Study of mixtures based on hydrocarbons used in ORC (Organic Rankine Cycle) for engine waste heat recovery

•A theoretical analysis of Organic Rankine Cycle for engine exhaust heat recovery is proposed.•Mixtures based on hydrocarbons as working fluids have been suggested.•Effects of the IHE (internal heat exchanger) on ORC system are investigated.•OMR (Optimal mixture ratio) changes with the evaporation temperature.•Using the system, maximum thermal efficiency can achieve 16.7%.

For high temperature ORC (Organic Rankine Cycle) used in engine waste heat recovery, it's very critical to select a high temperature working fluid. HCs (Hydrocarbons) usually have excellent cycle performance, but the flammability limits their practical application. Considering that some retardants can be used to suppress flammability, the paper presents an application of mixtures based on hydrocarbons blending with refrigerant retardants to engine waste heat ORC. Three pure hydrocarbons (cyclopentane, cyclohexane, benzene) and two retardants (R11, R123) are selected for combination. Thermal efficiency and exergy loss are selected as the main objective functions. Based on thermodynamic model, the effects of retardants mass fraction, evaporation temperature and IHE (internal heat exchanger) are investigated. Results show that zeotropic mixtures do have higher thermal efficiency and lower exergy loss than pure fluids, at a certain mixture ratio. There exists the OMR (optimal mixture ratio) for different mixtures, and it changes with the evaporation temperature. When adding IHE to system, cycle performance could be obviously improved, and for benzene/R11 (0.7/0.3), the efficiency growth is about 7.12%∼9.72%. Using it, the maximum thermal efficiency of the system can achieve 16.7%, and minimum exergy loss is only 30.76 kW.