Waste heat recovery system with constant power output

• US 7,866,157 B2
• Filed: 05/12/2008
• Issued: 01/11/2011
• Est. Priority Date: 05/12/2008
• Status: Active Grant

• Current Assignee: Cummins Incorporated
• Original Assignee: Cummins Incorporated
• Inventors: Ernst, Timothy C., Nelson, Christopher R.
• Primary Examiner(s): Denion; Thomas E
• Assistant Examiner(s): JETTON, CHRISTOPHER M
• Application Number:
  US12/152,088
• Publication Number:
  US 20090277173A1
• Time in Patent Office: 974 Days
• Field of Search: 60614-624
• US Class Current: 60/618
• 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: F02G 5/02 Profiting from waste heat of exhaust gases

Abstract

A waste heat recovery system for use with an engine. The waste heat recovery system receives heat input from both an exhaust gas recovery system and exhaust gas streams. The system includes a first loop and a second loop. The first loop is configured to receive heat from both the exhaust gas recovery system and the exhaust system as necessary. The second loop receives heat from the first loop and the exhaust gas recovery system. The second loop converts the heat energy into electrical energy through the use of a turbine.

Claims

1. A method for generating power using waste heat from an engine including an exhaust system and an exhaust gas recirculation system comprising the steps of:

transferring heat energy, using a first heat exchanger, from the exhaust gas recirculation system to a liquid flowing through a conduit defining a loop;

transferring heat energy from the exhaust system to the liquid of the loop;

combining the liquid heated by the exhaust system with the heated liquid flowing from said first heat exchanger at a junction in the loop;

transferring heat energy, using a second heat exchanger positioned downstream of said junction, from the exhaust gas recirculation system to the combined liquid heated by the exhaust system and by the exhaust gas recirculation system; and

generating electrical power with a turbine with the heat energy stored in the liquid of the loop.

2. The method for generating power using waste heat as set forth in claim 1 wherein the amount of heat energy transferred into the loop from the exhaust system increases as the amount of energy transferred into the loop from the exhaust gas recirculation system decreases.

3. The method for generating power using waste heat as set forth in claim 1 wherein the amount of heat energy transferred into the loop from the exhaust system decreases as the engine heats up.

4. The method for generating power using waste heat as set forth in claim 1 wherein the exhaust gas recirculation system may be in at least a high flow state and a low flow state and greater heat energy is transferred from the exhaust system into the loop when the exhaust gas recirculation system is in the low flow state than when the exhaust gas recirculation system is in the high flow state.

5. The method for generating power using waste heat as set forth in claim 1 wherein less heat energy is transferred into the liquid of the loop from the exhaust gas system as the engine warms.

6. A system configured to produce electricity from waste heat produced by an engine including:

an exhaust gas recirculation system; and

an exhaust system;

a loop including a conduit, fluid flowing through the conduit, a turbine,

a first heat exchanger to transfer heat energy from the exhaust gas recirculation system into the fluid, a second heat exchanger positioned downstream of said first heat exchanger to transfer heat energy from the exhaust gas recirculation system to the fluid in the loop, a third heat exchanger adapted to transfer heat from the exhaust system into the fluid, a junction positioned upstream of said second heat exchanger and downstream of said first heat exchanger to combine heated fluid flowing from said third heat exchanger with fluid flowing from said first heat exchanger prior to flowing into said second heat exchanger.

7. The system as set forth in claim 6 wherein the loop further includes a valve configured to control the flow of the fluid, the valve being configured to selectively direct a portion of the fluid to the third heat exchanger when the temperature of the fluid drops below a set point.

8. The system as set forth in claim 6 wherein the exhaust system includes a valve configured to allow exhaust gas to bypass the third heat exchanger.

9. The system as set forth in claim 6 wherein the loop further includes a pump configured to propel the fluid.