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.

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.

A dual loop organic Rankine cycle (DORC) system is designed to recover waste heat from a heavy-duty compressed natural gas engine (CNGE), and the performance of the DORC–CNGE combined system is simulated and discussed. The DORC system includes high-temperature (HT) and low-temperature (LT) cycles. The HT cycle recovers energy from the exhaust gas emitted by the engine, whereas the LT cycle recovers energy from intake air, engine coolant, and the HT cycle working fluid in the preheater. The mathematical model of the system is established based on the first and second laws of thermodynamics. The characteristics of waste heat energy from the CNGE are calculated according to engine test data under various operating conditions. Moreover, the performance of the DORC–CNGE combined system is simulated and analyzed using R245fa as the working fluid. Results show that the maximum net power output and the maximum thermal efficiency of the DORC system are 29.37 kW and 10.81%, respectively, under the rated power output condition of the engine. Compared with the original CNG engine, the maximum power output increase ratio and the maximum brake specific fuel consumption improvement ratio are 33.73% and 25%, respectively, in the DORC–CNGE combined system.

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.

The organic Rankine cycle (ORC) can be used to recover the waste heat from a stationary compressed natural gas (CNG) engine. However, the exhaust energy rate varies with engine load, which can influence the operating performance of the ORC system, therefore, it is necessary to study the running state of the ORC system. In this paper, first, the numerical simulation model of the ORC system is built by using GT-Suite software, with R245fa selected as the working fluid of the ORC system. The boundary conditions of the numerical simulation model are specified according to the measured data obtained by the stationary CNG engine test. Subsequently, the power output and dynamic characteristics of expander are analyzed to determine the running state of the ORC system. Investigations indicate that the fluctuation of refrigerant mass flow rate in the expander is obvious in the engine’s low-load regions (from 20% engine load to 40% engine load). The performances of ORC system and stationary CNG engine-ORC combined system (combined system) are finally investigated, respectively. The results show that the thermal efficiency of the combined system can be increased by a maximum 5.0% (at the engine rated condition), while the brake specific fuel consumption (BSFC) can be reduced by a maximum 4.0% (at the engine rated condition).

A rapid compression machine (RCM) test bench is developed in this study. The performance characterization and auto-ignition performance tests are conducted at an initial temperature of 293 K, a compression ratio of 9.5 to 16.5, a compressed temperature of 650 K to 850 K, a driving gas pressure range of 0.25 MPa to 0.7 MPa, an initial pressure of 0.04 MPa to 0.09 MPa, and a nitrogen dilution ratio of 35% to 65%. A new type of hydraulic piston is used to address the problem in which the hydraulic buffer adversely affects the rapid compression process. Auto-ignition performance tests of the RCM are then performed using a DME–O₂–N₂ mixture. The two-stage ignition delay and negative temperature coefficient (NTC) behavior of the mixture are observed. The effects of driving gas pressure, compression ratio, initial pressure, and nitrogen dilution ratio on the two-stage ignition delay are investigated. Results show that both the first-stage and overall ignition delays tend to increase with increasing driving gas pressure. The driving gas pressure within a certain range does not significantly influence the compressed pressure. With increasing compression ratio, the first-stage ignition delay is shortened, whereas the second-stage ignition delay is extended. With increasing initial pressure, both the first-stage and second-stage ignition delays are shortened. The second-stage ignition delay is shortened to a greater extent than that of the first-stage. With increasing nitrogen dilution ratio, the first-stage ignition delay is shortened, whereas the second-stage is extended. Thus, overall ignition delay presents different trends under various compression ratios and compressed pressure conditions.