Parametric optimization and heat transfer analysis of a dual loop ORC (organic Rankine cycle) system for CNG engine waste heat recovery

In this study, a dual loop ORC (organic Rankine cycle) system is adopted to recover exhaust energy, waste heat from the coolant system, and intercooler heat rejection of a six-cylinder CNG (compressed natural gas) engine. The thermodynamic, heat transfer, and optimization models for the dual loop ORC system are established. On the basis of the waste heat characteristics of the CNG engine over the whole operating range, a GA (genetic algorithm) is used to solve the Pareto solution for the thermodynamic and heat transfer performances to maximize net power output and minimize heat transfer area. Combined with optimization results, the optimal parameter regions of the dual loop ORC system are determined under various operating conditions. Then, the variation in the heat transfer area with the operating conditions of the CNG engine is analyzed. The results show that the optimal evaporation pressure and superheat degree of the HT (high temperature) cycle are mainly influenced by the operating conditions of the CNG engine. The optimal evaporation pressure and superheat degree of the HT cycle over the whole operating range are within 2.5–2.9 MPa and 0.43–12.35 K, respectively. The optimal condensation temperature of the HT cycle, evaporation and condensation temperatures of the LT (low temperature) cycle, and exhaust temperature at the outlet of evaporator 1 are kept nearly constant under various operating conditions of the CNG engine. The thermal efficiency of the dual loop ORC system is within the range of 8.79%–10.17%. The dual loop ORC system achieves the maximum net power output of 23.62 kW under the engine rated condition. In addition, the operating conditions of the CNG engine and the operating parameters of the dual loop ORC system significantly influence the heat transfer areas for each heat exchanger.