LAPSE:2023.3864
Published Article
LAPSE:2023.3864
Preliminary Development of a Free Piston Expander⁻Linear Generator for Small-Scale Organic Rankine Cycle (ORC) Waste Heat Recovery System
February 22, 2023
Abstract
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.
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.
Record ID
Keywords
3D numerical simulation, cam plate, conceptual design, dynamic characteristics, free piston expander (FPE)
Subject
Suggested Citation
Li G, Zhang H, Yang F, Song S, Chang Y, Yu F, Wang J, Yao B. Preliminary Development of a Free Piston Expander⁻Linear Generator for Small-Scale Organic Rankine Cycle (ORC) Waste Heat Recovery System. (2023). LAPSE:2023.3864
Author Affiliations
Li G: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Zhang H: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Yang F: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Song S: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Chang Y: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Yu F: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Wang J: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Yao B: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
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Zhang H: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Yang F: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Song S: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Chang Y: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Yu F: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Wang J: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
Yao B: College of Environmental and Energy Engineering, Beijing University of Technology, Pingleyuan No. 100, Beijing 100124, China; Collaborative Innovation Center of Electric Vehicles in Beijing, Pingleyuan No. 100, Beijing 100124, China
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Journal Name
Energies
Volume
9
Issue
4
Article Number
E300
Year
2016
Publication Date
2016-04-20
ISSN
1996-1073
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PII: en9040300, Publication Type: Journal Article
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LAPSE:2023.3864
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https://doi.org/10.3390/en9040300
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