Patent Application
20170335745
The present disclosure generally relates to waste heat recovery (“WHR”) systems for use with internal combustion (IC) engines, and also to methods and systems for integrating WHR heat exchangers into an integrated cooling system or module to improve overall cost effectiveness and reduce plumbing requirements.
Internal combustion engines used to power vehicles generate heat as a result of inherent inefficiencies of converting fuel into energy. As heat represents energy potential, recovery of the heat permits its conversion into mechanical and/or electrical power that would otherwise be lost through cooling and heat rejection. This recovery may enhance the fuel efficiency of the vehicle and reduce harmful emissions. Thus, recovering waste heat produced during the operation of internal combustion (IC) engines (e.g., diesel engines) provides one way to meet legislated and competitive fuel efficiency and emission requirements for IC engines.
Heat is generally recovered from sources of high temperature, for example, the exhaust gas produce by the IC engine, or compressed intake gas. Such high grade WHR systems include components which are configured to extract the heat from the high temperature source. These components can include exhaust gas recirculation (EGR) boilers, pre-charge air coolers (pre-CAC), exhaust system heat exchangers, or other components configured to extract heat from the high grade source of heat. The components included in conventional high grade WHR systems are disposed as separate components fluidly coupled together, and can be prone to leak paths. This can lead to reduced cost savings, poor performance, and reduced transient capability.
WHR systems exist for capturing heat energy generated by internal combustion engines that would be otherwise lost through cooling and/or exhaust. Such systems typically include many components mounted at various locations on the engine. Plumbing is used to transfer mass between the heat exchangers at the various locations in such systems. The distributed nature of the components and interconnected plumbing results in inefficient usage of the limited space in the engine compartment, and leads to heat losses through the plumbing. Conventional systems also increase the complexity of integrating a WHR system onto a base engine.
Accordingly, it would be desirable to provide an integrated arrangement of the heat exchangers of a WHR system such that mass transfer between the heat exchangers is more efficient and reduces the on-engine space claim of the system.
According to some embodiments, an integrated cooling system for a waste heat recovery (“WHR”) system comprising a frame configured for mounting to a vehicle chassis in a path of ram air entering an engine compartment of a vehicle, a radiator connected to the frame in the ram air path, a WHR condenser connected to the frame, a recouperator connected to the frame above the ram air path and coupled to the WHR condenser, and a coolant boiler connected to the frame below the ram air path and coupled to the radiator and recouperator is provided.
In additional embodiments, a cooling system for use in a WHR system is also provided that may comprise a condenser configured to condense a working fluid. An inlet header is disposed on a first end of the condenser. The inlet header is fluidically coupled to a heat exchanger to receive the working fluid from the expander or heat exchanger and communicate the working fluid to the condenser.
In various embodiments, the receiver may be fixedly disposed on a second end of the condenser opposite the first end and is configured to receive the working fluid from the condenser.
According to additional embodiments, a liftpump may be disposed in the receiver and configured to communicate a working fluid to the primary pump in the system (or feedpump). A level sensor may be disposed in the receiver and configured to measure a level of the working fluid in the receiver. In some embodiments, the condenser, the inlet header, the receiver, the liftpump and the level sensor may be fixedly coupled to each other in a single unit.
It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.
The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
Referring now to
As best shown in
According to principles known in the art and with the benefit of this disclosure, radiator 26 receives coolant from thermostat 44 through line 46 when the coolant is sufficiently heated by operation of engine 10. Valve 48, which is connected to water pump 50, controls the amount of coolant provided to radiator 26 and coolant boiler 14′ based on engine load. Control provided by valve 48 to coolant boiler 14′ aids in control of the top tank temperatures to specified values under various engine loads. More specifically, under full load conditions, radiator 26 gets full flow to ensure that the top tank temperature is maintained. An outlet of radiator 26 is connected to coolant boiler 14′ through line 52. An output of coolant boiler 14′ is connected to EGR boiler/superheater 36 through line 54. Finally, an outlet of WHR condenser 28 (through lift pump 56 and filter 58) is routed to feed pump 30.
As should be apparent from the foregoing, recouperator 12′ and coolant boiler 14′ function as heat exchangers in the WHR system. Recouperator 12′ receives hot refrigerant from expander 38 (
As best shown in
It should be understood that while WHR condenser 28 is described herein as being a vertical condenser, a horizontal condenser could also be used consistent with the teachings of the present disclosure. Moreover, it should be understood that while recouperator 12′ is described herein as being disposed at the uppermost position of system 20, recouperator 12′ may be disposed in a lower position. For example, recouperator 12′ could be located as low as the upper ⅔s (as viewed in
As best shown in
As shown in
As should be understood from the forgoing, the integrated compact cooling systems disclosed herein provide, among other things, “off-engine” heat exchangers and reduced plumbing for mass transfer between heat exchangers, thereby reducing the space claim of the WHR system on the engine. Moreover, various systems disclosed herein preserve the existing ram air path for the CAC and radiator by locating the non-ram cooled heat exchangers (i.e., the recouperator and coolant boiler) at the top and bottom of the system, respectively, outside the ram air path. Additionally, by moving the recouperator and coolant boiler off-engine, the systems reduce the complexity of incorporating a WHR system onto a base engine.
Various embodiments of the cooling system described herein for use in WHR systems may also provide numerous benefits including, for example: (1) integrating a receiver of a WHR system into a condenser of the WHR system in a single unit thereby reducing leak paths; (2) disposing a lift pump into the receiver to further reduce the leak paths, provide cost savings, and increased transient capability; (3) disposing a level sensor in the receiver to measure in real time the level of a working fluid in the receiver; (4) controlling the speed of the lift pump to control a flow rate of the working fluid in response to a level of the working fluid in the receiver or based on a feed pump inlet subcooling measured via pressure and temperature of the fluid supplied to the feed pump.
The WHR system 250 is configured to extract heat from a waste heat source (e.g., an exhaust gas and/or a compressed intake gas and/or coolant and/or engine oil) and convert the heat into usable energy. The heat exchanger 252 is configured to receive a waste heat source or sources from an engine 210. The engine 210 can include an IC engine, for example, a diesel engine, a gasoline engine, a natural gas engine, a positive displacement engine, a rotary engine, or any other suitable engine, which converts a fossil fuel into mechanical energy. The combustion of the fossil fuel (e.g., diesel) in the engine 210 produces an exhaust gas at an elevated temperature (e.g., in the range of about 550 degrees Fahrenheit to about 1300 degrees Fahrenheit). Furthermore, the engine 210 can be configured to receive an intake gas heated to a substantially high temperature (e.g., a compressed intake gas heated to a temperature of about 550 degrees Fahrenheit to about 1300 degrees Fahrenheit).
The feed pump 255 is fluidly coupled to the heat exchanger 252 and configured to pump a working fluid through the heat exchanger 252. The working fluid can include any suitable working fluid which can extract heat from the high grade heat source and change phase, for example, vaporize. Various working fluids can include, for example, Genetron® R-245fa from Honeywell, low-GWP alternatives of existing refrigerant based working fluids, Therminol®, Dowtherm J™ from Dow Chemical Co., Fluorinol® from American Nickeloid, toluene, dodecane, isododecane, methylundecane, neopentane, neopentane, octane, water/methanol mixtures, ethanol steam, and other fluids suitable for the anticipated temperature ranges and for the materials used in the various described devices and systems.
The working fluid can extract the heat from the waste heat source and change phase, for example, vaporize within the heat exchanger 252. The waste heat source can be directed either back to the engine if it is coolant, oil, charge air, exhaust gas that is part of an exhaust gas recirculation (EGR) system, or exhaust gas that is communicated to an aftertreatment system for removing particulates, SOx gases, NOx gases, or otherwise treating the exhaust gas before expelling the exhaust gas to the environment.
The vaporized working fluid is communicated to an energy conversion device 254 which is configured to perform additional work or transfer energy to another device or system. The energy conversion device 254 can include, for example, a turbine, piston, scroll, screw, or other type of expander devices that moves (e.g., rotates) as a result of expanding working fluid vapor to provide additional work. The additional work can be fed into the engine's driveline to supplement the engine's power either mechanically or electrically (e.g., by turning a generator), or it can be used to drive a generator and power electrical devices, parasitics or a storage battery (not shown). Alternatively, the energy conversion device 254 can be used to transfer energy from one system to another system (e.g., to transfer heat energy from waste heat recovery system 250 to a fluid for a heating system).
The working fluid is communicated from the energy conversion device 254 to the cooling system 260. The cooling system 260 includes a condenser 262 configured to condense the working fluid. For example, the condenser 262 can include a down flow heat exchanger such that the condensed working fluid can flow downwards under the influence of gravity into the receiver 266. In other embodiments, any other condenser that can extract heat from the working fluid and condense the working fluid (e.g., urge the working fluid to condense from a vapor or gas phase to a liquid phase) can be used. In some embodiments, the condenser 262 can also include a sub-cooler, or a sub-cooling portion. In such embodiments, the sub-cooler can be disposed downstream of the condenser 262 and upstream of the receiver 266.
An inlet header 264 is fixedly disposed on a first end of the condenser 262. The inlet header 264 is fluidically coupled to the heat exchanger 252 via the energy conversion device 254 and configured to receive the working fluid from the heat exchanger 252. The inlet header 264 can include a manifold, chamber, or compartment configured to receive the heated working fluid from the heat exchanger 252 and communicate the working fluid to the condenser 262.
A receiver 266 is fixedly disposed on a second end of the condenser 262 opposite the first end. The receiver 266 is configured to receive the working fluid from the condenser 262, and is integrated with the condenser 262 to serve as an outlet header for the condenser 262. The receiver 266 can, for example, be a manifold, chamber or compartment structured to collect the condensed working fluid and maintain a volume of the working fluid within an internal volume defined by the receiver 266.
A lift pump 267 is disposed in the receiver 266 and configured to communicate the working fluid to the feed pump 255. The lift pump 267 can include any suitable lift pump, for example, an electrically driven lift pump, or, a mechanically driven pump (e.g., a centrifugal type pump, a positive displacement pump, a gear pump, a piston type pump etc.). In some embodiments, the lift pump 267 can include an inducer to reduce a net positive suction head required, for example, to pump the working fluid to the feed pump 255. The lift pump 267 can be integrated with the receiver 266 such that the condenser 262, the inlet header 264, the receiver 266, and the lift pump 267 are integrated into a single unit. The lift pump 267 can be a fixed or variable speed pump. The lift pump 267 can be activated prior to starting the engine 210, for example, to prime the feed pump 255 and/or communicate working fluid to other components for cooling and/or lubrication. A pumping speed of the lift pump 267 can be varied to control the filling pressure of the feed pump 255 which can, for example, affect feed pump 255 flow rate.
In some embodiments, the lift pump 267 speed may be varied in response to lift pump 267 inlet pressure, lift pump 267 pressure rise, feed pump 255 inlet pressure, engine 210 speed, engine 210 load, ambient conditions, speed of a vehicle on which the engine 210 is mounted, working fluid temperature at lift pump 267, working fluid temperature at energy conversion device 254 inlet, feed pump 255 outlet pressure, and/or fault condition of the waste heat recovery system 200 or feed pump 255. Moreover, the lift pump 267 speed can be varied to control the level of the working fluid in the receiver 266.
A level sensor 269 is disposed in the receiver 266 and configured to measure a level of the working fluid in the receiver 266. The level sensor 269 can include a float sensor, a resistive level sensor, a capacitive level sensor, or any other suitable sensor that can measure a level of the working fluid disposed in the receiver 266 in real time. Measurement of the working fluid level in the receiver 266 by the level sensor 269 can, for example, be used to determine the flow rate of the working fluid through condenser 262, and/or an efficiency of the condenser 262. Based on this information, the speed of the lift pump 267 can be varied to control the level of the working fluid in the receiver 266.
In some embodiments, the condenser 262, the inlet header 264, the receiver 266, the lift pump 267 and the level sensor 269 can be integrated with each other in a single unit. In this manner, the cooling system 260 can be a single unit or otherwise which can be installed in a system, for example, a vehicle that includes the engine 210. This allows for easy installment or replacement of the cooling system 260.
Integration of the components into the single unit can reduce leak paths, increase performance, increase transient capability, and provide substantial cost savings (e.g., by reducing labor or materials cost during maintenance). The performance can be improved because the working fluid exiting the condenser 266 can be at or near saturation. Thus, the condenser 262 pressure can be lower for the cooling system 260 as the receiver 266 is disposed at the outlet of the condenser 262. Lower condenser 262 pressure results in greater energy conversion device 256 work in the working fluid cycle.
Disposing the lift pump 267 in the receiver 266 also allows more flexibility in placement of the feed pump 255 which performs the primary pressure rise of the working fluid within the waste heat recovery system 250. The lift pump 267 can supply the necessary pressure rise to provide sufficient suction pressure to the feed pump 255 to prevent cavitation.
Furthermore, the ability to control the lift pump 267 at variable speeds provides additional control and flexibility to the system 200, for example, feed pump 255 sub-cooling control and/or variable feed pump 255 flow rate by changing the sub-cooling at the inlet of the feed pump 255.
The cooling system 260 can be disposed in any suitable position in relation to other components, systems, or assemblies of a system that includes the WHR system 250.
While this disclosure has been described as having an exemplary design, the present disclosure may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains.
Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements. The scope is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.”
In the detailed description herein, references to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art with the benefit of the present disclosure to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.
Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. §112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
This application claims priority to U.S. Provisional Application Ser. No. 62/069,074, filed on Oct. 27, 2014 and U.S. Provisional Application Ser. No. 62/068,889, filed on Oct. 27, 2014, the entire disclosures of which are both hereby expressly incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US15/57668 | 10/27/2015 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62069074 | Oct 2014 | US | |
| 62068889 | Oct 2014 | US |
