher than the atmosphere pressure. R123, R236fa and R245fa are chosen for the LT loop. Parametric analysis is conducted to evaluate the influence of the HT loop condensation temperature and the residual heat load on the LT loop. The simulation results reveal that under different condensation conditions of the HT loop, the pinch point of the LT loop appears at different locations, resulting in different evaporation temperatures and other thermal parameters. With cyclohexane for the HT loop and R245fa for the LT loop, the maximum net power output of the dual loop ORC system reaches 111.2 kW. Since the original power output of the engine is 996 kW, the additional power generated by the dual loop ORC system can increase the engine power by 11.2%.