Upload
vancong
View
217
Download
1
Embed Size (px)
Citation preview
EVE, Energy Via Exhaust:
Waste heat recovery
15e cycle de conférences:
Utilisation rationnelle de
l’énergie et environnement
www.exoes.com
Waste heat recovery
through Rankine Cycle
on heavy duty vehicle
24-Mar-14 1
Date of creation 2009, May 20th
President Mr A. Desrentes
Exoès company
Employees 12 (10 engineers)
7Test benches
www.exoes.com 224-Mar-14
Web site www.exoes.com
Patents
7
Strategic committee with 3 former
top managers of international Tier 1 suppliers.
Test benches
8
Table of contents
• Context
• WHR state of the art
• Reminders
• RC design: key choices
www.exoes.com
• RC design: key choices
• RC state of the art
• Modeling
• Exoès technology, tests and results
• Conclusion
24-Mar-14 3
Table of contents
• Context• WHR state of the art
• Reminders
• RC design: key choices
www.exoes.com
• RC design: key choices
• RC state of the art
• Modeling
• Exoès technology, tests and results
• Conclusion
24-Mar-14 4
Key values on heavy duty market
• Heavy trucks account for around 11% of global oil consumption. (source OECD)
• 1990-2006 : +27% on GHG emissions from road transportation
but +77% from MD and HD truck sector. (source DoT 2010)
Context
www.exoes.com
• Fuel costs account for >30% of freight operator’s costs!
• Strong regulations are coming (EPA)
• Global commercial vehicles sales
forecast :
24-Mar-14 5
Context
Medium and heavy-duty
commercial vehicle CO2
emission forecasts
900
650
540
-25 to
-30%
-35 to
-40%
950
800
620
Average CO2 emissions for new vehicle fleet
Average CO emissions for vehicle stock
www.exoes.com
Average CO2 emissions for vehicle stock
0%
5%
10%
15%
20%
25%
30%
35%
1980 1990 2000 2010 2020 2030
Engine and vehicle improvements Aerodynamic
Telematics Waste heat recovery
Impact of HCVs(1) fuel consumption reduction
levers in the past 30 years
HCV manufacturers will
have to adopt new emission
saving technologies to meet
these targets ICE
aero
telematics
whr
24-Mar-14 6
�SCR, EGR, DPF, Heat management
�Tough reduction in emission limits
�New cycles with cold start
�Extensive OBD requirements
�Durability: 700,000km or 7 years
Synergies with existing solutions for HCV
Pollutant
regulation
Euro 6 in
June 2013
�Generalized EGR (high T source for
recovery)
�EGR and exhaust can be used as combined
hot sources
�Faster warm up of the ICE with a Rankine
system
Constraints
Technical solutions
Opportunity for exhaust heat recovery
Context
www.exoes.com
EPA
program to
reduce
greenhouse
gas
emissions
�42% is the best efficiency
of a modern Diesel engine
�EHR is identified as a
compulsory technology to
meet up with regulations
�Hybrid drivetrain will
appear for the inter urban
fleets, offering a new
opportunity market for EHR Source: Renault Trucks
Opportunity for EHR
7724-Mar-14
Table of contents
• Context
• WHR state of the art• Reminders
• RC design: key choices
www.exoes.com
• RC design: key choices
• RC state of the art
• Modeling
• Exoès technology, tests and results
• Conclusion
24-Mar-14 9
WHR technology
• What power flows exist in an ICE’s exhaust
– Kinetic power flow
– Thermal power flow
– Chemical power flow
WHR state of the art
BIG
BIG
SMALL
www.exoes.com
– Chemical power flow
– Latent heat power flow
24-Mar-14 10
SMALL
SMALL
Kinetic power flow
• The turbine, regenerating kinetic but also thermal energy, is
the basic element that serves in a variety of applications:
– Turbocharger (widely used)
– Mechanical turbocompound (Cummins-Scania, Volvo)
WHR state of the art
www.exoes.com
– Electrical turbocompound (John Deere, Caterpillar)
– Exhaust turbine generator (Visteon TIGERS)
24-Mar-14 11
WHR state of the art
Turbocharger Mech. turbocompound
www.exoes.com 24-Mar-14 12
Fuel economy
by downsizing
– Power density
– Good fuel economy
in loaded application.
– Very good drivebility
– High EGRflow
achievable
– Complexity, cost, weight
– Negative η @ low load
(back-pressure)
– Packaging of EGR and TC
– Reduced efficiency of ATS
3-5% total efficiency
WHR state of the art
Powt-Powc =
PowelG+L innotec GmbH & AVL
Electrical turbocompound TIGERS
www.exoes.com 24-Mar-14 13
Garrett TC with electrical
assistance
G+L innotec GmbH & AVL
List GmbH
+ : Less space, easier mounting
+ : Can speed up turbo
(No jet lag and better emissions
control)
+ : Power fed into veh. electrical
demand or stored into batteries
- : Gain clearly visible @ rpm
close to the max torque (max gas
p)3-5% on cycle, up to 10% peak fuel cut
• 800°C, 0.05kg/s, 80.000RPM
6kWe from 41kWth (enough for
the car electric system)
• Fuel consumption reduced from 5
to 10%
• Small and low cost for interesting
benefits
Thermal power flow
• Heat to heat converters
• Thermo electric (→electrical power)
• Thermo-dynamics (→mechanical power)
– Rankine cycle (steam or organic)
WHR state of the art
www.exoes.com
– Rankine cycle (steam or organic)
– Stirling engine
– Ericsson cycle
• Thermo-chemical (→chemical power)
• Thermo-acousOcs (→mechanical power)
24-Mar-14 14
Heat to heat converters
• Faster engine coolant and cabine heating leads to lower
emissions and fuel consumption
WHR state of the art
www.exoes.com 24-Mar-14 15
Faurecia RTE system on C4
Picasso (gen 1)
EHR system on Toyota Prius
3rd gen.
Faurecia EHRM system on
Ford Cmax hyb.(gen 2)
• Comfort system
•Faster heating of the cabine in cold countries
• Replace a 1000W electric radiator (2000W for
the ICE = 1l/100km)
•Dedicated loop with electric pump
• Depollution system through faster
warming up of the engine coolant
•Dedicated loop with electric pump
•Faster ICE cut off thus better fuel
cut (+30%)
Thermo electric generators
• Based on Seebeck effect : ∆T → proporOonal voltage
• Reversibility possible (Pelletier effect).
• Many projects targetting 3 to 5% fuel reduction with TEG from 300 to 1200W.
• Low maturity for the market. Works on the performance/cost ratio are in progress
on:
– Materials (expensive Bi2Te3 → Mg2Si , Mn2Si , nanomaterials, etc.)
WHR state of the art
www.exoes.com
– Materials (expensive Bi2Te3 → Mg2Si , Mn2Si , nanomaterials, etc.)
– Better heat repartition with low back pressure
24-Mar-14 16
TEG on BMW X6 prototype
Table of contents
• Context
• WHR state of the art
• Reminders• RC design: key choices
www.exoes.com
• RC design: key choices
• RC state of the art
• Modeling
• Exoès technology, tests and results
• Conclusion
24-Mar-14 17
• A Rankine cycle is a closed loop in which a working fluid (WF)
is evaporated and condensed to produce power during the
vapor expansion: basically, it is a « steam cycle ».
• A Rankine cycle needs a hot source and a cold sink.
Reminders
By-pass LP steam 4
Rankine cycle
www.exoes.com
G
Eva
po
rato
r Co
nd
en
ser
Feed
pump
Expander
By-pass
Fluid tank
HP liquid
HP steam
LP steam
LP liquid
LP: low pressure
HP: high pressure
12
3
Exh
au
st,
EG
R,
etc
.
1824-Mar-14
0
50
100
150
200
250
300
-1,00 0,00 1,00 2,00 3,00
Temperature [°C]
Entropy [kJ/kg/K]
Temperature-entropy diagram
Parameters:
• Working fluid parameters:
– Working fluid: ethanol
– High pressure: 30 BarA
– Over-heat: 30°C
– Sub-cooling : 10°C
Reminders
Rankine cycle : example
www.exoes.com
Entropy [kJ/kg/K]
Saturation curve Working fluid Cycle
0
1
10
100
-500 0 500 1000 1500
Pressure [barA]
Enthalpy [kJ/kg]
Pressure-enthalpy diagram
– Sub-cooling : 10°C
• Condenser parameters:
– Indirect cooling HT
– Cooling fluid temperature:
90°C
• Hot source parameters:
– ESC point: B75
191924-Mar-14
• Pinch phenomenon:
– Energy balances are not sufficient
– The evaporation plateau impedes a complete energy recovery
– It exists a minimal gap (=pinch) where heat fluxes are critically low
• An evaporator design with small pinches would lead to extra sized evaporators.
Exhaust evaporator area on ESC B100
Reminders
Evaporator thermodynamics: pinch
www.exoes.com
0
100
200
300
400
0 50 100 150
Tem
pe
ratu
re [°C
]
Exchanged power [kW]
Working fluidExhaust gases
PINCH POINT
PREHEAT
EVAPORATION
OVERHEAT
Exhaust evaporator area on ESC B100
0
20
40
60
80
100
120
140
0
5
10
15
20
25
30
0 20 40 60
Po
we
r [k
W]
Are
a [
m²]
Pinch [°C]
Area [ m² ]
Power [ kW]
2024-Mar-14
• There are huge variations in the heat transfer coefficients while evaporating:
10
100
1000
10000
100000
200
300
400
500
600
700
He
at
tra
nsf
ert
co
eff
ice
int
[W/m
²/k
]
Tem
pé
ratu
re °
C
Working fluid temperature [°C]
Gases temperature [°C]
Wall Temperature [°C]
WF heat transfert coefficient
Reminders
Evaporator thermodynamics: heat transfer
www.exoes.com
• Exhaust gases have the lowest heat transfer coefficients: this will directly size the
exchange area.
• The highest evaporator wall temperatures will be in the superheating region (when in
counterflow)
� It impacts the evaporator design when trying to avoid the fluid and lubricant
breakdown
1
10
-
100
200
0% 50% 100% He
at
tra
nsf
ert
co
eff
ice
int
[W/m
²/k
]
Tem
pé
ratu
re
Exchanged power [%]
WF heat transfert coefficient
[W/m²/K]Gases heat transfert coefficient
[W/m²/K]
2124-Mar-14
• A = nlo + 0.25(nhi - nlo)
B = nlo + 0.50(nhi - nlo)
C = nlo + 0.75(nhi - nlo)
• nhi: highest engine speed where
the power equals 70% of the
Reminders
ESC cycle for HCV
www.exoes.com
hi
the power equals 70% of the
maximum net power.
• nlo: lowest engine speed where
the power equals 50% of the
maximum net power.
2224-Mar-14
Table of contents
• Context
• WHR state of the art
• Reminders
• RC design: key choices
www.exoes.com
• RC design: key choices• RC state of the art
• Modeling
• Exoès technology, tests and results
• Conclusion
24-Mar-14 23
What are the key choices when desinging a RC?
• Hot source
• Cold sink
• Working fluid
• Expander and transmission
RC design: key choices
www.exoes.com
• Expander and transmission
24-Mar-14 24
Hot source
• Exhaust waste heat as favorite heat source (high T)
– Exhaust: evaporator after the ATS (no emissions penalty)
– EGR:
• Adopted by a majority of truck makers to face EURO6
RC design: key choices
www.exoes.com
• Adopted by a majority of truck makers to face EURO6
• EGR must already be cooled down
• A combination of EGR and exhaust evaporators will boost the
fuel economy but increase weight, integration issues and
control complexity
24-Mar-14 25
Hot source: examples
RC design: key choices
Main radiator
ICE ATSCondenser & subcooler
EGR Boiler
Exhaust
counter
flow
www.exoes.com 24-Mar-14 26
Expander
PumpTank
EGR Boiler
Hot source: examples
RC design: key choices
Exhaust
counter
flow
EGR
co flow
www.exoes.com 24-Mar-14 27
→16 arrangement possibiliOes when considering coflow or counter flow!
Exhaust
+ EGR in
parallel
EGR +
exhaust
in series
Exhaust counter flow EGR coflow
RC design: key choices
Hot source: pinch
0
100
200
300
400
500
600
0 200 400 600 800 1000 1200
Tem
pera
ture
[°C]
Working fluid
EGR gases
0
100
200
300
400
500
600
0 200 400 600 800 1000 1200
Tem
pera
ture
[°C
]
Enthalpy [kJk /g]
Working fluid
Exhaust gases
www.exoes.com
EGR coflow + Exhaust counter flow in parallel
0
100
200
300
400
500
600
0 200 400 600 800 1000 1200
Tem
pera
ture
[°C
]
Enthalpy [kJ/kg]
Working fluidExhaust gasesEGR gases
EGR coflow + Exhaust counter flow in series
0
100
200
300
400
500
600
0 200 400 600 800 1000 1200
Tem
pera
ture
[°C
]
Enthalpy [kJ/kg]
Working fluidEGR gasesExhaust gases
Enthalpy [kJ/kg]Enthalpy [kJk /g]
2824-Mar-14
• Example for ethanol, ESC point B75
First criteria: EGR gas T ≈ 100°C to fulfill with depollution and performance targets
→ only 6 configuraOons remaining on 16 possibiliOes.
Second criteria: Max Twall to prevent from breaking down WF and lubricant
Third criteria: Trade-off cost / packaging / performance
RC design: key choices
Which evaporator configuration choice?
www.exoes.com
0
20
40
60
80
100
120
140
160
Exhaust & EGR
parallel
EGR & Exhaust
series
Exhaust co flow
& EGR parallel
EGR & Exhaust
co-flow series
Exhaust only EGR only
[%]
Recovered power / Gases power [%] Exchange Area / max exchange Area [%]
Exhaust recovered power / Gases power [%] Twall/ max Twall [%]
29
123
24-Mar-14
RC design: key choices
Which configuration choice?
• EGR counter flow & Exhaust co-flow in series configuration is the simplest way to design quickly an evaporator but also the least efficient in this final group of solutions.
1
www.exoes.com
• & are more efficient than the previous configuration but need a special flow arrangement on the exhaust and/or the EGR evaporator to limit the wall temperature.
30
2 3
24-Mar-14
Cold sink
• The majority of the tailpipe exhaust heat may be rejected under hood!
• Trade-off to be found between weight, packaging, fan on time and aero complexities.
– Aerodynamic drag = 19% of truck losses
RC design: key choices
www.exoes.com
– Aerodynamic drag = 19% of truck losses
– Extra-weight = fuel penalty
• The cold sink can be:
– the existing LT (for the CAC) cooling loop,
– the existing HT (for the ICE) cooling loop,
– a dedicated very LT cooling loop with an additional front radiator.
• Direct link with working fluid choice
24-Mar-14 31
Cold sink
Dedicate
d cooling
(direct)
Existing
cooling
RC design: key choices
Condenser& subcooler
Condenser & subcooler
www.exoes.com 24-Mar-14 32
Mix :
additional
subcooler
Subcooler
Condenser
Working fluid: which one?
• Selection example (source IVECO)
RC design: key choices
www.exoes.com 24-Mar-14 33
RC design: key choices
• No fluid fulfilling all the requirements
• Focus on 3 fluids: ethanol, R245fa and
water
• Mass flow:
Working fluid
www.exoes.com
• Mass flow:
• Area : amount of energy that can be
transferred to 1kg fluid
• If small, high mass flow for a given
amount of energy
• QR245fa > Qeth > Qwater [L/h]
• Same for the pipes and pumps
3424-Mar-14
• The impact of the cooling temperature is huge.
• To have the lowest cooling temperature a direct cooling with an additional
front radiator is the best solution.
• Using the existing loops implies to accept their temperatures.
• Hereafter are plotted some results extracted from an Exoès paper, on a serial
assembly of the evaporators (EGR first):
RC design: key choices
Cold sink and working fluid interaction
www.exoes.com
assembly of the evaporators (EGR first):
Cooling temp.: 80°C Cooling temp.: 100°C
35
2,2
3,74,1
Fuel cuts [%]
3,4
4,74,1
Fuel cuts [%]
R245fa Ethanol Water (1 bar)
24-Mar-14
Impulse turbine Manufacturers: Barber Nichols (US), Bosch (DE)
+ : compact, efficient, oil-free
- : erosion with droplets, costly, high speed
Piston expander Manufacturers: Amovis & Voith (DE), Exoès (FR)
+ : robustness, cost, low rotary speed
- : Poor compactness, lubrication issues
RC design: key choices
Expander and transmission
• No consensus on expander
www.exoes.com
- : Poor compactness, lubrication issues
Screw expander Manufacturers: Eaton [US]
+ : compact, robustness
- : cost, efficiency
Scroll expander Manufacturer: Sanden [JP]
+ : robustness, low cost, low rotary speed
- : poor compactness, lubricated, efficiency
Transmission:
• Mechanical transmission (Classic HCV, fixed speed ratio).
• Electrical production for hybrid trucks.
3624-Mar-14
Table of contents
• Context
• WHR state of the art
• Reminders
• RC design: key choices
www.exoes.com
• RC design: key choices
• RC state of the art• Modeling
• Exoès technology, tests and results
• Conclusion
24-Mar-14 37
• AVL claims more than 1,000h of running of a RC. They seems the most advanced
company on this topic and they work already with several OEMs.
• Layout suggested by AVL:
– parallel evaporators
– indirect cooling on existing HT loop plus an additional MT loop.
RC state of the art
Example 1: AVL
www.exoes.com 3824-Mar-14
• Cummins has benefited from the
DOE Supertruck program to develop
a complete on-board Rankine cycle.
• Layout suggested by Cummins:
– Parallel evaporators but
common superheater (from
MODINE)
RC state of the art
Example 2: Cummins
www.exoes.com
MODINE)
– Recuperator
– Direct cooling with additional
cooling loop only
– R245fa with a turbine
3924-Mar-14
Table of contents
• Context
• WHR state of the art
• Reminders
• RC design: key choices
www.exoes.com
• RC design: key choices
• RC state of the art
• Modeling• Exoès technology, tests and results
• Conclusion
24-Mar-14 41
4 to1: Intake
1 to 2: Expansion
2 to 3: Exhaust
3 to 4: Compression
OD expander model
• Simple and robust inlet and exhaust
system
• “Symmetrical” valve timing at TDC and
BDC
Modeling
Pressure
Pin
24
1
www.exoes.com
BDC
• Expander characterized by its swept
volume and expansion ratio:
24-Mar-14 42
0 VTDC VIVO = VIVC VEVC =VEVO VBDC
Volume
Pex 3
EVO EVCE C
IVC IVO
V VR R
V V= = =
EVO : exhaust valve opening
IVC : inlet valve closing
TDC
BDC
IVO IVC
EVOEVC
INTAKE
EXHAUST
Modeling strategy
• 0D model set by geometric data and corrected by coefficients calculated from both test bench measurements and more complex 1D models.
– the isentropic efficiency:
Modeling
wfisentropicwf
xpandermechis Flowh
Pow
.,
e,
∆=η
Flow
www.exoes.com
– the filling factor:
• Several phenomena will change these indicators:
– the internal leaks
– the friction losses
– the pressure drops
– the heat exchanges
24-Mar-14 43
Modeled
Neglected
theorywf
realwf
Flow
Flow
,
,=φ
Data and indicatorsPts E.U.
normTice
[Nm]Nice
[rpm]Occurrence
[%]
9: B25 700 1200 20
3: B50 1200 1200 30
4: B75 1500 1200 40
8: B100 2250 1200 10
Modeling
Data (confidential):
Indicators:
www.exoes.com 24-Mar-14 44
2
,
1v / 2
,
1
.
.
i i i
j j j
wf wf evap
iap waste
hf hf evap
j
m hR
m h
=
=
∆=
∆
∑
∑
&
&
.exp/ICE
,
i mecha pp
ICE mecha
W WR
W
η=
−& &
&
Indicators:
wf : working fluid pp : pump hf : hot fluid
• Pure ethanol, 800cc, 3600rpm (drive ratio 3), Pexhaust 1bar
• EGR only
Results
PointsPwf
[Bar]Wi,exp[kW]
mwf[kg/h]
Rvap/waste[%]
Rexp/ICE[%]
B25 28,4 2,8 63,3 40,4 2,8
B50 31,1 4,7 99,5 37,7 2,8
Modeling
www.exoes.com
• Simplicity:
• No air infiltration
• No additional cooling load
B50 31,1 4,7 99,5 37,7 2,8
B75 32,7 5,8 120,3 39 2,7
B100 35,8 8,0 163,4 39,2 2,5
Rexp/ICE average = 2,7%
24-Mar-14 45
• Pure ethanol, 800cc, 3600rpm (drive ratio 3), Pexhaust 1bar
• EGR and exhaust in parallel
Results
PointsPwf
[Bar]Wi,exp[kW]
mwf[kg/h]
Rvap/waste[%]
Rexp/ICE[%]
B25 32,9 6,0 123,8 79,4 6,0
B50 41,4 12,1 243,3 92,9 7,1
Modeling
www.exoes.com
• Better solution regarding pure efficiency without any other
considerations
B50 41,4 12,1 243,3 92,9 7,1
B75 44,2 14,2 283,8 92,6 6,7
B100 49,7 18,4 367,7 88,8 5,7
Rexp/ICE average = 6,6%
24-Mar-14 46
• Pure ethanol, 800cc, 3600rpm (drive ratio 3), Pexhaust 1bar
• EGR and exhaust in series (counter flow)
Results
PointsPwf
[Bar]Wi,exp[kW]
mwf[kg/h]
Rvap/waste[%]
Rexp/ICE[%]
B25 23,8 4,6 104,1 66,1 4,5
B50 28,2 8,4 182,9 69,2 4,9
B75 29,9 9,8 213,0 68,8 4,6
Modeling
www.exoes.com
• Best performance/cost trade-off
• Smaller exhaust evaporator → lower back-pressure and easier integration
• Less heat to dissipate under hood
• Easier control of the system (no 3 ways valve)
B75 29,9 9,8 213,0 68,8 4,6
B100 33,3 12,8 275,3 66,0 4,0
Rexp/ICE average = 4,6%
24-Mar-14 47
Cost analysis
• Hypothesis:
– 150,000km/an
– 33L/100km
– 1.1€/L
– 50,000units/y after 4y
Modeling
Maximum speed
EVE for HCV expander datasheet
7,500 RPM
www.exoes.com
– 50,000units/y after 4y
24-Mar-14 48
Maximum speed
Isentropic eff.
Expander length
Expander diam.
Expander weight
Architecture
Peak shaft power
7,500 RPM
350mm
~15kg
12kW
60%
6 pistons,
SP, optional
generator
200mm
Price of the system for the end customer
€3,500
Annual fuel savings€2,700 / 2,500 l
ROILess than 1.5 year
Fuel consumption reduction
5%
Net margin of fleet owners
Multiplied by 2 to 3
Table of contents
• Context
• WHR state of the art
• Reminders
• RC design: key choices
www.exoes.com
• RC design: key choices
• RC state of the art
• Modeling
• Exoès technology, tests and results• Conclusion
24-Mar-14 49
Exoes technology
Data Value / Description
Engine architecture Swashplate – 5 cylinders
Capacity 183cm3
Speed range 1000 – 6000rpm
Expansion ratio Adjustable from 5 to 9
Weight 18kg
Size L270mmxD160mm
Working fluid Water or Ethanol
Maximal inlet pressure 45 bar
www.exoes.com 24-Mar-14 50
Maximal inlet pressure 45 bar
Maximal exhaust pressure 2.5 bar
Maximal inlet temperature 300°C
Minimal oil circulating rate 0% - it can run oil-free
Peak shaft power 4kW
Performance test with water• Effective isentropic efficiency:
• 40- 45% @:
• Inlet pressure: 30-32bar
• Outlet pressure: 1bar
PinTin
PexTex
MwfSubcooler
HP pump
Feed pump
Torque
Heat
HeatHeat
Exp
).( ,isexinwf
mechis hhM
W
−=
&
&
η
Exoes technology
www.exoes.com 24-Mar-14 51
• Outlet pressure: 1bar
• Inlet temperature: 290-300degC
• RPM: 2,000-3,500rpm
• Losses repartition:
• Internal leakage (inlet, rings)
• Friction
• Low expansion ratio
• Target for future developments: 65%
Water tank
CondenserHeatHeat
0,5
0,6
0,7
0,8
Isen
trop
ic e
ffici
ency
[-]Isentropic efficiency
as a function of the piston annular radial clearanc eand the expander expansion ratio
δ= 0.00000 mm
δ= 0.01000 mm
Exoes technology
Last test result early 2014
Performance enhancement timing
Intern leaks 0
Intern leaks +
www.exoes.com
0
0,1
0,2
0,3
0,4
2,5 5 7,5 10 12,5 15
Isen
trop
ic e
ffici
ency
[
Expansion Ratio [-]
δ= 0.01500 mm
δ= 0.02000 mm
Tests with ethanol are in progress, better results expected
Assumptions:
Water, 30bar, 330°C
No friction losses
3500RPM
To be tested mid 2014
To be tested end 2014
52
Intern leaks ++
Intern leaks +++
24-Mar-14
• Expander lubrication concept:
• Lubrication in the crankcase only
• Piston rings moves oil-free
• Endurance test bench:
• Test of the piston rings in an oil-free single cylinder
• Rotates at 1200rpm to reach an average linear speed of 3.1 m/s
Exoes technology
www.exoes.com 24-Mar-14 53
• Rotates at 1200rpm to reach an average linear speed of 3.1 m/s
• Pure water steam is sent at 6 bars, 180 degC
Wear rate
[mm3/N.m]
10E-910E-810E-710E-610E-5
Lubricated Oil-free
Achieved in 2013 Target 2015
1,E-08
1,E-07
0 5 000 10 000
We
ar
rate
[mm
3/N
.m]
Sliding distance [km]
Exoes technology
www.exoes.com 24-Mar-14 54
Lubricated
systems
Oil-free
systemsPrototype lifetime:
•
where:
Tw: Worn thickness
Kv: Wear rate =5x10^-8 mm3/N.m
PSaverage=2.3 Mpa.m/s
� To reach the car market lifetime of
15,000h, our goal is to decrease the wear
rate by a factor of 5 which will result in a
worn thickness of 1.2mm
PSaveKv
TwLifetime
.=
Table of contents
• Context
• WHR state of the art
• Reminders
• RC design: key choices
www.exoes.com
• RC design: key choices
• RC state of the art
• Modeling
• Exoès technology, tests and results
• Conclusion
24-Mar-14 55
Exhaust heat recovery on HCVs
• Incentive regulatory context : WHR mandatory on the
medium term
• Still no consensus on expander type and working fluid
• Exoès:
– Calibrated tools for expander design
Conclusion
www.exoes.com
– Calibrated tools for expander design
– Compact expander prototype manufactured
– Possibility of oil-free running demonstrated
– Efficiency improvement by reducing the internal leakage
– 5% fuel economy leading to an ROI of 1.5 year
24-Mar-14 56
www.exoes.com
Thank you for your attention !
Follow us at SAE congress (April 2014)
57
24-Mar-14