Direct integration of an organic Rankine cycle into an internal combustion engine cooling system for comprehensive and simplified waste heat recovery

Cogeneration systems based on internal combustion engines (ICE) provide decent efficiency and flexibility. In order to further improve the efficiency, organic Rankine cycle (ORC) can be used to convert high temperature (waste) heat from flue gas to electricity. There is a large amount of heat in jacket cooling at lower temperatures for which there is often no demand so it has to be rejected into the ambient. Previous systems trying to utilise this heat in the ORC cycle end up as too complex and expensive. This study introduces an innovative jacket cooling method. In the cooling system of an ICE, instead of typical water or oil-based heat transfer fluids, the working fluid of an ORC is used as the engine coolant, recovering the low-potential heat. Preheated organic fluid is then directly used in the bottoming ORC with further heat input from the flue gas. This concept allows utilising both low and high potential heat from the cooling of the ICE and from the flue gas recovery, while omitting the intermediate heat-transfer circuits commonly found in ORC waste heat recovery applications. Presented thermodynamic analysis shows a strong dependency of the ORC utilisation efficiency on cooling fluid allowed pressure in the ICE jacket and on the heat flow ratio between the coolant and the flue gas of the ICE. A baseline study with a specific 83 kWe ICE with the novel configuration provides an improvement of nearly 10 kW in comparison with 7 kW of an ORC utilising only flue gas. More general parametric analysis has shown the potential of the ORC power output improvement by more than 60% for specific ICE types and higher pressures and temperatures in the engine cooling circuit. In a cogeneration regime, these benefits in electrical power output come at the cost of a very slight decrease in overall efficiency.