Browse Topic: Waste heat recovery

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Potential of ORC-Based Waste Heat Recovery in Conventional and Hybrid Heavy-Duty Powertrains2026-37-0018To be published on 06/09/2026
Heavy-duty vehicles are major contributors to greenhouse gas emissions and urban air pollution, particularly under cold-start and transient operating conditions where engine efficiency and exhaust aftertreatment effectiveness are reduced. In this context, waste heat recovery (WHR) technologies represent a practical pathway for improving fuel efficiency and reducing CO₂ emissions in real-world heavy-duty applications. This study investigates the integration of an Organic Rankine Cycle (ORC)–based WHR system within conventional and hybrid electric powertrain architectures applied to a reference heavy-duty truck (ISUZU FTR850). A sensitivity analysis is performed on four WHR configurations, combining shell-and-tube and plate heat exchangers with simple and regenerative ORC layouts. For the parallel hybrid configuration, two engine sizes and two energy management strategies are compared: a fuel-minimizing fuzzy logic rule-based strategy and a constant-power strategy aimed at stabilizing
Donateo, Teresa, Morrone, Pietropaolo
Novel Air System for 300 kW Heavy Duty Fuel Cell2026-01-04344/7/2026
Hydrogen fuel cell powered vehicles for heavy duty trucking are a promising path for reducing future vehicle emissions due to their reduced mass for storage and faster refueling compared to battery electric trucks. These benefits come at the cost of increased system complexity stemming from the fact that fuel cells generate electricity through a chemical reaction which must be tightly controlled. The air handling system delivers the proper amount of air (oxygen) to react with fuel (hydrogen) in the fuel cell to produce power. Air delivery requires significant power and is the largest parasitic loss for a 300 kW fuel cell. Today’s systems use an electric motor driving an air compressor to supply pressurized air to the fuel cell stack. By operating at elevated pressure levels, fuel cells can achieve higher power density, which is important for vehicle powertrains. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air
Reich, Evan, Swartzlander, Matthew, Wine, Jonathan, McCarthy, Jr., James, Miller, Eric, Akhtar, Saad, Reddy, Sharan, Lawy, TJ
Standardization of On-Vehicle Measurement of BEV Thermal System Energy Consumption and Range Impacts2026-01-01324/7/2026
This paper presents research and digital twin modeling results to support work on a methodology to properly account for the energy consumed by the thermal system of a BEV, for use within both existing Petroleum-Equivalent Fuel Economy (PEFE) calculations, and the proposed addition of hot and cold weather range values to the consumer-facing Monroney label [1]. Properly accounting for thermal system impacts would incentivize minimizing energy consumption of these systems, since 1) BEV PEFE is a direct input to an OEMs overall CAFE performance, and 2) the values on the Monroney label has some impact on consumer vehicle choice. The impetus for this work was Final Rules issued by the EPA and NHTSA in early 2024 eliminating A/C Efficiency Credits for BEVs from the 2027 MY, thus eliminating regulatory incentives to minimize energy consumption of these systems. Higher energy consumption will produce a number of negative secondary effects, including higher real-world greenhouse gas emissions
Taylor, Dwayne
Modular Smart Corner Systems for Next-Generation Electric Vehicle Architecture2026-01-06394/7/2026
The transition to software-defined vehicles (SDVs) necessitates a paradigm shift in both control strategies and vehicle architecture. The EU-funded R&D project SmartCorners addresses this challenge by developing integrated, modular, and scalable smart corner systems (SCS) that combine in-wheel motor (IWM)-based propulsion, brake blending, active suspension system, and steer-by-wire functionality in one module. These SCS can be retrofit or smoothly integrated into the highly adaptable skateboard chassis architecture of modern electric vehicles (EVs), enabling scalable deployment across diverse vehicle types. The central approach of this paper is the utilization of artificial intelligence (AI) and machine learning (ML) to implement multi-layer, data-driven control strategies, facilitating real-time actuation, fault mitigation, and user-centric EV architecture. The SmartCorners project strives to demonstrate significant enhancements, including improved real-world driving range due to
Ratz, Florian, Armengaud, Eric, Formento, Cecilia, Moscone, Giulia, Sorrentino, Gennaro, Bisciaio, Giorgio, Sorniotti, Aldo, Amati, Nicola, Braun, Daniel, Deibler, Bernd, Boxberger, Valerius, Sottile, Salvatore, Ivanov, Valentin, Fuse, Hiroyuki, Kompara, Tomaž
The Membrane Engine: Concept, Model, and First Results03-19-01-00032/12/2026
This study investigates the feasibility of a novel internal combustion engine (ICE) architecture, termed the membrane engine, in which the conventional piston is replaced by a flexible elastic membrane. Although the concept appears in several patent documents proposing reduced friction, improved sealing, and lower heat losses, no empirical data has been published to support these claims. To the authors’ knowledge, this work presents the first membrane engine built and experimentally tested. The primary aim is to verify whether such an engine can operate as a functional ICE, regardless of its current efficiency or performance level. To support concept validation, a simplified mathematical model was developed to describe the membrane’s deformation and its effect on combustion chamber volume. Unlike conventional piston engines, the membrane introduces a pressure-dependent geometry, enabling a variable compression ratio. The model is not intended to predict performance but to assist in
Allmägi, Roland, Ilves, Risto
TwinAV: Valve Timing Strategy for Divided Exhaust Periods in Turbocharged Spark-Ignition Engines: A Simulation-Based Evaluation03-19-01-00022/6/2026
Turbocharging is a common and simple method to utilize the exhaust heat of an internal combustion engine. However, conventional turbocharging exhibits the drawback of exhaust gas backpressure and thus increased residual gas mass in the cylinder. A promising concept to increase optimum efficiency is found in the TwinAV concept, which assigns divided exhaust valve cam timing and exhaust manifold configuration. This concept is hypothesized to reduce the static backpressure in the gas exchange loop and the residual exhaust gas amount in the gas exchange phase. In this article, a 1D simulation model was adapted to an existing 4-cylinder gasoline TC engine. Subsequently, the engine concept was applied to this engine model, whereas the focus was to achieve an engine layout for the entire engine speed range applicable for use in passenger vehicles. The results were compared at the full RPM range. Also, a load variation was conducted and benchmarked. The found results show an additional
Gotter, Andreas, Gotter, Alexander
Thermal Management Control Strategy for Primary & Secondary Drive Cooling Hybrid Electric Tractor2026-26-00691/16/2026
Global emission norms are getting very strict due to combat the harmful pollutants from internal combustion engine. Hence internal combustion engine (ICE)-based agricultural tractors need to introduce complex after-treatment systems and fuel optimization to provide same or higher value to farmers as cost of these systems drive the overall cost of the product. Engineers around the world are building Electric vehicles to combat the problem and has range issues due to design constraints & Hybrid tractors have emerged as a promising intermittent solution. It helps in combining the advantages of respective ICE and electrification solutions while reducing overall vehicle emissions and enhances operational flexibility. This paper presents a modular thermal modes system developed for a hybrid electric tractor platform where a downsized diesel engine operates at optimal efficiency DC generator used to charge the battery & DC converter is used to charge the auxiliary battery. Battery which is
K, Sunil, D, Mari, Natarajan, Saravanan, Kumawat, Deepak, rojamanikandan, Arumugham, K, Mala, V, Sridharan, Muniappan, Balakrishnan, Makana, Mohan
Waste Heat Recovery Evaluation in FCEV Truck on Different Drive-Cycles2026-26-02591/16/2026
Growing global warming and the associated climate change have expedited the need for adoption of carbon-neutral technologies. The transportation sector accounts for ~ 25 % of total carbon emissions. Hydrogen (H2) is widely explored as an alternative for decarbonizing the transport sector. The application of H2 through PEM Fuel Cells is one of the available technologies for the trucking industry, due to their relatively higher efficiency (~50%) and power density. However, at present the cost of an FCEV truck is considerably higher than its diesel equivalent. Hence, new technologies either enabling cost reduction or efficiency improvement for FCEVs are imperative for their widespread adoption. FCEVs have a system efficiency around 40-60% implying that around half of the input energy is lost to the environment as waste heat. However, recapturing this significant amount of waste heat into useful work is a challenge. This paper discusses the feasibility of waste heat recovery (WHR
P V, Navaneeth
Design and Analysis on Integrated Thermal Management Solution for Electric Vehicles2025-28-041810/30/2025
Thermal Management System (TMS) for Battery Electric Vehicles (BEV) incorporates maintaining optimum temperature for cabin, battery and e-powertrain subsystems under different charging and discharging conditions at various ambient temperatures. Current methods of thermal management are inefficient, complex and lead to wastage of energy and battery capacity loss due to inability of energy transfer between subsystems. In this paper, the energy consumption of an electric vehicle's thermal management system is reduced by a novel approach for integration of various subsystems. Integrated Thermal Management System (ITMS) integrates air conditioning system, battery thermal management and e-powertrain system. Characteristics of existing integration strategies are studied, compared, and classified based on their energy efficiency for different operating conditions. A new integrated system is proposed with a heat pump system for cabin and waste heat recovery from e-powertrain. Various cooling
K, Muthukrishnan, S, Saikrishna, Mahobia, Tanmay, Vijayaraj, Jayanth Murali
A Critical Assessment of Alternative Refrigerants and Waste Heat Recovery for Sustainable Thermal Systems2025-28-035610/30/2025
The increasing demand for heating and cooling, coupled with growing environmental concerns, necessitates a paradigm shift towards sustainable thermal management practices. This paper presents a rigorous and scholarly investigation into innovative heating and cooling concepts, with a specific focus on the development and implementation of alternative refrigerants and waste heat recovery systems. The transition away from conventional refrigerants, with their detrimental impact on the environment, is explored through a comprehensive analysis of promising alternatives. Hydrofluoroolefins (HFOs), natural refrigerants (e.g., CO2, hydrocarbons, ammonia), and their blends are critically evaluated, considering their thermodynamic properties, environmental impact (GWP, ODP), safety considerations (flammability, toxicity), and application-specific performance. The paper delves into the intricacies of advanced cooling technologies, including absorption cooling, adsorption cooling, and
K, Neelima, Ch, Kavya, C, Somasundar, B, Harichandana, Satyam, Satyam, P, Geetha
Thermodynamic Exergy Analysis of PEMFC Systems for System Efficiency and Waste Heat Recovery2025-28-035210/30/2025
Proton Exchange Membrane Fuel Cell (PEMFC) vehicles are emerging as a promising green alternative to fossil fuel and battery-operated electric vehicles. Fuel cells convert the chemical energy of fuel to direct current (DC) through electrochemical reactions, rejecting some heat in the process. This study aims to minimize heat generated during these reactions within the fuel cell stack and utilize it to enhance stack efficiency. Through thermodynamic modeling and exergy analysis, the research focuses on reducing waste heat from exothermic reactions in PEMFC stacks. It investigates using low-temperature waste heat for heating hydrogen and inlet air also examining into how stoichiometry and current density influence heat reduction. Analytical studies were carried out using air stoichiometry ranging from 1.5 to 2 and ambient temperatures typical of Bangalore's climate (15°C to 35°C). The results show that increasing the current density from 1 A/cm2 to 1.5 A/cm2 significantly raises the
Sahu, Tomesh Kumar, Bansode, Annasaheb
Thermal Management in Electrified Transportation: A Comparative Study of Different Powertrain Technologies2025-28-041210/30/2025
The transition towards sustainable transportation necessitates the development of advanced thermal management systems (TMS) for electric vehicles (EVs), hybrid electric vehicles (HEVs), hydrogen fuel cell vehicles (FCVs), and hydrogen internal combustion engine vehicles (HICEVs). Effective thermal control is crucial for passenger comfort and the performance, longevity, and safety of critical vehicle components. This paper presents a rigorous and comparative analysis of TMS strategies across these diverse powertrain technologies. It systematically examines the unique thermal challenges associated with each subsystem, including cabin HVAC, battery packs, fuel cell stacks, traction motors, and power electronics. For cabin HVAC, the paper explores methods for minimizing energy consumption while maintaining thermal comfort, considering factors such as ambient temperature, humidity, and occupant load. The critical importance of battery thermal management is emphasized, with a focus on
K, Neelima, K, Anisha, Ch, Kavya, C, Somasundar, Satyam, Satyam, P, Geetha
Zero-Carbon Port Fueling for Heavy Propulsion through a Recuperated Split Cycle Engine2025-24-00449/7/2025
Upcoming global emissions regulations demand innovation in heavy-duty road and marine transport. This research explores emissions-compliant concepts using both experiments and simulations focused on the Recuperated Split Cycle Engine (RSCE), which separates compression and expansion to enable internal heat recovery and quasi-isothermal compression. A single-cylinder research engine representing the expansion cylinder of an RSCE demonstrated direct injection diesel and port injection hydrogen co-firing. A validated Chemkin-Pro Multi-Zone model first reproduced, then extended this work, evaluating partial diesel substitution with hydrogen or ammonia alongside secondary working fluids (SWF’s liquid N₂, H₂O, NH₃). For the extension, two variants of the split cycle architecture were employed; the RSCE in combination with hydrogen fueling for the heavy-duty road sector, and the novel recuperated reformed split cycle engine (R2SCE), a new architectural and simulation contribution enabling on
Wylie, Elisa, Panesar, Angad
Waste Heat Recovery in Hydrogen Fueled Internal Combustion Engines2025-24-01089/7/2025
Waste Heat Recovery is one of the most investigated and promising technologies for energy efficiency in the transportation sector. It consents to maintain the high-level technology of the present propulsion systems, based on Internal Combustion Engines, while increasing the overall engine and vehicle system efficiency. At the same time, the use of alternative fuels, like hydrogen, has the same crucial role to reduce harmful and greenhouse emissions, without overturn the existing mature technology. A hydrogen-fueled Internal Combustion Engine is proposed in this paper, equipped with waste heat recovery consisting in an additional radial turbine downstream the turbocharger of the engine (Turbo-Compound). The aim is to have a reduction of the specific consumption in most of the operating points of the engine, considering the effect of the recovery and the engine equilibrium rearrangement. The use of hydrogen increases recoverable enthalpy at the engine exhaust, which is intended to be
Di Battista, Davide, Cipollone, Roberto, Corti, Enrico, Brancaleoni, Pier Paolo, Di Prospero, Federico, Ravaglioli, Vittorio
Analysis and Simulation of Fuel Consumption and Emissions in a Heavy-Duty Diesel Truck under Real-World Driving Conditions for Hybridization and Waste Heat Recovery2025-24-00969/7/2025
Heavy-duty vehicles contribute significantly to global greenhouse gas emissions and are now facing challenges in meeting emission regulatory standards, particularly cold-start operations. These challenges are particularly significant during transient operations, where fuel efficiency drops and emissions peak due to suboptimal thermal conditions. Advanced powertrains that use hybridization and waste heat recovery with phase-changing materials offer potential pathways to mitigate fuel consumption and emissions under real-world driving conditions. Still, they need to be accurately sized, and the energy flows handled to overcome the disadvantages of increased mass and complexity. This investigation lays the groundwork for the development of advanced power systems by implementing a scalable, map-based model for heavy-duty diesel engines. The model is validated using an open-access dataset related to a heavy-duty vehicle equipped with a 6-cylinder diesel engine, which performed 28 different
Donateo, Teresa, Mujahid, Talha, Morrone, Pietropaolo, Algieri, Angelo
Investigation on Thermal Management of Heavy-Duty Commercial FCEV with Focus on Vehicle System Efficiency2025-01-02657/2/2025
The primary approach to meet the objectives of the EU Heavy Duty CO2 Regulation involves decarbonizing the road transport sector by battery electric vehicles (BEV) or hydrogen-fueled vehicles. Even though the well-to-wheel efficiency of hydrogen-fueled powertrains like fuel cell electric vehicles (FCEV) and H2-internal combustion engines (H2-ICE) is much lower in comparison to BEV, they are better suited for on-road heavy-duty trucks, long haul transport missions and regions with scarce charging infrastructure. Hence, this paper focuses on heavy-duty FCEVs and their overall energetic efficiency enhancement by intelligently managing energy transfer across coolant circuit boundaries through waste heat recovery, while ensuring that all relevant components remain within required temperature boundaries under both cold and hot ambient conditions. Results were obtained using a 1D-model that comprises all thermal fluid circuits (refrigerant, coolant, air) created through GT-Suite software
Uhde, Sophia, Langhorst, Thorsten, Wuest, Marcel, Naber, Dirk
Modeling and Simulation Analysis of an Electric Vehicle in Cold Ambient Conditions: Energy Consumption and Impact of Battery Heating on Driving Range2025-01-81424/1/2025
Thanks to greatly increased energy density of battery, the average driving range of an electric vehicle has been advanced quite a lot. However, drastic reduction of driving range in cold ambient conditions still greatly restricts the wide application of electric vehicles. This paper presents a methodology of establishing multi-discipline coupled full vehicle model in AMESim to investigate the energy consumption of a pure electric vehicle in cold ambient conditions. Different strategies of battery heating through Positive Temperature Coefficient (PTC) part and/or combination of Motor Waste Heat Recovery (MWHR) were also investigated to study whether there is an improvement of driving range. Firstly, basic framework of the full vehicle model established in AMESim was introduced. Next, modeling details of individual sub-systems were illustrated respectively. Then, full vehicle energy consumption test was carried out in -7°C ambient condition to check the simulation accuracy. Finally, a
Zhou, Shuai, Liu, Huaiju, YU, Huili, Yan, Xu, Yan, Junjie
PRODUCT BRIEFS25TOFHP04_114/1/2025
Development of Composite PCM To Enhance Heat Transfer Rate with the Addition of Nanoparticles in Thermal Energy Storage2025-28-00232/7/2025
This paper explores the augmentation of thermal conductivity in paraffin wax through the incorporation of aluminum oxide (Al2O3) and copper oxide (CuO) nanoparticles, leading to the development of composite phase change materials (PCMs). The objective is to enhance heat transfer rates, crucial for various energy storage applications including industrial waste heat recovery and solar thermal energy storage. Differential Scanning Calorimetry (DSC) testing was employed to experimentally investigate the thermal properties of the resulting nanocomposite PCM. The experimental results reveal that the nanocomposite PCM, composed of 96.14% paraffin wax, 2% aluminum oxide, and 1.6% copper oxide, exhibits 1.35 times increase in heat transfer rate compared to conventional paraffin wax. The integration of nanoparticles into the PCM matrix, facilitated by a magnetic stirrer at 50oC for 4 hours, results in uniform distribution and improved grain morphology, as evidenced by SEM images. Moreover, the
Tarigonda, Hariprasad, Kumar, YB Kishore, Kala, Lakshmi K, R L, Krupakaran
Design and Performance Optimization of Automotive Thermoelectric Generator System Integrated with Heat Pipes2025-01-70601/31/2025
In the field of static power generation, thermoelectric technology has become an important solution for utilizing automotive exhaust waste heat. This study presents a new design for a heat exchanger integrated with heat pipes, aimed at augmenting the installation area of thermoelectric modules and improving the hot end temperature by high heat transfer rate. Moreover, the number of heat pipes in each region is optimized to reduce the temperature gradient along the direction of exhaust flow and maximize overall output performance. A comprehensive numerical model of the thermoelectric generator system is developed to conduct the performance prediction and parameter optimization. The results reveal that the integration of heat pipes substantially boosts the performance of the automotive thermoelectric generator system, characterized by enhanced heat transfer, increased power output, and improved conversion efficiency. And the optimization yields an optimal configuration with 5 heat pipes
Zhao, JinFu, Ding, Renkai, Chen, Jie, Wang, Ruochen, Luo, Ding
Efficiency Analysis of Hydrogen Internal Combustion Engine Power Generation System Based on Organic Hydrogen Storage Solution2025-01-71171/31/2025
Organic solution is an ideal hydrogen storage and transport carrier, and the dehydrogenation of solution is an endothermic process. High dehydrogenation heat demand becomes a key factor restricting its application. Hydrogen internal combustion engine (HICE) is an ideal power device under the current background of emphasizing clean and low carbon. In this study, dibenzyltoluene (DBT) was selected as liquid organic hydrogen carrier (LOHC), the residual heat of engine exhaust was used as the heat source of organic solution dehydrogenation, and the residual heat of engine exhaust is used as the heat source of organic solution dehydrogenation, using the combustion of dehydrogenated hydrogen products to supplement the heat absorption of hydrogen released by organic solution. Taking hydrogen internal combustion engine power generation as the application scenario, the power generation system of liquid organic hydrogen storage solution combined with hydrogen internal combustion engine (LOHC
Zhang, Yulong, Luo, Qinghe, Sun, Baigang, Tang, Hongyang
Structure Design and Performance Enhancement of Automobile Thermoelectric Generator System Integrated with a Spoiler2025-01-70661/31/2025
The thermoelectric generator system is regarded as an advanced technology for recovering waste heat from automotive exhaust. To address the issue of uneven temperature distribution within the heat exchanger that limits the output performance of the system, this study designs a novel thermoelectric generation system integrated with turbulence enhancers. This configuration aims to enhance convective heat transfer at the rear end of the heat exchanger and improve overall temperature uniformity. A multiphysics coupled model is established to evaluate the impact of the turbulence enhancers on the system's temperature distribution and electrical output, comparing its performance with that of traditional systems. The findings indicate that the integration of turbulence enhancers significantly increases the heat transfer rate and temperature uniformity at the rear end of the heat exchanger. However, it also leads to an increase in exhaust back pressure, which negatively affects system
Chen, Jie, Ding, Renkai, Wang, Ruochen, Liu, Wei, Luo, Ding
Experimental Study on the Thermoelectric Performance of PCM-TEG System2025-01-70671/31/2025
The integration of phase change materials (PCMs) with thermoelectric generators (TEGs) presents a solution to the challenge of unstable output resulting from fluctuations in the heat source. This study involved the establishment of an experimental test setup for PCM-TEG system to examine the impact of heat source power on the thermoelectric performance of PCM-TEG system. The results suggest that incorporating PCM effectively mitigates output voltage fluctuations, while higher heating power levels correspond to a notable extension in effective operational duration. In situations of low heat source power, incomplete PCM melting may lead to a significant decline in electricity generation during non-heating stages. Notably, the electricity generation during non-heating stages at 90 W heating power surpasses that at 30 W heating power by a factor of 11.78. Furthermore, the electricity generated during non-heating stages contributes to 22.4% of the total electricity generation. These
Tian, Meng, Wu, Fengyu, Zuo, Ao, Xuan, Zhiwei, Zhao, Yulong
Modeling and Simulation Analysis of Thermal Management System for Hydrogen Fuel Cell Vehicle2025-01-70911/31/2025
An effective vehicle integrated thermal management system (ITMS) is critical for the safe and efficient operation of proton exchange membrane fuel cell (PEMFC) vehicles. This paper takes a fuel cell vehicle (FCV) as the research object, comprehensively considers the vehicle layout environment and thermal management requirements, and designs a complete thermal management system for FCV. The key components are selected and designed to match the performance and the control strategy of ITMS of fuel cell vehicle is developed. To do that, the ITMS model is established based on the heating principle and heat transfer theory of each key component. Then, the ITMS under Worldwide Harmonized Light Vehicles Test Cycle (WLTC) operating conditions at different ambient temperatures are simulated and analyzed by selecting indicators such as coolant flow rate and temperature. Under the ambient temperature of 40°C, the temperature of PEMFC is basically stable between 78 °C and 83°C, the coolant outlet
Jiang, Qi, Xiong, Shusheng, Wang, Yupeng, Zhu, Shaopeng, Chen, Huipeng
Research on the Characteristics of an Integrated Thermoelectric Generation, Catalytic Conversion, and Noise Suppression System2025-01-70621/31/2025
In the context of global energy shortages and increasing environmental pollution, improving energy efficiency in automobiles has become a key area of research. Traditional internal combustion engines exhibit low energy conversion efficiency, with a significant portion of fuel energy wasted as exhaust heat. To address this issue, this paper proposes an integrated thermoelectric generation, catalytic conversion, and noise suppression system (ITGCMS) aimed at recovering waste heat from vehicle exhaust, while optimizing emissions and noise reduction through the combination of a catalytic converter and a muffler. A three-dimensional model was established using COMSOL software to thoroughly analyze the system's thermoelectric generation, catalytic conversion, and acoustic performance. The study found that Model B demonstrated the best thermoelectric performance, with an average surface temperature of 300.2°C and a more uniform temperature distribution across the thermoelectric modules
Wu, Ji-Xin, Su, Chu-Qi, Wang, Yi-Ping, Yuan, Xiao-Hong, Liu, Xun
Fusion Control Strategy Based on Rule and Dynamic Objective of Heat Pump Type Thermal Management System for Electric Vehicles2025-01-70231/31/2025
Thermal management system of electric vehicles (EVs) is critical for the vehicle's safety and stability. While maintaining the components within their optimal temperature ranges, it is also essential to reduce the energy consumption of thermal management system. Firstly, a kind of architecture for the integrated thermal management system (ITMS) is proposed, which can operate in multiple modes to meet various demands. Two typical operating modes for vehicle cooling in summer and heating in winter, which utilizes the residual heat from the electric drive system, are respectively introduced. The ITMS based on heat pump enables efficient heat transfer between different components. Subsequently, an ITMS model is developed, including subsystems such as the battery system, powertrain system, heat pump system and cabin system. The description of modeling process for each subsystem is provided in detail. The model is tested under world light vehicle test cycle (WLTC) condition of six different
Zhao, Luhao, Tan, Piqiang, Yang, Xiaomei, Yao, Chaojie, Liu, Xiang
Experimental and 1D Modeling Analysis of Thermoelectric Generation to Improve the Performance of Compressed Natural Gas Heavy-Duty Engines Used in Commercial 22-Ton Trucks13-06-03-00191/27/2025
A significant amount of chemical fuel energy in internal combustion engines is wasted through exhaust heat. Waste heat recovery (WHR) systems can transform the heat into electrical energy using thermoelectric generators (TEG). This work utilizes a 1D CFD model to demonstrate the potential of TEG-WHR in improving the thermal efficiency of mass-production, compressed natural gas (CNG) engines used in commercial 22-ton heavy-duty trucks. First, the TEG with heat exchanger experiments are performed to measure thermal and electrical performance data under different fin pitches and inlet gas conditions (Re number, temperature, gas flow rate). These data are used to develop and validate a TEG model, which considers user-defined functions of heat transfer and flow friction coefficients to reproduce measured thermal/electrical characteristics of the integrated TEG with its heat exchanger. The engine experiments are conducted based on the speed–torque map (51 test conditions) of the JE05 heavy
Sok, Ratnak, Kusaka, Jin
Review on Integrated Thermal Management Systems of Electric Vehicles2024-28-022712/5/2024
Electric Vehicles use Li-ion batteries due to their high energy and power densities. Performance of Li-ion cell is sensitive to temperature. Temperature control of these batteries becomes very important to provide safety and performance under different working conditions. This paper review different integrated thermal management system developed for Electric Vehicles. integrated thermal management content. Battery thermal management, Cabin thermal management and Electric drive thermal management. These systems share some common objectives and common parts. Integration of these systems will help to optimize the number of components in the Electric Vehicles thermal management system. The integrated thermal management system also helps to optimize the weight and use of waste heat to heat the cabin or battery. This will help in optimization of energy consumed by the thermal management system and range improvement. Integrating different systems which content refrigerant and coolant circuit
Mhaske, Pramodkumar Chimaji
Efficiency Improvement in a 48-Volt Mild Hybrid Vehicle Using Rankine Cycle Waste Heat Recovery2024-01-431711/5/2024
The automotive industry faces significant obstacles in its efforts to improve fuel economy and reduce carbon dioxide emissions. Current conventional automotive powertrain systems are approaching their technical limits and will not be able to meet future carbon dioxide emission targets as defined by the tank-to-wheel benchmark test. As automakers transition to low-carbon transportation solutions through electrification, there are significant challenges in managing energy and improving overall vehicle efficiency, particularly in real-world driving scenarios. While electrification offers a promising path to low-carbon transportation, it also presents significant challenges in terms of energy management and vehicle efficiency, particularly in real-world scenarios. Battery electric vehicles have a favorable tank-to-wheel balance but are constrained by limited range due to the low battery energy density inherent in their technology. This limitation has led to the development of hybrid
Kraljevic, Ivica, Spicher, Ulrich
Computational and Experimental Evaluation of Thermoelectric Generator for Waste Heat Recovery in Internal Combustion Engine Applications2024-01-50768/5/2024
Much of the thermal energy derived from combustion of fuel is lost through exhaust gases. By effectively recovering waste heat energy in the form of electricity, it can be used to recharge batteries or power auxiliary systems thus improving both performance and fuel economy. In this work, the use of thermoelectric generators (TEG) for energy recovery were studied using both computational and experimental strategies. The efficiency of TEG (ȠTEG) was analyzed through computational methods by changing temperature gradients, Seebeck coefficient (α), and dimensions of the P- and N-type plates individually. The results of computational analysis showed that in comparison to vertical and planar configuration, mixed-type thermocouple delivered 83.3% and 96% more power, respectively. Raising the α, enhanced the ȠTEG by 57% and lowering α affected the ȠTEG by 9.5% for mixed thermocouples. A marginal development in the ȠTEG was achieved by increasing the length of the P- and N-type semiconductors
Chelladorai, Prabhu, Atekov, Parahat, Balakrishnan, Navaneetha Krishnan, Kashyap, A., Chakravarty, P., Naresh, G.
The Hybrid Concept of Turboshaft Engine Enhanced by Steam Cycle Using Waste Heat Recovery—Combined Analytical and Numerical Calculation of Its Efficiency03-17-06-00456/4/2024
The article presents a hybrid concept of a turboshaft engine that fits into the area of PGE (pressure-gained combustion). It combines the advantages and elements of a piston engine and a turbine engine. The combustion takes place in isochoric chambers. The proposed timing system of the engine efficiently realizes the Humphrey cycle. Additionally, the main gas cycle engine was enhanced by the Clausius–Rankine steam cycle to achieve effective power of engine equal to 1231.3 kW. It was supplied by waste heat recovery from the exhaust gas. The enhancement of the engine by the secondary steam cycle significantly improved engine effective efficiency with a final value reaching 0.446. The effective efficiency and specific fuel consumption of the engine were calculated using merged analytical–numerical CFD (computational fluid dynamics) analysis. The centrifugal compressor, gas turbine, and steam turbine can work on the common shaft whose rotational velocity is 35,000 rpm. Because of
Tarnawski, Piotr, Ostapski, Wiesław
Use of Accurate Simulation Workflows to Optimize Waste Heat Recovery from Thermoacoustic Engines2024-01-25904/9/2024
Thermoacoustic heat engines convert heat into useful energy by generating acoustic waves from a heat source that can then be extracted as useful work. These engines are inexpensive, robust, versatile, and capable of extracting energy from a wide variety of heat sources ranging from waste heat from power plants to exhaust heat of vehicles. In this article, our investigation focuses on using simulation workflows to improve the performance of thermoacoustic engines. We begin with validating the workflows with published data for both traveling wave and standing wave thermoacoustic engines. Following that, we investigate the effect of changing the working fluid and the operating pressure to increase acoustic power. This study uses a coupled PowerFLOW™ and PowerTHERM™ methodology to simulate the buoyancy-driven flows that generate acoustic pressure waves. Good correlations were observed for both traveling and standing wave thermoacoustic engines. For the design iterations, the most improved
Mukutmoni, Devadatta, Powell, Robert, Kandasamy, Satheesh
Investigating Route Gradient and Thermal Demand on Hydrogen Fuel Cell Electric Bus Energy Consumption2024-01-21764/9/2024
In 2022 in the UK, the transport sector was the largest single contributing sector to greenhouse gas emissions, responsible 34% of all territorial carbon dioxide emissions [1]. In the UK there is growing uptake in zero emission powertrain technologies, with the most promising variants based on battery electric or hydrogen fuel cell electric configurations. Given the limited number of fuel cell electric buses currently in operation in Europe, vehicle models and simulations are one of the few methods available to estimate energy consumption and provide the necessary increased confidence in operating range. This paper investigates the impact of route characteristics, thermal demand and coefficient of performance of different heat source configurations on the operational energy consumption of fuel cell electric buses. Using a MATLAB/Simulink model, the total energy demand of a vehicle operating in different route/elevation profiles is considered. The findings from this study show that
O'Boyle, Conor, Blades, Luke Aubrey William, McGrath, Teresa, Early, Juliana, Harris, Andrew
On the Application of Joule-Cycle-Based Waste Heat Recovery to Heavy-Duty Vehicles2024-01-25894/9/2024
Internal combustion engines are becoming ever more efficient as mankind seeks to mitigate the effects of climate change while still maintaining the benefits that a mechanized society has brought to the global economy. As peak values, mass production spark-ignition engines can now achieve approximately 40% brake thermal efficiency and heavy-duty truck compression-ignition engines can approach 50%. While commendable, the unfortunate truth is that the remainder gets emitted as waste heat and is sent to the atmosphere to no useful purpose. Clearly, if one could recover some of this waste heat for beneficial use then this is likely to become important as new means of mitigating fossil CO2 emissions are demanded. A previous study by the authors has identified that the closed Joule cycle (or complications of it beginning to approximate the closed Ericsson cycle) could reasonably be developed to provide a practical means of recovering exhaust heat when applied to a large ship engine. In that
Turner, James, Kenkoh, Kesty Yong, Gubba, Sreenivasa, Vorraro, Giovanni
WITHDRAWAL NOTICE2024-01-2591.014/9/2024
This paper has been withdrawn by the publisher because of non-attendance and not presenting at WCX 2024.
Cost Effective Techniques for SCEV to Improve Performance & Life of Battery and Motor by Using Efficient Thermal Systems2024-26-02751/16/2024
The automotive world is moving towards electric powertrain systems. The electric powertrain systems have emerged as a promising alternative to the conventional powertrain system. The performance of electric vehicle is highly dependent on operating temperature of electric and electronic components of the vehicle. All power electronics and electric components in EV generate heat during operation and it must be removed to prevent overheating of components. Higher temperatures raise safety concerns whereas lower temperatures deteriorate the performance of power electronics & electric components. These power electronics & electrical components perform efficiently and safely if operated within certain temperature range. This paper presents an advanced efficient cost-effective thermal technique for small commercial electric vehicle (SCEV) to improve the performance & life of major electric components. It is observed from literature survey that this is a novel technology for small commercial
Chormule, Suhas Rangrao
Turbo Compounding of a Naturally Aspirated Single Cylinder Diesel Engine – A Simulation and Experimental Study2023-01-184510/24/2023
Almost one-third of the fuel energy is wasted into the atmosphere via exhaust gas from an internal combustion engine. Despite several advancements in waste heat recovery technology, single-cylinder engines in the market that are currently in production remain naturally aspirated without any waste heat recovery techniques. Turbocharging is one of the best waste heat recovery techniques. However, a standard turbocharger cannot be employed in the single-cylinder engine due to technical challenges such as pulsated flow conditions at the exhaust, phase lag in the intake and exhaust valve opening. Of late, the emphasis on reducing exhaust emissions has been a primary focus for any internal combustion engine manufacturer, with the onset of stricter emission norms. Thus, the engine designer must prioritize emission reduction without compromising engine performance. Current work focuses on enhancing the power output of a 0.6-litre, single-cylinder naturally aspirated diesel engine by employing
Ramkumar, J, Krishnasamy, Anand, Ramesh, A
Insights into combustion and performance of HCCI engine fed with PODE 1 and H 2 -rich PODE 1 -reformate2023-32-00049/29/2023
A transition to sustainable energy sources, carbon- free/neutral energy carriers and efficient combustion technologies is intensively discussed as a key pathway in achieving a greener, more secure energy future. In particular, enhancement of internal combustion engine (ICE) performance using promising alternative carbon- neutral propellants, waste heat recovery (WHR) and state-of-the-art combustion methods has gained high research attention. Polyoxymethylene dimethyl ethers (PODEn, OMEn), well-suited for compression-ignition (CI) combustion, arouse strong interest as potentially sustainable and cleaner alternatives to diesel fuel. This study reports for the first-time numerically examined combustion performance characteristics of reforming- controlled compression ignition (RefCCI) ICE engine, managed by mixing of polyoxymethylene dimethyl ether 1 (PODE1) and its hydrogen-rich reforming products (PODE1-reformate) obtained through thermo- chemical recuperation. The results showed that
Buntin, Denis, Tartakovsky, Leonid
Efficiency Improvement of Heat Pump for Low Ambient Conditions Using Waste Heat from Electrical Vehicle Traction Motor2023-28-00139/14/2023
Electric vehicles (EV) have become very significant and potential way to reduce greenhouse gas emissions on a worldwide scale. EV also provides Energy security, as it reduces the dependency on petroleum producing countries of the world. Similar to the conventional Internal Combustion Engine Cars, in Electrical Vehicles also the efficient air conditioning system is very important for providing thermal comfort and for giving safe driving conditions. In Air Conditioning systems for EV, the heating option is available in the form of Electrical heaters and Heat Pump systems. The Heat pumps have become more popular compared to the electrical Positive Temperature Coefficient (PTC) heaters because of their highly efficient and energy saving designs. However, there are still some issues with using heat pumps. One of such issue is their less Coefficient of performance (COP) at low ambient conditions. Experimental results also show that the driving range decreases by using the electric heating
Dagar, Aakash, Sharma, Nishant, Suman, Saurabh, Kushwah, Yogendra Singh
A Novel Way to Convert Heat to ElectricityTBMG-489339/1/2023
Researchers at the National Institute of Standards and Technology (NIST) have fabricated a novel device that could dramatically boost the conversion of heat into electricity. If perfected, the technology could help recoup some of the recoverable heat energy that is wasted in the U.S. at a rate of about $100 billion each year.
Direct and Indirect Exhaust Heat Recovery from Turbocharged Heavy-Duty Engine2023-24-01228/28/2023
Waste Heat Recovery (WHR) is one of the most viable opportunities to reduce fuel consumption and CO2 emissions from internal combustion engines in the transportation sector. Hybrid thermal and electrical propulsion systems appear particularly interesting because of the presence of an electric battery that simplifies the management of the electrical energy produced by the recovery system. The different technologies proposed for WHR can be categorized into direct and indirect ones, if the working fluid operating inside the recovery system is the exhaust gas itself or a different one whose sequence of transformations follows a thermodynamic cycle. In this paper, a turbocharged diesel engine (F1C Iveco) equipped with a Variable Geometry Turbine (VGT) has been tested to assess the energy recoverable from the exhaust gases both for direct and indirect recovery. A direct technology based on an auxiliary turbine placed in the exhaust pipe (turbo-compounding) has been considered and compared
Di Bartolomeo, Marco, Di Battista, Davide, Fatigati, Fabio, Cau, Giorgio, Cipollone, Roberto
A Synergic Use of Innovative Technologies for the Next Generation of High Efficiency Internal Combustion Engines for PHEVs: The PHOENICE Project2023-01-02244/11/2023
Despite the legislation targets set by several governments of a full electrification of new light-duty vehicle fleets by 2035, the development of innovative, environmental-friendly Internal Combustion Engines (ICEs) is still crucial to be on track toward the complete decarbonization of on road-mobility of the future. In such a framework, the PHOENICE (PHev towards zerO EmissioNs & ultimate ICE efficiency) project aims at developing a C SUV-class plug-in hybrid (P0/P4) vehicle demonstrator capable to achieve a -10% fuel consumption reduction with respect to current EU6 vehicle while complying with upcoming EU7 pollutant emissions limits. Such ambitious targets will require the optimization of the whole engine system, exploiting the possible synergies among the combustion, the aftertreatment and the exhaust waste heat recovery systems. Focusing on the first aspect, the combined use of innovative in-cylinder charge motion, Miller cycle with high compression ratio, lean mixture with cooled
TAHTOUH, Toni, Millo, Federico, Rolando, Luciano, Castellano, Giuseppe, Brignone, Mauro, Cleeton, Jason, Demeilliers, Nicolas, Lucignano, Gennaro, Sierra Castellanos, Juan, Perazzo, Alessandro
Application of Model Predictive Control to Cabin Climate Control Leading to Increased Electric Vehicle Range2023-01-01374/11/2023
For electric vehicles (EVs), driving range is one of the major concerns for wider customer acceptance and the cabin climate system represents the most significant auxiliary load for battery consumption. Unlike internally combustion engine (ICE) vehicles, EVs cannot utilize the waste heat from an engine to heat the cabin through the heating, ventilation and air conditioning (HVAC) system. Instead, EVs use battery energy for cabin heating, this reduces the driving range. To mitigate this situation, one of the most promising solutions is to optimize the recirculation of cabin air, to minimize the energy consumed by heating the cold ambient air through the HVAC system, whilst maintaining the same level of cabin comfort. However, the development of this controller is challenging, due to the coupled, nonlinear and multi-input multi-output nature of the HVAC and thermal systems. Furthermore, the controller must satisfy different control requirements by leveraging multiple control actuators
Fussey, Peter, Ma, He, Dutta, Nilabza
Waste Exhaust Heat Recovery in Diesel Engine by Using Optimum Design and Rankine Cycle2023-01-09444/11/2023
The waste heat recovery (WHR) system appears to lower overall fuel consumption of the engine by producing additional power and curtailing greenhouse emissions per unit of power produced. In this project, a 25.5 kW diesel engine is used and simulated, which has an exhaust temperature of about 470°C. During optimization of the heat exchangers, the overall weight of the heat exchangers is kept low to reduce the final cost. Additionally, the overall pressure drops across the superheater, boiler, and economiser are kept at around 200 kPa to expel the exhaust gas into the atmosphere easily. To accomplish high heat-transfer across the heat exchangers, the pinch temperature of the hot and cold fluids is kept above 20°C. In this project, under the design constraints and available heat at the exhaust gases, the WHR system has enhanced the power and reduced the break specific fuel consumption by around 6.2% and 5.8%, respectively at 40 bar pressure. The maximum net power produced is around 1.5 kW
Bari, Saiful, Randhawa, Tejpal
Printed Thermoelectric Generators for Power GenerationTBMG-473271/1/2023
Thermoelectric generators (TEGs) convert ambient heat into electrical power. They enable maintenance-free, environmentally friendly, and autonomous power supply of the continuously growing number of sensors and devices for the Internet of Things (IoT) and recovery of waste heat. Scientists have now developed three-dimensional component architectures based on novel, printable thermoelectric materials.
Research on Modeling and Control of Fuel Cell Vehicle Integrated Thermal Management System15-16-02-000912/6/2022
The heat pump system has the advantages of high heating efficiency and low energy consumption and is more and more widely used in vehicles. In order to improve the economy and thermal management effect, this article introduces the heat pump system into the fuel cell vehicle thermal management system, designs the fuel cell vehicle integrated thermal management system (VITMS), and conducts research. First, the temperature control objectives of each subsystem are determined, the refrigeration and heating schemes of the integrated thermal management system are designed, and the working state and pipeline design of system components under different working modes are clarified. Then the modeling is carried out according to the working mechanism of the key components in the thermal management system and the corresponding control strategy is proposed for the key components in the VITMS. The simulation tests of the thermal management system at different temperatures are carried out to verify
Zeng, Xiaohua, Wang, Shupeng, Song, Dafeng, Ning, Jing
Thermomagnetic Generators Convert Waste Heat into Electrical PowerTBMG-457705/1/2022
Many technical processes only use part of the energy consumed. The remaining fraction leaves the system in the form of waste heat. Frequently, this heat is released into the environment unused; however, it can also be used for heat supply or power generation. The higher the temperature of the waste heat, the easier and cheaper it is to reuse.
Design and Research on the Thermal Management Integrated Control System of BEV Based on Heat Pump Air Conditioner15-15-02-00073/22/2022
Aiming at solving the battery electric vehicle (BEV) problems of high energy consumption and low efficiency in heating at low temperature, this study takes the thermal management system of BEV as the research object and develops an integrated thermal management control system based on heat pump air-conditioning for BEV. First, the functional requirements and optimal operating temperature range of each BEV subsystem are defined. Second, on the basis of the thermodynamic cycle principle of the air-conditioning system and compared with the traditional positive temperature coefficient thermistor (PTC) heating mode, the high heating efficiency and low energy consumption advantages of the heat pump system in winter are highlighted. Third, combined with the special structural characteristics of BEV, a hybrid heating scheme (i.e., heat pump system + PTC) is proposed, and a “motor/electronic control system waste heat recovery” scheme is formulated to realize the secondary recovery of energy
Zeng, Xiaohua, Huang, Yufeng, Song, Dafeng, Gao, Fuwang
Fuel-Economy Performance Analysis with Exhaust Heat Recovery System on Gasoline Engine03-15-06-00452/8/2022
As the electrification and connectivity technologies penetrate the market, the opportunities for intelligent thermal management of the vehicles become more salient. When an exhaust gas heat recovery (EGHR) system is used to recover waste heat from gasoline engine exhaust, the thermal parameters of the exhaust gas vary greatly, and these influence the performance of the heat exchanger (HE) system. To improve the recovery of exhaust waste heat and its conversion to faster coolant warm-up and cabin heating performance effectively, the heat transfer evaluation and optimal performance analysis are conducted on different EGHR system designs with different exhaust thermal parameters. This study aims at analyzing the fuel economy benefit with state-of-the-art HE designs in the automotive industry for exhaust gas-to-oil and exhaust gas-to-coolant heat transfer. Both physical testing and virtual simulation helped us develop a method to take advantage of the exhaust gas heat. The test result
Kumar, Vivek, Dadam, Sumanth Reddy, Zhu, Di, Mehring, Jan
Evaluation of the use of hydrated ethanol in different concentrations in reformers coupled with internal combustion engines2021-36-00292/4/2022
In recent years, fossil fuel dependence has generated a worldwide concern about the environmental consequences arising from its burning. The high oil demand has also generated the risk of shortage for this mineral and, consequently, of the products derived from it. Ethanol onboard reforming is regarded as a prominent technology that is able to recover waste heat from the exhaust system of internal combustion engines, as well as reduce emissions. The process is based on exploring the potential of endothermic reactions to convert hydrated ethanol into high energy density products, such as hydrogen and methane. This paper had the objective of implementing a thermodynamics and chemical kinetics model to evaluate the effects of ethanol-water content, reactor inlet temperature and ethanol to exhaust gas ratio in the reformate composition and reformer process efficiency using a platinum-based catalyst. The main reforming mechanisms for these conditions are ethanol thermal decomposition and
Vecchio, Bernardo O., Terra, Tiago M., Brito, Cristiano H. G., Vilela, Marcela R. M.
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