AN INTERNAL COMBUSTION ENGINE HEAT ENERGY RECOVERY SYSTEM

• US 20170122254A1
• Filed: 06/29/2015
• Published: 05/04/2017
• Est. Priority Date: 06/30/2014
• Status: Abandoned Application

• Current Assignee: KERBS AutoTech Pty. Ltd.
• Original Assignee: KERBS AutoTech Pty. Ltd.
• Inventors: Urch, Michael John, Bennett, Stephen
• Application Number:
  US15/323,000
• Publication Number:
  US 20170122254A1
• Time in Patent Office: Days
• CPC Class Codes: B60K 6/24 characterised by the combustion engines
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: F01K 23/065 the combustion taking place in an internal combustion piston engine, e.g. a diesel engine
• CPC Class Codes: F01K 23/10 with exhaust fluid of one cycle heating the fluid in another cycle F01K17/025 takes precedence
• CPC Class Codes: F01K 25/103 Carbon dioxide F01K25/065 takes precedence
• CPC Class Codes: F01K 27/02 Plants modified to use their waste heat, other than that of exhaust, e.g. engine-friction heat
• CPC Class Codes: F01N 5/025 the device being thermoelectric generators
• CPC Class Codes: F02B 37/10 at least one pump being alternatively or simultaneously driven by exhaust and other drive, e.g. by pressurised fluid from a reservoir or an engine-driven pump
• CPC Class Codes: F02G 2260/00 Recuperating heat from exhaust gases of combustion engines and heat from cooling circuits
• CPC Class Codes: F02G 2262/00 Recuperating heat from exhaust gases of combustion engines and heat from lubrication circuits
• CPC Class Codes: F02G 5/04 in combination with other waste heat from combustion engines
• CPC Class Codes: Y02B 30/52 Heat recovery pumps, i.e. heat pump based systems or units able to transfer the thermal energy from one area of the premises or part of the facilities to a different one, improving the overall efficiency
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

An internal combustion engine heat energy recovery system (1) comprises a first heat exchanger (20) arranged in heat communication with at least one heat energy source of an internal combustion engine (10) and with a working fluid of the system (1) for the transfer of heat energy from the heat energy source to the working fluid of the system (1). A turbine (30) is arranged in fluid communication with the working fluid heated in the first heat exchanger (20) for the expansion of the working fluid to produce shaft power. A second heat exchanger (40) is arranged in heat communication with the expanded working fluid to remove waste heat therefrom and transfer it to an external source such as the atmosphere. A first compressor (50) is arranged in fluid communication with the working fluid exiting the heat exchanger for increasing the pressure of the cooled working fluid prior to its entry into the first heat exchanger (20). The working fluid of the system is a substantially supercritical fluid.

Claims

1. An internal combustion engine heat energy recovery system, comprising:

a first heat exchanger arranged in heat communication, more preferably fluid communication, with at least one heat energy source of an internal combustion engine and with a working fluid of the system for the transfer of heat energy from the heat energy source to the working fluid of the system;

a turbine arranged in fluid communication with the working fluid heated in the first heat exchanger for the expansion of the working fluid to produce shaft power;

a second heat exchanger arranged in heat communication, more preferably fluid communication, with the expanded working fluid to remove waste heat therefrom and transfer it to an external source such as the atmosphere; and

a first compressor arranged in fluid communication with the working fluid exiting the heat exchanger for increasing the pressure of the cooled working fluid prior to its entry into the first heat exchanger, wherein the working fluid of the system is a supercritical fluid.

3. The internal combustion engine heat energy recovery system of claim 1 or claim 2, wherein the working fluid is supercritical carbon dioxide.

4. The internal combustion engine heat energy recovery system of claim 1 or claim 2, wherein the working fluid is supercritical water or other refrigerant.

5. The internal combustion engine heat energy recovery system of any one of claims 1 to 4, wherein the system includes a generator operatively associated with the turbine for converting the shaft power produced by the turbine into electrical power.

6. The internal combustion engine heat energy recovery system of claim 5, wherein the system includes a battery adapted for storing the electrical power generated by the generator.

7. The internal combustion engine heat energy recovery system of any one of claims 1 to 6, wherein the at least one or first heat energy source of the internal combustion engine is exhaust gas.

8. The internal combustion engine heat energy recovery system of any one of claims 1 to 7, wherein the at least one heat energy source or second heat energy source of the internal combustion engine is engine coolant.

9. The internal combustion engine heat energy recovery system of claim 8, wherein the system includes a coolant recirculation conduit arranged to recirculate engine coolant cooled by the first heat exchanger back to the internal combustion engine.

10. The internal combustion engine heat energy recovery system of claim 9, wherein the coolant recirculation conduit is arranged to recirculate the engine coolant in a water circuit inside the engine.

11. The internal combustion engine heat energy recovery system of claim 9, wherein a water circuit is arranged inside the engine for circulation of the working fluid.

12. The internal combustion engine heat energy recovery system of any one of claims 1 to 12, wherein the at least one or first heat energy source of the internal combustion engine is engine oil.

13. The internal combustion engine heat energy recovery system of claim 12, wherein the system includes an engine oil recirculation conduit arranged to recirculate engine oil cooled by the first heat exchanger back to the internal combustion engine.

14. The internal combustion engine heat energy recovery system of claim 13, wherein the engine oil recirculation conduit is arranged to recirculate engine oil back inside the engine in an oil circuit.

15. The internal combustion engine heat energy recovery system of any one of claims 1 to 14, wherein the at least one heat energy source is condenser heat emitted by the air conditioning system of a vehicle.

16. The internal combustion engine heat energy recovery system of any one of claims 1 to 15, wherein the system is arranged to recover heat energy from a plurality of heat energy sources of the internal combustion engine.

17. The internal combustion engine heat energy recovery system of claim 16, wherein the first heat exchanger is arranged in heat communication, more preferably fluid communication, with each of a first heat energy source in the form of engine exhaust gas and a second heat energy source in the form of engine coolant.

18. The internal combustion engine heat energy recovery system of claim 17, wherein the first heat exchanger comprises an exhaust gas receiving heat exchanger for the transfer of heat energy from the exhaust gas to the working fluid, and a coolant receiving heat exchanger for the transfer of heat energy from the engine coolant to the working fluid.

19. The internal combustion engine heat energy recovery system of claim 17 or claim 18, wherein the first heat exchanger further includes an oil receiving heat exchanger arranged in heat communication, more preferably fluid communication, with a further heat energy source in the form of engine oil for the transfer of heat energy from the engine oil to the working fluid.

20. The internal combustion engine heat energy recovery system of any one of claims 1 to 19, wherein the first compressor is operatively associated with an output shaft of the turbine so as to be driven by the turbine.

21. The internal combustion engine heat energy recovery system of any one of claims 6 to 19, wherein the system includes a motor arranged to draw electrical power from the battery.

22. The internal combustion engine heat energy recovery system of claim 21, wherein the first compressor is operatively associated with and driven by the motor.

23. The internal combustion engine heat energy recovery system of any one of claims 1 to 19, in which the first compressor is driven by shaft power produced by the internal combustion engine.

24. The internal combustion engine heat energy recovery system of claim 5, wherein the first compressor is driven directly by the electrical power generated by the generator.

25. The internal combustion engine heat energy recovery system of claim 5, wherein the system further includes a digitally controlled motor device with storage arranged to draw electrical power from the generator.

26. The internal combustion engine heat energy recovery system of claim 25, wherein the digitally controlled motor device comprises a fly wheel for the storage of mechanical power.

27. The internal combustion engine heat energy recovery system of claim 25 or 26, wherein the digitally controlled motor device further includes a rotor arranged in magnetic communication with the fly wheel.

28. The internal combustion engine heat energy recovery system of claim 27, wherein the fly wheel and the rotor are adapted to operate at different speeds of rotation.

29. The internal combustion engine heat energy recovery system of any one of claims 25 to 28, wherein at least a portion of electrical power generated by the digitally controlled motor device is employed to drive the first compressor.

30. The internal combustion engine heat energy recovery system of any one of claims 25 to 28 when dependent upon claim 6, wherein the digitally controlled motor device is arranged to divert at least a portion of electrical power generated therein to the battery for storage.

31. The internal combustion engine heat energy recovery system of any one of claims 1 to 30, wherein the system further includes a second compressor in fluid communication with an air supply and a first intercooler arranged for cooling compressed air exiting the second compressor, wherein the cooled compressed air is arranged in fluid communication with an intake of the internal combustion engine.

32. The internal combustion engine heat energy recovery system of claim 31, wherein a portion of the working fluid cooled by the second heat exchanger is diverted through the intercooler prior to its entry into the first compressor for cooling the compressed air.

33. The internal combustion engine heat energy recovery system of claim 31, wherein the system includes a second intercooler in heat communication, more preferably fluid communication, with the first intercooler, the first intercooler and second intercooler being arranged in a closed loop through which an intercooler fluid flows, wherein a portion of the working fluid cooled by the second heat exchanger is diverted through the second intercooler for heat exchange with the intercooler fluid prior to its entry into the first compressor.

34. The internal combustion engine heat energy recovery system of claim 33, wherein the intercooler fluid is water.

35. The internal combustion engine heat energy recovery system of claim 31 when dependent upon claim 5, wherein the second compressor is driven directly by electrical power generated by the generator.

36. The internal combustion engine heat energy recovery system of claim 31 when dependent upon claim 6, wherein the second compressor is driven by a motor powered by electrical power stored in the battery.

37. The internal combustion engine heat energy recovery system of any one of claims 7 to 34 when dependent upon claim 6, wherein the system further includes a motor generator powered by a portion of the electrical power stored in the battery.

38. The internal combustion engine heat energy recovery system of claim 37, wherein the motor generator is operatively associated with a drive shaft of a vehicle powered by the internal combustion engine.

39. The internal combustion engine heat energy recovery system of claim 37 or claim 38, wherein the motor generator is adapted to draw electrical power from the battery to rotate a drive shaft of the vehicle.

40. The internal combustion engine heat energy recovery system of any one of claims 31 to 39 when dependent upon claim 25, wherein a portion of the electrical power generated by the digital gearbox motor is used to drive the first compressor and another portion of the electrical power is used to drive the second compressor.

41. The internal combustion engine heat energy recovery system of any one of claims 30 to 40 when dependent upon claim 6, further including a first digitally controlled motor device with storage arranged in operable communication with both the turbine and the first compressor for driving the first compressor and further includes a second digitally controlled motor device with storage operatively associated with the drive shaft of the vehicle and adapted to draw electrical power from the battery to rotate the drive shaft of the vehicle.

42. The internal combustion engine heat energy recovery system of any one of claims 1 to 41, wherein the working fluid is circulated through the internal combustion engine in heat communication with at least one engine component for the transfer of heat energy from the at least one engine component to the working fluid prior to its entry into the first heat exchanger.

43. The internal combustion engine heat energy recovery system of claim 42, wherein the at least one engine component is a combustion cylinder.

44. The internal combustion engine heat energy recovery system of claim 42, wherein the at least one engine component is engine oil.

45. The internal combustion engine heat energy recovery system of any one of claims 1 to 44, further comprising a recuperator arranged in heat communication, preferably fluid communication, with the working fluid upon its exit from the internal combustion engine for the transfer of heat energy to the working fluid prior to its entry into the first heat exchanger.

46. The internal combustion engine heat energy recovery system of claim 45, wherein the recuperator is also arranged in heat communication, preferably fluid communication, with the expanded working fluid for the transfer of heat energy from the working fluid prior to its entry into the second heat exchanger.

60. The internal combustion engine heat energy recovery system of any one of claims 1 to 60, wherein the working fluid is supercritical at least prior to its entry into the turbine.

2. An internal combustion engine heat energy recovery system, comprising:

a first heat exchanger arranged in heat communication, more preferably fluid communication, with a first heat energy source of an internal combustion engine and with a second heat energy source of the internal combustion engine for the transfer of heat energy from the first heat energy source to the second heat energy source;

an intermediary heat exchanger arranged in heat communication with the second heat energy source heated in the first heat exchanger and with a working fluid of the system for the transfer of heat energy from the second heat energy source to the working fluid of the system;

a turbine arranged in fluid communication with the working fluid heated in the intermediary heat exchanger for the expansion of the working fluid to produce shaft power;

a second heat exchanger arranged in heat communication, more preferably fluid communication, with the expanded working fluid to remove waste heat therefrom and transfer it to an external source such as the atmosphere; and

a first compressor arranged in fluid communication with the working fluid exiting the heat exchanger for increasing the pressure of the cooled working fluid prior to its entry into the intermediary heat exchanger, wherein the working fluid of the system is a substantially supercritical fluid.

47. The internal combustion engine heat energy recovery system of claim 44 or claim 45 when dependent on claim 2, wherein the recuperator is arranged in heat communication, preferably fluid communication, with the working fluid upon its exit from the first compressor for the transfer of heat energy to the working fluid prior to its entry into the intermediary heat exchanger.

48. The internal combustion engine heat energy recovery system of claim 47, wherein the recuperator is also arranged in heat communication, preferably fluid communication, with the expanded working fluid for the transfer of heat energy from the working fluid prior to its entry into the second heat exchanger.

49. There is further disclosed herein an internal combustion engine heat energy recovery system, comprising:

an internal combustion engine heat exchanger arranged in heat communication with at least one component of the internal combustion engine for the transfer of heat energy from the at least one component of the internal combustion engine to a working fluid of the system, a first heat exchanger arranged in heat communication, more preferably fluid communication, with the working fluid heated by the internal combustion heat exchanger and in heat communication, preferably fluid communication, with at least one further heat energy source of the internal combustion engine for the transfer of heat energy from the heat energy source to the working fluid of the system;

a turbine arranged in fluid communication with the working fluid heated in the first heat exchanger for the expansion of the working fluid to produce shaft power;

a recuperator arranged in fluid communication with the expanded working fluid from the turbine to recuperate the heat therein, and further being arranged in fluid communication with the working fluid heated by the internal combustion engine heat exchanger to cool the working fluid prior to its entry into the first heat exchanger;

a second heat exchanger arranged in fluid communication with the working fluid heated in the recuperator for the removal of waste heat therefrom and transfer it to an external source such as the atmosphere; and

a first compressor arranged in fluid communication with the working fluid exiting the second heat exchanger for increasing the pressure of the cooled working fluid prior to its entry into the internal combustion engine heat exchanger, wherein the working fluid of the system is a supercritical fluid.

50. The internal combustion engine heat energy recovery system of claim 49, wherein the internal combustion engine heat exchanger is or includes a conduit arranged in heat communication with the at least one component of the internal combustion engine.

51. The internal combustion engine heat energy recovery system of claim 50, wherein the conduit is arranged to transport the working fluid through the internal combustion engine.

52. The internal combustion engine heat energy recovery system of claim 49, further including a third heat exchanger in fluid communication with the working fluid exiting the first compressor, in which the working fluid passing through the third heat exchanger is in heat communication with ambient air for cooling the working fluid.

53. The internal combustion engine heat energy recovery system of claim 52, further comprising a second compressor in fluid communication with an air supply and a first intercooler arranged for cooling compressed air exiting the second compressor, wherein the cooled compressed air is in heat communication with the working fluid exiting the third heat exchanger for cooling the compressed air prior to its entry into the internal combustion engine.

54. The internal combustion engine heat energy recovery system of any one of claims 49 to 53, wherein the internal combustion engine heat exchanger is located inside the internal combustion engine.

55. The internal combustion engine heat energy recovery system of any one of claims 49 to 54, wherein the at least one engine component is either a combustion cylinder or engine oil.

56. The internal combustion engine heat energy recovery system of any one of claims 49 to 55, wherein the second heat exchanger is arranged to transfer the waste heat from the working fluid to the atmosphere.

57. An internal combustion engine heat energy recovery system, comprising:

a first heat exchanger arranged in heat communication, more preferably fluid communication, with at least one heat energy source of an internal combustion engine and with a working fluid of the system for the transfer of heat energy from the heat energy source to the working fluid of the system;

a turbine arranged in fluid communication with the working fluid heated in the first heat exchanger for the expansion of the working fluid to produce shaft power;

a second heat exchanger arranged in heat communication, more preferably fluid communication, with the expanded working fluid to remove waste heat therefrom and transfer it to the atmosphere; and

a first compressor arranged in fluid communication with the working fluid exiting the heat exchanger for increasing the pressure of the cooled working fluid prior to its entry into the first heat exchanger, wherein the working fluid of the system is a substantially supercritical fluid.

58. An internal combustion engine heat energy recovery system, comprising:

a first heat exchanger arranged in heat communication, more preferably fluid communication, with at least one heat energy source of an internal combustion engine and with a working fluid of the system for the transfer of heat energy from the heat energy source to the working fluid of the system;

a turbine arranged in fluid communication with the working fluid heated in the first heat exchanger for the expansion of the working fluid to produce shaft power;

a second heat exchanger arranged in heat communication, more preferably fluid communication, with the expanded working fluid to remove waste heat therefrom and transfer it to the atmosphere; and

a first pressurising device arranged in fluid communication with the working fluid exiting the heat exchanger for increasing the pressure of the cooled working fluid prior to its entry into the first heat exchanger, wherein the working fluid of the system is a substantially supercritical fluid.

59. The internal combustion engine heat energy recovery system of claim 58, wherein the pressurising device is a heat pump.