Development of a 48V ORC Turbo-pump for Waste Heat Recovery in the Coolant of Light Duty and Commercial Vehicles

orc2019 Tracking Number 21

In the next 10 years, a 30% CO2 emission reduction is awaited on road vehicles in Europe. Complementary to electrification and hybridization, waste heat recovery (WHR) appears to be a necessity to improve vehicle efficiency and provide significant reduction in fuel consumption of passenger cars and commercial vehicles. In this context IFP Energies nouvelles accompanied by ENOGIA have actively worked on Organic Rankine Cycle (ORC) dedicated to transport to adapt this mature technology in stationary application to the small scale road transport industry. A cost-driven approach using low temperature waste heat recovery was selected has key driver in this development. It is based on an Organic Rankine Cycle with the engine coolant as heat source and an integrated mechanical compact kinetic turbine and pump as compression and expansion devices. Compared to other WHR based on exhaust gas heat recovery with high efficiency, this solution offers a safe, lightweight and low-cost module readily pluggable onto engines and compatible with 48V hybridization. Simulations and experimental results highlighted a potential of 2% and up to 3% fuel economy on regulatory cycle WLTP for light duty vehicle with thermal management. In this paper results of system and CFD simulations, design process of the electric ORC turbo-pump as well as experimental results will be presented.