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Chapter 2: The Organic Rankine Cycle an ICE is not new and the first technical developments followed the 70’s energy crisis. For instance, Mack Trucks (Patel & Doyle, 1976) designed and built a prototype of such a system operating on the exhaust gas of a 288 HP truck engine. A 450 km on-road test demonstrated the technical feasibility of the system and its economical interest: an improvement of 12.5% of the fuel consumption was reported. Systems developed today differ from those of the 70’s because of the advances in the development of expansion devices and the broader choice of working fluids. However, at the present time, Rankine cycle systems are under development, but no commercial solution seems to be available yet. Most of the systems under development recover heat from the exhaust gases and from the cooling circuit (Freymann et al., 2008). By contrast, the system developed by (Oomori & Ogino 1993) only recovers heat from the cooling circuit. Different architectures can be proposed to recover engine waste heat: The heat recovery system can be a direct evaporation system or a heat transfer loop system. In the first case, the evaporator of the ORC is directly connected to the exhaust gases. The advantage of such a configuration is the high temperature of the heat recovery, allowing higher cycle efficiency. In the second case, thermal oil is used to recover heat on the exhaust gases and is then directed to the evaporator. This second system acts as buffer and reduces the transient character of the ORC heat source, which simplifies its control. It also shows the advantage of avoiding hot spots in the evaporator, which could damage the organic working fluid. The expander output can be mechanical or electrical. With a mechanical system, the expander shaft is directly connected to the engine drive belt, with a clutch to avoid power losses when the ORC cycle power output is too low. The main drawback of this configuration is the imposed expander speed: this speed is a fixed ratio of the engine speed and is not necessarily the optimal speed for maximizing cycle efficiency. In the case of electricity generation, the expander is coupled to an alternator, used to refill the batteries or supply auxiliary equipments such as the air conditioning. It should be noted that current vehicle alternators show a quite low efficiency (about 50 to 60%), which reduces the ORC output power. As for the expander, the pump can be directly connected to the drive belt, to the expander shaft, or to an electrical motor. In the latter case, the working fluid flow rate can be independently controlled, which makes the regulation of such a system much easier. The control of the system is particularly complex due to the (often) transient regime of the heat source. However, optimizing the control is crucial to improve the performance of the system. It is generally necessary to control both the pump speed and the expander speed to maintain the required conditions (temperature, pressure) at the expander inlet. Performance of the recently developed prototypes of Rankine cycles is promising. For instance, the system designed by Honda (Endo et al., 2007) 8PDF Image | Sustainable Energy Conversion Through the Use of Organic Rankine Cycles for Waste Heat Recovery and Solar Applications.
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