Further Development of Exhaust Waste Heat Recovery
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Further Development of Exhaust Waste Heat Recovery
© Mahle
AUTHORS
Reducing truck fleet consumption is of high importance to OEMs and fleet operators in order to comply with stricter CO2 legislation, to re duce total cost of ownership and to face the social and environmental responsibility. Exhaust waste heat recovery proved to be a promising single measure for conventional drivetrains to achieve this goal. Against the backdrop of the first stage of CO2 legislation in 2025, Mahle is pushing ahead with exhaust waste heat recovery develop ment and supporting the integration into the simulation tool Vecto.
MOTIVATION
The exhaust Waste Heat Recovery (WHR) system from Mahle is based on a Rankine cycle and was designed for the thermodynamic boundary conditions of a long haul truck. In order to balance efficiency and costs in the overall system and to meet the requirements of OEMs with regard to a high degree of system maturity, the development of the core components was raised to the system level. The electric WHR Box (eWHR
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Box) concept was presented last year [1]. In order to demonstrate the synergies of WHR with the electrification trend, a prototype 48-V mild hybrid system was implemented in a demonstrator truck. The fuel saving potential was demonstrated during independent tests by the Joint Research Centre (JRC) of the European Commission and Lastauto Omnibus and was in normal mode between 1.4 [2] and 3.8 % [3] depending on the cycle and total weight. With a standard load of approximately
Dipl.-Ing. Hannes Marlok is Project Leader for WHR Technologies at Mahle GmbH in Stuttgart (Germany).
Dipl.-Ing. Michael Bucher is Product Expert for WHR Systems at Mahle Amovis GmbH in Berlin (Germany).
Nicolas Ferrand is Head of Predevelopment WHR Heat Exchangers at Mahle Behr GmbH & Co. KG in Stuttgart (Germany).
34 t total weight, this corresponds to an average fuel saving of 3.2 %. Due to the low maturity level of the prototype hybrid system, which predominantly serves as a consumer for the WHR energy, the additional electrical power is more suitable for evaluating the potential of the eWHR Box. In the mentioned cycles with the truck with a total weight of 34 t, the measured potential shown in TABLE 1 is obtained. This re sults in an average of 3.9 % additional electrical power. Through the independent tests, WHR has established itself as a promising technology for achieving CO2 limits. In order to facilitate the path to a successful market launch, it is necessary to further optimize the cost to benefit ratio and to adapt the eWHR Box to the specific vehicle requirements and boundary conditions. Another important step is the correct consideration of WHR fuel saving in the CO2 legislation. SIMULATIVE DETERMINATION OF CO 2 EMISSIONS
The correct implementation of new technologies into the CO2 legislation is of high priority in order to enable technologyopen competition. If they are not implemented, this can lead to promising technologies not being used or the certified fuel consumption in real-world operation be
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