Professional Documents
Culture Documents
Review Article
A REVIEW ON WASTE HEAT RECOVERY AND
UTILIZATION FROM DIESEL ENGINES
S.L Nadaf*1, P.B Gangavati2
Table 2: Typical waste heat at medium temperature The engine exhausts gas can be applied directly for
range from various sources process drying. Generally, the hot water and low
Type of Device Temperature, C pressure steam produced by reciprocating engine
Steam boiler exhausts 230480 system is appropriate for low temperature process
Gas turbine exhausts 370540 needs, space heating, potable water heating, air
Reciprocating engine exhausts 315600
conditioning or refrigeration and to drive absorption
Reciprocating engine exhausts 230370
chillers providing cold water.
(turbo charged)
Heat treating furnaces 425650
2. WASTE HEAT RECOVERY TECHNOLOGIES
Drying and baking ovens 230600
FROM ENGINE
Catalytic crackers 425650 WHR system requires waste recovery equipment to
Annealing furnace cooling 425650 recover heat from the streams and transform it into a
systems useful form for utilization. This is done using energy
The single largest amount of unused heat from the conversion devices. Over the past two decades, much
engine is the exhaust heat, which contains about 30% research has been directed towards this.
of the fuel energy. It is evident that exhaust gases S N Srinivasa et. al.,(2012) have attempted to explore
comes out from the exhaust port at a very high the various possibilities of waste heat energy
temperature, it has been seen that in diesel engines recovery methods in conventional commercial two
exhaust emission are at the high temperature of wheeler and four wheelers. In this context, a new
250C to 600C (approx.) with high quality and concept of hybrid engine has also been discussed.
quantity. As shown in the Table 3 which might be The heat energy contained in the exhaust gases are
used in an efficient way. If the waste heat were put to recovered in three different methodologies.
appropriate use, there would be great energy or fuel Firstly, the waste heat energy is utilized to burn
savings. an additional amount of fuel.
Table 3: Typical Waste Heat quality and quantity from The second stage, a thermoelectric generator
engine producing electrical energy by utilizing the heat
Waste Heat Quality Quantity of exhaust gases.
Sources The third stage energy recovery is done by
Exhaust High High coupling a compressor and an alternator.
EGR High Low Kruiswyk (2008) developed components,
Coolant Low High technologies, and methods to recover energy lost in
Intercooler Low Low the exhaust processes of an internal combustion
1.2 Benefits of waste heat recovery from engines. engine and utilize that energy to improve engine
Benefits of waste heat recovery from engines can be thermal efficiency by 10%. Saidu et al. (2012) have
broadly classified in two categories studied the different technologies to recover the heat
Direct Benefits: Recovery of waste heat has a direct wasted from the exhaust gas of IC engines and
effect on the combustion process efficiency. This is concluded that there is a huge potential for extracting
reflected by reduction in the utility consumption and the waste heat from the exhaust gas of IC engines.
process cost. Shekh Nisar Hossain Rubaiyat(2010) conducted
Indirect Benefits: experiments to measure the exhaust waste heat
a) Reduction in pollution: A number of toxic available from a 60 kW automobile engine and a
combustible wastes such as carbon monoxide (CO), computer simulation was carried out to improve the
hydrocarbons (HC), nitrogen oxides (NOx), and design of the heat exchanger. Two heat exchangers
particulate matter (PM) etc, releasing to atmosphere. were used: one to generate saturated and the other to
Recovering of heat reduces the environmental generate super heated vapor. It is found that with the
pollution levels. exhaust heat available from the diesel engine at least
b) Reduction in equipment sizes: Waste heat recovery 18% additional power can be achieved. Janak
reduces the fuel consumption, which leads to Rathavi et. al. (2012) have carried out the
reduction in the flue gas produced. This results in experimental study of waste heat recovery technique
reduction in equipment sizes. and observed that such systems increase the
c) Reduction in auxiliary energy consumption: efficiency and reduce the emissions. Kiran K. Katta
Reduction in equipment sizes gives additional (2007) composed a two phase cooling system for
benefits in the form of reduction in auxiliary energy waste heat recovery using exhaust heat exchanger,
consumption (H. Teng, G. Regner, C. Cowland, and mini-turbine (expander) to generate auxiliary
2007). power via harvesting engine cooling and exhaust heat
There are various ways of utilizing waste heat loss from heavy duty vehicles. Aly(1988) have
depending on the quality and the quantity of exhaust studied the comprehensive applications of exhaust
waste heat. A few uses have been shown in Table 4. gas recycling and circulating cooling water WH
Table 4: Possible uses of waste heat and temperature recovery of internal combustion engine. Joshua A
range.
Jiricek (2007) designed and modeled a new steam
Possible Uses Temperature
Range sterilization system for proper sterilization and
(C) cleaning of medical equipment for field hospitals
Absorption Refrigeration 120-140 C steam using waste engine heat from exhaust system of a
Adsorption Refrigeration 120-140 C steam diesel generator and decreases the reliance on
DeHumidification 80-85 C hot water electricity of traditional sterilization methods. J. S.
Building Heating 80 - 130 C Jadhao et al. (2013) have reviewed the technology of
Organic Rankine cycle Around 65 C exhaust gas heat recovery for I.C. engine and
Steam Rankine Cycle Around 530 C concluded that such system would provide the
Int J Adv Engg Tech/Vol. V/Issue IV/Oct.-Dec.,2014/31-39
Nadaf et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945
pipe, but over the last ten years huge leaps have been losses from the flue gases are reduced. Mohd.Izam
made in the development of thermoelectric (2013) have carried out the experimental
assemblies to recycle some of this wasted energy. investigation of the thermoelectric generator modules
Specifically, TEGs can be attached to the outside with different techniques of cooling system and
surfaces of the exhaust pipe to remove heat. Although proposed that the water based cooling system would
TEG systems can only capture a small percentage of provide better performance
the worlds waste energy, on a global scale this Mori et al.(2009) studied the potentials of
amounts to a huge potential savings. thermoelectric technology in regards to fuel economy
The utilization of waste heat energy from exhaust gas of vehicles by implementing thermoelectric materials
in IC engines is another novel application of Hussain et al (2009) studied the effects of
electricity generation using thermoelectric power thermoelectric waste heat recovery for hybrid
generators. In an automobile engine, the radiator and vehicles. Jorge Martins(2011) reported the combined
exhaust gas systems are the main heat output of an IC use of Heat Pipes and commercially available TEG
engine, Zhang and Chau(2011)reported that presently system for energy recovery of waste heat from the
TEG systems are installed in the most of exhaust gas exhaust gases of automotive IC engines. The heat
system as shown in the Figure 3 (exhaust manifold) pipes were used as a means of efficiently transferring
due to its simplicity and low influence on the the heat from the hot exhaust gases to the TEGs.
operation of the engine. Furthermore, TEG system Stobart and Milner explored the possibility of
including the heat exchanger is commonly installed thermoelectric regeneration in vehicles in which they
in the exhaust manifold suitable for its high found out that the1.3kW output of the TE device
temperature region. These systems have a lot of could potentially replace the alternator of a small
potential and the BMW/Ford, General Motors, passenger vehicle. Stobart et al. reported the
General Electric, Chevrolet, Volkswagen and potentials in fuel saving of thermoelectric devices for
Cummins companies have worked on TEG vehicles and they concluded that Upto 4.7% of fuel
architectures and are all developing TEG systems. economy efficiency could be achieved. Zhang and
Most cars electronic systems are supplied with Chau(2011) proposed the TEG system coupled to
power from thermoelectric-generated electricity achieve maximum power output. They reported that
using DEWH, so we may see them on all the cars the power improvement is recorded from7.5%
very soon. P. Yodovard (2001), N.ESPINOSA to9.4%when the hot-side temperature of the TEG is
(2010),and Gunerhan(2005). heated from100 C to 250 C. From these articles, the
understanding of TEG technology has been
comprehensively discussed as a promising new
technology to recover waste heat from internal
combustion engines. Studies on thermoelectric
devices are still an ongoing matter.
3.3 Air Conditioning and Refrigeration
The A/C system adds nearly 35 % extra cost in fuel
expenses. Alternately, it is a matter of investigation
that waste recovery of an engine for application in
A/C can reduce the fuel economy of vehicles. From
Figure 3: Typical TEG waste heat energy recovery the reviews of various literatures there is an
system (Yu C, Chau KT. 2009) indication that an automobile engine utilizes only
D. Crane et al(2001) have been proposed several about 35% of available energy and rests are lost to
different thermoelectric systems and also tested for cooling and exhaust system. Therefore automobile
generating power via waste heat recovery Basel I. becomes costlier, uneconomical and less efficient
Ismail reported that the thermoelectric power with addition of air conditioner in car also decreases
generation offers a potential application in the direct the life of engine and increases the fuel consumption.
conversion of waste-heat energy into electrical power Keeping these problems in mind, a car air
where it is unnecessary to consider the cost of the conditioning system studied from recovery of engine
thermal energy input. The application of this waste heat using radiator water as source / exhaust
alternative green technology in converting waste-heat heat.
energy directly into electrical power can also improve
the overall efficiencies of energy conversion systems.
John LaGrandeur designed primary heat exchanger
(PHx) to recover waste heat from the exhaust gas
(downstream from the catalytic converter) and
provide high quality thermal energy to the TGM PHx
optimized to manage wide variations in exhaust gas
mass flow and temperatures. S. R. Jumade, V. W.
Khond (2012) have carried out a survey on waste heat
recovery from internal combustion engine using
thermoelectric technology and concluded that the use
of copper for the support structure would provide
better results. Marian, et. al. (2013) have investigated
the possibility of using thermo-electric power to
convert flue gas waste heat from a small-scale Figure 4: Schematic of a triple fluid vapours
domestic pellet boiler and concluded that the heat absorption refrigeration system (Abhilash Pathania)
Abhilash Pathania reported the application of exhaust gas driven automotive air conditioning
radiator hot water to run the refrigeration system as in working on a new hydride pair. The results showed
figure 5 above. R. J. Yadav reported that the exhaust that cooling power and system coefficient of
gases of these gensets have a very large amount of performance increase while the minimum
heat at about 700 C at full load and waste heat of refrigeration temperature decreases with growth of
coolant at about 120 C can be exploited to run a the heat source temperature. System heat transfer
central air conditioning plant based on vapour properties still needed to be improved for better
absorption chiller. And concluded that the vapour performance.
absorption chiller based central air conditioning plant 3.4 Strengthened Environmental Restrictions
can be run by tapping waste heat of the exhaust (14.5 During the last several decades internal combustion
TR ) and coolant heat (15.5 TR ) of 125 HP genset. engine technology has achieved significant progress
The energy cost may reduce approximately by 35 %. in reducing fuel consumption and exhaust emissions.
Koehler et al. designed, built and tested a prototype In particular, strict emission regulation made it
of an absorption refrigeration system for truck possible to reduce exhaust emissions of modern
refrigeration using heat from the exhaust gas heat engines.
which can replace the conventional compression Yoshihiro Ichiki(2011), of Mitsubishi Heavy
refrigeration system. The refrigeration cycle was Industries, Ltd. (MHI) has developed a super waste-
simulated by a computer model and validated by test heat recovery system for a main marine propulsion
data. Yousef and Najjar,(1996) experimental research engine as a solution for strengthened environmental
shows that it is feasible to drive refrigeration system restrictions and increasing demand for improved fuel
with automobile engine exhaust waste heat. Horuz, oil consumption. The newly developed super waste-
(1999),Manzela et al.,(2010) studied ammonia- water heat recovery system consists of a conventional
absorption refrigeration system with automobile combined system and a power turbine (gas turbine)
engine exhaust waste heat drive, and analyzed its that utilizes a portion of the exhaust gas. This system
economic feasibility. Hilalil and Soylemez (2008) increases the marine engine plant efficiency by 8%
studied the structure of the vehicle exhaust-driven 10%. While reducing Co2 emissions. Hou
refrigeration system, and conducted optimized Xuejun(2012) analyzed the diesel engine exhaust gas
calculation of its waste heat recovery rate and components, emission rates and waste heat rates.
operation economical efficiency. Wu and Schulden Then, the mainly harmful components are analyzed
(1995) studied improved Carnot-Cycle heat engine and the corresponding methods of purification and
driven by high-temperature waste heat and found the processing about Z12V190 diesel engine exhaust gas
relation of a temperature range of high-temperature pollution discussed. In order to achieve full recovery
waste heat and the maximum specific power. Yoon et of waste heat, save energy, purify treatment
al. (2003) studied the exhaust waste heat driven pollution, the comprehensive process flows of
refrigeration system. The highly energy-saving Z12V190 diesel engine exhaust gas pollution
technology with exhaust waste heat has the processing and waste heat recovery are designed.
remarkable effect in food. Kaudinya J.V et al.(1988) Khan et al.(2002) reported that with features of being
studied the feasibility of vehicle air-conditioning by energy-saving and environment-friendly, the waste
exhaust gas operated open cycle absorption cooling heat (WH) recovery and waste gas pollution
system and it has been shown that the cooling processing have received significant attention.
potential in the exhaust gas is much greater than the Approximately, 30 to 40% of the heat generated in
required for cooling of the vehicles interior space. the fuel combustion process is converted into useful
Vincent Mei et al. (1982) reported that truck exhaust mechanical work in contemporary internal
gas operated refrigeration system can suitable combustion engines. Yang, Yuan, & Lin,(2003) set up
installed and successfully operated for low practical heat pipe heat exchanger for heating HS663,
temperature application. a large bus. Giving comfort to passengers in cold, by
Zhao et al. (2003) studied two combined conveying the heat of automotive exhausts gas into
absorption/compression refrigeration cycles using the bus carriage utilizing gravity assisted heat pipe in
ammonia and water as the working fluid. The the heating using exhaust gas.
combined cycle with one solution circuit was a 3.5 Preheating of Biodiesels
conventional absorption chiller with a mechanical It is found from the review Table 4 that, bio-diesel is
compressor, using both the work and heat output the fuel rapidly growing in use, and if we use it in
from an engine. R.Q.Zhu, M.Suzuki (2011) studied diesel engines then it should have good fluidity, low
the feasibility of adsorption cooling for viscosity and good atomization which can only
automobile/engine waste heat recovery. Wu and possible if its preheated. This preheating might be by
Schulden(1995) presented a modified Carnot cycle high temperature exhaust gases coming out of the
for the application of air conditioning on a heat exhaust port, these exhaust gases if let free in to
engine using high-temperature waste heat. Jiangzhou atmosphere can cause great trouble related to health.
et al.(2002) presented an adsorption air conditioning It is also a fact that use of some electrical mean to
system used in internal combustion engine heat the fuel externally can cause extra cost of
locomotive driver cabin. The system consists of an operating. So an idea extract from above is to design
absorber and a cold storage evaporator driven by the such a device which can eliminate the use of this
engine exhaust gas waste heat, and employs zeolite external power and can also reduce the temperature
water as working pair. Qin et al.(2007) developed an of the exhaust gases to a greater extent.
Int J Adv Engg Tech/Vol. V/Issue IV/Oct.-Dec.,2014/31-39
Nadaf et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945
Waste heat recovery entails capturing and CH. Satyanarayana, and P. V. Rao Influence of Key
Properties of Pongamia Biodiesel on Performance
reusing the waste heat from internal Combustion and Emission Characteristics of a DI
combustion engine and using it for heating or Diesel Engine Wseas Transactions On Heat And Mass
generating mechanical or electrical work. Transfer ISSN: 1790-5044 Issue 2, Volume 4, April
The common technologies used for waste heat 2009.
Crane D.T., Jackson G.S., Holloway D. Towards
recovery from engine include thermoelectric optimisation of automotive waste heat recovery using
devices, organic Rankine cycle, air- thermoelectric. SAE International, 2001 (2001-01-
conditioning and refrigeration and preheating 1021)
of biodiesels using heat exchangers. Dinesha P, Mohanan P Experimental investigations on
the performance and emission characteristics of diesel
The study identified that the incorporated engine using preheated pongamia methyl ester as fuel
technologies add maximized energy efficiency International Journal of Advances in Engineering &
of the vehicles with improved power and Technology, Nov. 2012. Vol. 5, Issue 1, pp. 591-600.
reduced emissions. D.A.Reay, E & F.N.Span, Heat Recovery Systems,
London, 1979.
The waste heat recovery leads to less
Endo T., Kawajiri S., Kojima Y., Takahashi K., Study
production of pollutants like NOx andSO2 on maximizing exergy in automotive engines, Honda,
during creating the same amount of power. SAE, 2007-01-0257, 2007.
The idea of extract required heat for Feng Yang , Xiugan Yuan, Guiping Lin Waste heat
recovery using heat pipe heat exchanger for heating
preheating biodiesels from exhaust gases in automobile using exhaust gasApplied Thermal
design such a device which can eliminate the Engineering 23 (2003) 367372.
use of this external power and can also reduce H. Gunerhan and A. Hepbasli, Utilization of basalt
the temperature of the exhaust gases to a stone as a sensible heat storage material, ENERGY
greater extent. SOURCES, vol. 27, pp.1357-1366, 2005.
H Masjuki, M Z Abdulmuin, H S Sii, Investigations
It would also help to recognize the on Preheated Palm Oil Methyl Esters in the Diesel
improvement in performance and emissions of Engine Proceedings of the Institution of Mechanical
the engine if these technologies were adopted Engineers, Part A: Journal of Power and Energy April
by the automotive manufacturers. 1996 vol. 210 no. 2 131-138.
H. Teng, G. Regner, C. Cowland, Waste Heat
REFERENCES Recovery of Heavy-Duty Diesel Engines by Organic
Abhilash Pathania, Recovery of Engine Waste Heat for Rankine Cycle Part I: Hybrid Energy System of Diesel
Reutilization in Air Conditioning System in an and Rankine Engines, SAE Int. Publication 2007-01-
Automobile: Global Journal of researches in 0537 (2007).
engineering Mechanical and mechanics engineering Hatazawa M, Sugita H, Ogawa T, Seo Y. Performance
Volume 12 Issue 1 Version 1.0 January 2012. of a thermoacoustic sound wave generator driven with
Agarwal A K and Rajamanoharan K, Experimental waste heat of automobile gasoline engine.
Investigations of Performance and Emissions of Transactions of the Japan Society of Mechanical
Karanja Oil and its Blends in a Single Cylinder Engineers 2004;70(689):2929.
Agricultural Diesel Engine, Applied Energy, Vol. 86, Hazar, H. and Aydin, H., 2010, Performance and
pp. 106-12. emission evaluation of a CI engine fueled with
Alias Mohd Noor A, Rosnizam Che Puteh B And preheated raw rapeseed oil (RRO)diesel blends,
Mazlan Said A Waste Heat Recovery Technologies in Applied Energy, 87: 786790
Turbocharged Automotive Engine A Review Hevendro colonhese delali bera, et al, Performance of
Proceedings of Global Engineering, Science and a diesel engine fuelled with preheated blend of Soy
Technology Conference 1 - 2 April 2013, Dubai, UAE, bean Oil and Petrol Diesel
ISBN: 978-1-922069-21-4 . Hilalil, M.S. Soylemez, On the optimum sizing of
Alpesh Mehta, Mehul Joshi , Ghanshyam Patel , exhaust gas-driven automotive absorption cooling
Mohammad Juned Saiyad Review article performance systems. Int. J. Energ. Res., 32: 655-660. 2008.
of single cylinder diesel engine using jatropha oil with Horuz, I., 1999. Vapor absorption refrigeration in road
exhaust heat recovery system International Journal of transport vehicles. J. Energ. Eng., 125(2): 48-58.
Advanced Engineering Technology E-ISSN 0976-3945
Hossain A K and Davies P A, Plant Oils as Fuels for
IJAET/Vol.III/ Issue IV/Oct.-Dec., 2012/01-07.
Compression Ignition Engines: A Technical Review and
Aly, S.E., 1988. Diesel engine waste-heat power Life-Cycle Analysis, Renewable Energy, 2010, Vol.
cycle.Appl. Energ., 29: 179-189. 35, pp. 1-13.
Arif Canacik, Ahmet Donmez Fuel preheating system Hou Xuejun, Analysis of Exhaust Gas Waste Heat
United States patent (19) September 1988. Patent Recovery and Pollution Processing for Z12V190 Diesel
No.0167221 Al. July 2010. Engine Research Journal of Applied Sciences,
Athanasios Balafoutis, Spyros Fountas, Athanasios Engineering and Technology 4(11): 1604-1611, 2012
Natsis, and George PapadakisPerformance and ISSN: 2040-7467.
Emissions of Sunflower, Rapeseed, and Cottonseed Oils Hussain QE, Brigham DR, Maranville CW.
as Fuels in an Agricultural Tractor Engine Thermoelectric exhaust heat recovery for hybrid
International Scholarly Research Network ISRN vehicles, SAE Paper no. 2009-01-1327, Presented at
Renewable Energy Volume 2011, Article ID 531510, SAE World Congress & Exhibition April 2009, Detroit,
12 pages. MI, USA, Session: Advanced Hybrid Vehicle
Bhupendra Singh Chauhan, Naveen Kumar and Haeng Powertrains - Hybrid Engine & Emissions, Thermo-
Muk Cho Performance and emission studies on an Electric Conversion (Part 1 of 6).
agriculture engine on neat Jatropha oil Journal of Vaja and A. Gambarotta, Internal combustion engine
Mechanical Science and Technology 24 (2) (2010) (ICE) bottoming with organic rankine cycles (ORCs),
529~535. Energy, 35 (2) (2010) 1084-1093.
Bhupendra Singh Chauhan, , Naveen Kumar, Yong Du J. S. Jadhao, D. G. Thombare Review on Exhaust Gas
Juna, Kum Bae Lee Performance and emission study Heat Recovery for I.C. Engine International Journal of
of preheated Jatropha oil on medium capacity diesel Engineering and Innovative Technology (IJEIT)
engine April 2010. Volume 2, Issue 12, June 2013.
Basel I. Ismail, Wael H. Ahmed. Thermoelectric Janak Rathavi, Mr. Amitesh Paul, Dr. G.R. Selokar
Power Generation Using Waste-Heat Energy as an Experimental study of waste heat recovery technique
Alternative Green Technology Recent Patents on to increase efficiency and to decrease hazardous
Electrical Engineering 2009, 2, 27-39 27 1874- emissions in CI engine International Journal of
4761/09