A novel free piston expander-linear generator (FPE-LG) integrated unit was proposed to recover waste heat efficiently from vehicle engine. This integrated unit can be used in a small-scale Organic Rankine Cycle (ORC) system and can directly convert the thermodynamic energy of working fluid into electric energy. The conceptual design of the free piston expander (FPE) was introduced and discussed. A cam plate and the corresponding valve train were used to control the inlet and outlet valve timing of the FPE. The working principle of the FPE-LG was proven to be feasible using an air test rig. The indicated efficiency of the FPE was obtained from the p–V indicator diagram. The dynamic characteristics of the in-cylinder flow field during the intake and exhaust processes of the FPE were analyzed based on Fluent software and 3D numerical simulation models using a computation fluid dynamics method. Results show that the indicated efficiency of the FPE can reach 66.2% and the maximal electric power output of the FPE-LG can reach 22.7 W when the working frequency is 3 Hz and intake pressure is 0.2 MPa. Two large-scale vortices are formed during the intake process because of the non-uniform distribution of velocity and pressure. The vortex flow will convert pressure energy and kinetic energy into thermodynamic energy for the working fluid, which weakens the power capacity of the working fluid.

To achieve energy saving and emission reduction for vehicle diesel engines, the organic Rankine cycle (ORC) was employed to recover waste heat from vehicle diesel engines, R245fa was used as ORC working fluid, and the resulting vehicle diesel engine-ORC combined system was presented. The variation law of engine exhaust energy rate under various operating conditions was obtained, and the running performances of the screw expander were introduced. Based on thermodynamic models and theoretical calculations, the running performance of the vehicle diesel engine-ORC combined system was analyzed under various engine operating condition scenarios. Four evaluation indexes were defined: engine thermal efficiency increasing ratio (ETEIR), waste heat recovery efficiency (WHRE), brake specific fuel consumption (BSFC) of the combined system, and improvement ratio of BSFC (IRBSFC). Results showed that when the diesel engine speed is 2200 r/min and diesel engine torque is 1200 N·m, the power output of the combined system reaches its maximum of approximately 308.6 kW, which is 28.6 kW higher than that of the diesel engine. ETEIR, WHRE, and IRBSFC all reach their maxima at 10.25%, 9.90%, and 9.30%, respectively. Compared with that of the diesel engine, the BSFC of the combined system is obviously improved under various engine operating conditions.

This study analyzed the variation law of engine exhaust energy under various operating conditions to improve the thermal efficiency and fuel economy of diesel engines. An organic Rankine cycle (ORC) waste heat recovery system with internal heat exchanger (IHE) was designed to recover waste heat from the diesel engine exhaust. The zeotropic mixture R416A was used as the working fluid for the ORC. Three evaluation indexes were presented as follows: waste heat recovery efficiency (WHRE), engine thermal efficiency increasing ratio (ETEIR), and output energy density of working fluid (OEDWF). In terms of various operating conditions of the diesel engine, this study investigated the variation tendencies of the running performances of the ORC waste heat recovery system and the effects of the degree of superheat on the running performance of the ORC waste heat recovery system through theoretical calculations. The research findings showed that the net power output, WHRE, and ETEIR of the ORC waste heat recovery system reach their maxima when the degree of superheat is 40 K, engine speed is 2200 r/min, and engine torque is 1200 N·m. OEDWF gradually increases with the increase in the degree of superheat, which indicates that the required mass flow rate of R416A decreases for a certain net power output, thereby significantly decreasing the risk of environmental pollution.

The main purpose of this research is to analyze the performance of an evaporator for the organic Rankine cycle (ORC) system and discuss the influence of the evaporator on the operating characteristics of diesel engine. A simulation model of fin-and-tube evaporator of the ORC system is established by using Fluent software. Then, the flow and heat transfer characteristics of the exhaust at the evaporator shell side are obtained, and then the performance of the fin-and-tube evaporator of the ORC system is analyzed based on the field synergy principle. The field synergy angle (β) is the intersection angle between the velocity vector and the temperature gradient. When the absolute values of velocity and temperature gradient are constant and β < 90°, heat transfer enhancement can be achieved with the decrease of the β. When the absolute values of velocity and temperature gradient are constant and β >90°, heat transfer enhancement can be achieved with the increase of the β. Subsequently, the influence of the evaporator of the ORC system on diesel engine performance is studied. A simulation model of the diesel engine is built by using GT–Power software under various operating conditions, and the variation tendency of engine power, torque, and brake specific fuel consumption (BSFC) are obtained. The variation tendency of the power output and BSFC of diesel engine–ORC combined system are obtained when the evaporation pressure ranges from 1.0 MPa to 3.5 MPa. Results show that the field synergy effect for the areas among the tube bundles of the evaporator main body and the field synergy effect for the areas among the fins on the windward side are satisfactory. However, the field synergy effect in the areas among the fins on the leeward side is weak. As a result of the pressure drop caused by the evaporator of the ORC system, the diesel engine power and torque decreases slightly, whereas the BSFC increases slightly with the increase of exhaust back pressure. With the increase of engine speed, power loss, torque loss, and BSFC increment increase gradually, where the most significant change is less than 1%. Compared with the diesel engine itself, the maximum increase of power output of the diesel engine–ORC combined system is 6.5% and the maximum decrease of BSFC is 6.1%.

One way to increase the thermal efficiency of vehicle diesel engines is to recover waste heat by using an organic Rankine cycle (ORC) system. Tests were conducted to study the running performances of diesel engines in the whole operating range. The law of variation of the exhaust energy rate under various engine operating conditions was also analyzed. A diesel engine-ORC combined system was designed, and relevant evaluation indexes proposed. The variation of the running performances of the combined system under various engine operating conditions was investigated. R245fa and R152a were selected as the components of the mixed working fluid. Thereafter, six kinds of mixed working fluids with different compositions were presented. The effects of mixed working fluids with different compositions on the running performances of the combined system were revealed. Results show that the running performances of the combined system can be improved effectively when mass fraction R152a in the mixed working fluid is high and the engine operates with high power. For the mixed working fluid M1 (R245fa/R152a, 0.1/0.9, by mass fraction), the net power output of the combined system reaches the maximum of 34.61 kW. Output energy density of working fluid (OEDWF), waste heat recovery efficiency (WHRE), and engine thermal efficiency increasing ratio (ETEIR) all reach their maximum values at 42.7 kJ/kg, 10.90%, and 11.29%, respectively.

To efficiently recover the waste heat from a diesel engine exhaust, a regenerative organic Rankine cycle (RORC) system was employed, and butane, R124, R416A, and R134a were used as the working fluids. The resulting diesel engine-RORC combined system was defined and the relevant evaluation indexes were proposed. First, the variation tendency of the exhaust energy rate under various diesel engine operating conditions was analyzed using experimental data. The thermodynamic model of the RORC system was established based on the first and second laws of thermodynamics, and the net power output and exergy destruction rate of the RORC system were selected as the objective functions. A particle swarm optimization (PSO) algorithm was used to optimize the operating parameters of the RORC system, including evaporating pressure, intermediate pressure, and degree of superheat. The operating performances of the RORC system and diesel engine-RORC combined system were studied for the four selected working fluids under various operating conditions of the diesel engine. The results show that the operating performances of the RORC system and the combined system using butane are optimal on the basis of optimizing the operating parameters; when the engine speed is 2200 r/min and engine torque is 1215 N·m, the net power output of the RORC system using butane is 36.57 kW, and the power output increasing ratio (POIR) of the combined system using butane is 11.56%.