The exhaust gas in an internal combustion engine provides favorable conditions for a waste-heat recovery (WHR) system. The highest potential is achieved by the Rankine cycle as a heat recovery technology. There are only few experimental studies that investigate full-scale systems using water-based working fluids and their effects on the performance and operation of a Rankine cycle heat recovery system. This paper discusses experimental results and practical challenges with a WHR system when utilizing heat from the exhaust gas recirculation system of a truck engine. The results showed that the boiler’s pinch point necessitated trade-offs between maintaining adequate boiling pressure while achieving acceptable cooling of the EGR and superheating of the water. The expander used in the system had a geometric compression ratio of 21 together with a steam outlet timing that caused high re-compression. Inlet pressures of up to 30 bar were therefore required for a stable expander power output. Such high pressures increased the pump power, and reduced the EGR cooling in the boiler because of pinch-point effects. Simulations indicated that reducing the expander’s compression ratio from 21 to 13 would allow 30% lower steam supply pressures without adversely affecting the expander’s power output.

Several technological challenges delay the adoption of electrified powertrains in the heavy-duty transport sector. For fuel-cell hybrid electric trucks, key issues include slow cold start, reduced cooling power during high ambient temperatures, and uncertainties regarding durability. In addition, the engineers must handle the complexity of the system. In this article, a Matlab/Simulink library is introduced, which has been developed to aid engineers in the design and optimization of energy management systems and strategies of this complex system that consider mechanical, electrochemical, and thermal energy flows. The library is introduced through five example vehicle models, and through case studies that highlight the various kinds of analysis that can be performed using the provided models. All library code is open source, open for commercial use, and runs in Matlab/Simulink without any need for external libraries.