Waste Heat Recovery Systems for ICE Vehicles

Detailed overview of innovation with sample startups and prominent university research


What it is

Waste heat recovery systems in ICE vehicles capture the heat energy that is typically lost through the engine’s exhaust and cooling systems. This captured heat is then converted into useful energy, either to generate electricity, provide cabin heating, or preheat the engine, improving overall efficiency and reducing fuel consumption.

Impact on climate action

Waste Heat Recovery Systems for Low-Carbon ICE Vehicles amplify energy efficiency by capturing and repurposing engine heat. This innovation reduces emissions, enhances fuel economy, and extends vehicle range, marking a significant stride in climate action. It underscores the vital synergy between technological advancements and sustainable transportation solutions.

Underlying
Technology

  • Thermodynamics: Waste heat recovery systems leverage the principles of thermodynamics, transferring heat energy from a high-temperature source (engine exhaust or coolant) to a lower-temperature sink (a working fluid or electricity generation system).
  • Rankine Cycle: One common approach utilizes the Rankine cycle, a thermodynamic cycle that converts heat energy into mechanical work, which can then be used to generate electricity.
  • Thermoelectric Generators (TEGs): TEGs directly convert heat energy into electricity using the Seebeck effect, a phenomenon where a temperature difference between two dissimilar materials generates an electrical voltage.
  • Heat Exchangers: Efficient heat exchangers are crucial for transferring heat energy from the exhaust gases or coolant to the working fluid in a Rankine cycle system or to the TEGs.
  • System Integration: Integrating waste heat recovery systems into the vehicle’s overall powertrain and thermal management system is essential for optimizing performance and efficiency.

TRL : 7-8


Prominent Innovation themes

  • High-Temperature Thermoelectric Generators: Developing TEGs that can operate efficiently at the high temperatures found in engine exhaust systems can significantly improve energy recovery potential.
  • Organic Rankine Cycle (ORC) Systems: ORC systems use organic fluids with lower boiling points compared to water, allowing them to operate more efficiently at lower temperatures, expanding the range of waste heat sources that can be utilized.
  • Integrated Thermal Management: Developing integrated thermal management systems that combine waste heat recovery with engine cooling and cabin climate control to optimize overall energy efficiency.
  • Exhaust Gas Recirculation (EGR) Integration: Integrating waste heat recovery systems with EGR systems, which recirculate a portion of exhaust gases back into the engine to reduce emissions, can further improve efficiency.
  • Hybrid System Synergy: Combining waste heat recovery with hybrid electric powertrains can enhance the efficiency of both systems, using recovered heat to preheat the engine or generate electricity for the hybrid battery.

Other Innovation Subthemes

  • Waste Heat to Electrical Power Conversion
  • Rankine Cycle Integration in Vehicles
  • Thermoelectric Generator Advancements
  • High-Temperature TEG Development
  • Heat Exchanger Efficiency Enhancement
  • System Integration for Efficiency Optimization
  • Organic Rankine Cycle Implementation
  • ORC Fluid Selection for Efficiency
  • Integrated Thermal Management Systems
  • Cabin Climate Control Optimization
  • Waste Heat Recovery in Engine Cooling
  • EGR and Waste Heat Recovery Synergy
  • Preheating Engine with Recovered Heat

Related Innovations

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Sample Global Startups and Companies

  • BMW:
    • Technology Focus: BMW is likely focusing on waste heat recovery systems in the automotive industry. Their systems could capture and utilize heat generated by the vehicle’s engine or exhaust system, converting it into usable energy for various applications within the vehicle.
    • Uniqueness: BMW’s waste heat recovery systems may stand out for their integration with the vehicle’s overall design and performance, optimizing efficiency without compromising on driving experience or safety.
    • End-User Segments: Their primary end-users would be consumers of BMW vehicles, particularly those interested in eco-friendly and fuel-efficient transportation solutions.
  • MAHLE:
    • Technology Focus: MAHLE is a renowned automotive supplier known for its expertise in thermal management solutions. Their waste heat recovery systems are likely designed to optimize energy usage and reduce emissions in vehicles.
    • Uniqueness: MAHLE’s systems may be unique for their advanced engineering and integration capabilities, seamlessly integrating with existing vehicle architectures while delivering significant efficiency gains.
    • End-User Segments: MAHLE’s solutions would primarily target automotive manufacturers looking to enhance the sustainability and efficiency of their vehicle fleets, as well as consumers seeking eco-friendly transportation options.
  • Gentherm:
    • Technology Focus: Gentherm specializes in thermal management technologies, including waste heat recovery systems for various applications beyond automotive, such as industrial and consumer electronics.
    • Uniqueness: Gentherm’s systems may offer versatility and adaptability, catering to diverse end-user needs across multiple industries. They might also stand out for their innovation in materials and design, maximizing heat recovery efficiency.
    • End-User Segments: Their target segments could include automotive manufacturers, industrial companies, and consumer electronics manufacturers looking to improve energy efficiency and reduce environmental impact across their operations.

Sample Research At Top-Tier Universities

  1. Aachen University:
    • Technology Enhancements: Aachen University is at the forefront of developing advanced waste heat recovery systems for low-carbon ICE vehicles. Their research focuses on improving the efficiency of capturing and utilizing waste heat generated during engine operation through innovative thermal management systems and heat exchanger designs.
    • Uniqueness of Research: Aachen University’s approach involves a combination of experimental testing and computational modeling to optimize the performance of waste heat recovery systems under real-world driving conditions. They are exploring novel materials and heat transfer fluids to enhance heat recovery efficiency and durability.
    • End-use Applications: The research outcomes from Aachen University have direct implications for automotive manufacturers aiming to reduce fuel consumption and greenhouse gas emissions in ICE vehicles. Waste heat recovery systems can improve the overall efficiency of the vehicle and extend its driving range, making low-carbon transportation more accessible and sustainable.
  2. Technical University of Denmark (DTU):
    • Technology Enhancements: DTU researchers are focusing on integrating waste heat recovery systems with low-carbon ICE vehicles to maximize energy efficiency and minimize environmental impact. Their research involves developing compact and lightweight heat exchangers, thermoelectric generators, and organic Rankine cycles tailored for automotive applications.
    • Uniqueness of Research: DTU’s approach combines expertise in thermodynamics, materials science, and automotive engineering to design waste heat recovery systems optimized for different operating conditions and vehicle architectures. They are investigating advanced control strategies and hybridization techniques to enhance system performance and reliability.
    • End-use Applications: The research conducted at DTU has practical implications for automotive OEMs and suppliers seeking to meet stringent emissions regulations and improve fuel economy in ICE vehicles. Waste heat recovery systems can be integrated into conventional and hybrid powertrains to reduce CO2 emissions and enhance the competitiveness of low-carbon transportation solutions.
  3. Purdue University:
    • Technology Enhancements: Purdue University is spearheading research efforts to develop innovative waste heat recovery technologies for low-carbon ICE vehicles. Their research focuses on harnessing waste heat from exhaust gases, coolant, and lubricants to drive auxiliary systems, improve engine efficiency, and enhance overall vehicle performance.
    • Uniqueness of Research: Purdue’s research integrates principles of thermodynamics, fluid dynamics, and mechanical engineering to design and optimize waste heat recovery systems for automotive applications. They are exploring novel heat exchanger geometries, advanced heat transfer fluids, and thermal energy storage solutions to maximize energy recovery and minimize system complexity.
    • End-use Applications: The research outcomes from Purdue University have practical implications for automakers, fleet operators, and policymakers seeking to accelerate the adoption of low-carbon transportation technologies. Waste heat recovery systems can play a crucial role in reducing fuel consumption, lowering operating costs, and mitigating the environmental impact of ICE vehicles, thus facilitating the transition towards a sustainable mobility ecosystem.

commercial_img Commercial Implementation

While waste heat recovery systems for ICE vehicles are not yet widely adopted, several automotive manufacturers have introduced models with this technology. BMW has offered their TurboSteamer system in some of their production vehicles, and other manufacturers are exploring the integration of waste heat recovery into their future models.



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