Abstract: A waste heat recovery (WHR) system that can be utilized in internal combustion engine systems includes at least two circuits, one having a low pressure working fluid and another having a high pressure working fluid. Each circuit can include heat exchangers to allow the working fluid to absorb heat form one or more heat source fluids associated with the engine. The system can also include an expander configured to receive the working fluid from the at least two circuits, and generating mechanical power. The system also can include a condenser, a sub cooler, and at least one working fluid pump to pump the working fluid in the at least two circuits. The cooling system also includes a controller that can receive temperature and pressure values from various locations in the WHR system and control at least the flow rates of the working fluids in the at least two circuits.

Abstract: A waste heat recovery (WHR) system that can be utilized in internal combustion engine systems includes at least two circuits, one having a low pressure working fluid and another having a high pressure working fluid. Each circuit can include heat exchangers to allow the working fluid to absorb heat form one or more heat source fluids associated with the engine. The system can also include an expander configured to receive the working fluid from the at least two circuits, and generating mechanical power. The system also can include a condenser, a sub cooler, and at least one working fluid pump to pump the working fluid in the at least two circuits. The cooling system also includes a controller that can receive temperature and pressure values from various locations in the WHR system and control at least the flow rates of the working fluids in the at least two circuits.

Abstract: A waste heat recovery (WHR) and coolant system with active coolant pressure control includes an engine cooling system, a WHR system, and a coolant pressure control system. A coolant heat exchanger positioned along each of the engine cooling and working fluid circuits, and is structured to transfer heat from the coolant fluid to the working fluid. The coolant pressure control system includes a pressure line operatively coupled to an air brake system and to the coolant tank. A valve is coupled to the pressure line upstream of the coolant tank. A coolant pressure controller is in operative communication with each of the valve, an air pressure sensor, and a coolant temperature sensor. The coolant pressure controller is structured to determine a target coolant pressure based on a coolant temperature and control a valve position of the valve so as to cause the air pressure to approach the target coolant pressure.

Abstract: A power generation system having a combustion engine with a Rankine bottoming cycle, the system including a first flow path for a process fluid and a second flow path for a working fluid, and a heat exchanger arranged along both the first and the second flow paths to transfer waste heat from the process fluid to the working fluid. The heat exchanger includes a first flow conduit being bounded by a first wall section and configured to convey the process fluid, a second flow conduit to convey the working fluid, the second flow conduit being bounded by a second wall section spaced apart from the first wall section to define a gap therebetween, and a thermally conductive structure arranged within the gap and joined to the first and second wall sections to transfer heat therebetween, the gap being fluidly isolated from both the process fluid and the working fluid.

Abstract: An apparatus includes a pump circuit structured to receive pump data indicative of an operating characteristic of a pump feeding a fluid to a waste heat recovery (WHR) system; a flow circuit structured to receive valve position data indicative of a position of a valve downstream of the pump, estimate a flow rate of the fluid exiting the pump, and estimate the flow rate of the fluid exiting the valve; and a pressure circuit structured to receive pressure data indicative of the pressure of the fluid exiting the valve, estimate a change in pressure of the fluid across the WHR system, and determine a pressure of the fluid in a hot section of the WHR system based on the pressure of the fluid exiting the valve and the change in the pressure of the fluid across the WHR system.

Abstract: Integrated cooling systems including a frame configured for mounting to a vehicle chassis in a path of ram air entering an engine compartment of a vehicle, a radiator connected to the frame in the ram air path, a waste heat recovery (WHR) condenser, a recouperator connected to the frame above a ram air path and coupled to the WHR condenser, and a coolant boiler connected to the frame below the ram air path and coupled to the radiator and recouperator are disclosed. Cooling systems configured for use in a WHR system, including an inlet header fixedly disposed on a first end of a condenser, the inlet header fluidly coupled to a heat exchanger to receive the working fluid, and a receiver fixedly disposed on a second end of the condenser opposite the first end, the receiver configured to receive the working fluid from the condenser are also disclosed.

Abstract: An apparatus includes a pump circuit structured to receive pump data indicative of an operating characteristic of a pump feeding a fluid to a waste heat recovery (WHR) system; a flow circuit structured to receive valve position data indicative of a position of a valve downstream of the pump, estimate a flow rate of the fluid exiting the pump, and estimate the flow rate of the fluid exiting the valve; and a pressure circuit structured to receive pressure data indicative of the pressure of the fluid exiting the valve, estimate a change in pressure of the fluid across the WHR system, and determine a pressure of the fluid in a hot section of the WHR system based on the pressure of the fluid exiting the valve and the change in the pressure of the fluid across the WHR system.

Abstract: An apparatus includes a pump circuit structured to receive pump data indicative of an operating characteristic of a pump feeding a fluid to a waste heat recovery (WHR) system; a flow circuit structured to receive valve position data indicative of a position of a valve downstream of the pump, estimate a flow rate of the fluid exiting the pump, and estimate the flow rate of the fluid exiting the valve; and a pressure circuit structured to receive pressure data indicative of the pressure of the fluid exiting the valve, estimate a change in pressure of the fluid across the WHR system, and determine a pressure of the fluid in a hot section of the WHR system based on the pressure of the fluid exiting the valve and the change in the pressure of the fluid across the WHR system.

Abstract: A waste heat recovery (WHR) and coolant system with active coolant pressure control includes an engine cooling system, a WHR system, and a coolant pressure control system. A coolant heat exchanger positioned along each of the engine cooling and working fluid circuits, and is structured to transfer heat from the coolant fluid to the working fluid. The coolant pressure control system includes a pressure line operatively coupled to an air brake system and to the coolant tank. A valve is coupled to the pressure line upstream of the coolant tank. A coolant pressure controller is in operative communication with each of the valve, an air pressure sensor, and a coolant temperature sensor. The coolant pressure controller is structured to determine a target coolant pressure based on a coolant temperature and control a valve position of the valve so as to cause the air pressure to approach the target coolant pressure.

Abstract: A waste heat recovery system includes a Rankine cycle (RC) circuit having a pump, a boiler, an energy converter, and a condenser fluidly coupled via conduits in that order, to provide additional work. The additional work is fed to an input of a gearbox assembly including a capacity for oil by mechanically coupling to the energy converter to a gear assembly. An interface is positioned between the RC circuit and the gearbox assembly to partially restrict movement of oil present in the gear assembly into the RC circuit and partially restrict movement of working fluid present in the RC circuit into the gear assembly. An oil return line is fluidly connected to at least one of the conduits fluidly coupling the RC components to one another and is operable to return to the gear assembly oil that has moved across the interface from the gear assembly to the RC circuit.

Abstract: Integrated cooling systems including a frame configured for mounting to a vehicle chassis in a path of ram air entering an engine compartment of a vehicle, a radiator connected to the frame in the ram air path, a waste heat recovery (WHR) condenser, a recouperator connected to the frame above a ram air path and coupled to the WHR condenser, and a coolant boiler connected to the frame below the ram air path and coupled to the radiator and recouperator are disclosed. Cooling systems configured for use in a WHR system, including an inlet header fixedly disposed on a first end of a condenser, the inlet header fluidly coupled to a heat exchanger to receive the working fluid, and a receiver fixedly disposed on a second end of the condenser opposite the first end, the receiver configured to receive the working fluid from the condenser are also disclosed.

Abstract: An apparatus includes a pump circuit structured to receive pump data indicative of an operating characteristic of a pump feeding a fluid to a waste heat recovery (WHR) system; a flow circuit structured to receive valve position data indicative of a position of a valve downstream of the pump, estimate a flow rate of the fluid exiting the pump, and estimate the flow rate of the fluid exiting the valve; and a pressure circuit structured to receive pressure data indicative of the pressure of the fluid exiting the valve, estimate a change in pressure of the fluid across the WHR system, and determine a pressure of the fluid in a hot section of the WHR system based on the pressure of the fluid exiting the valve and the change in the pressure of the fluid across the WHR system.

Abstract: The disclosure describes a non-condensable gas collection, detection, and removal system for a WHR system that helps to maintain cycle efficiency of the WHR system across the life of an engine system associated with the WHR system. A storage volume is configured to collect non-condensable gas received from the working fluid circuit, and a release valve is configured to selectively release non-condensable gas contained within the storage volume.

Abstract: An engine including a WHR system includes a clutch positioned to engage or disengage a WHR feedpump that moves working fluid through a WHR circuit. The clutch engages or disengages the feedpump under certain operating conditions of the engine and/or the WHR system, and/or at the request of an operator of the engine. Conditions may include cool or cold components, and insufficient working fluid. The operator may also request the clutch be disengaged, such as might be advantageous if the operator detects an operational problem with the WHR system or determines there is an advantage to operating the engine without the WHR system.

Abstract: The disclosure provides a waste heat recovery system with a system and method for calculation of the net output torque from the waste heat recovery system. The calculation uses inputs from existing pressure and speed sensors to create a virtual pump torque sensor and a virtual expander torque sensor, and uses these sensors to provide an accurate net torque output from the WHR system.

Abstract: An apparatus for dithering fuel into an internal combustion engine includes a turbine that is powered by the internal combustion engine and a first fuel injector that injects a first fuel into an air stream to create a fuel/air stream. The apparatus also includes an air/fuel compressor that provides a compressed fuel/air stream to the internal combustion engine. The air/fuel compressor is powered by the turbine, and the air/fuel compressor compresses the fuel/air stream to create the compressed fuel/air stream. Additionally, the apparatus includes a second fuel injector that injects a second fuel into the compressed fuel/air stream prior to the compressed fuel/air stream entering the engine and after the compressed fuel/air stream exits the air/fuel compressor.

Abstract: A power generation system having a combustion engine with a Rankine bottoming cycle, the system including a first flow path for a process fluid and a second flow path for a working fluid, and a heat exchanger arranged along both the first and the second flow paths to transfer waste heat from the process fluid to the working fluid. The heat exchanger includes a first flow conduit being bounded by a first wall section and configured to convey the process fluid, a second flow conduit to convey the working fluid, the second flow conduit being bounded by a second wall section spaced apart from the first wall section to define a gap therebetween, and a thermally conductive structure arranged within the gap and joined to the first and second wall sections to transfer heat therebetween, the gap being fluidly isolated from both the process fluid and the working fluid.

Abstract: An engine including a WHR system includes a clutch positioned to engage or disengage a WHR feedpump that moves working fluid through a WHR circuit. The clutch engages or disengages the feedpump under certain operating conditions of the engine and/or the WHR system, and/or at the request of an operator of the engine. Conditions may include cool or cold components, and insufficient working fluid. The operator may also request the clutch be disengaged, such as might be advantageous if the operator detects an operational problem with the WHR system or determines there is an advantage to operating the engine without the WHR system.

Abstract: The disclosure provides a waste heat recovery system with a system and method for calculation of the net output torque from the waste heat recovery system. The calculation uses inputs from existing pressure and speed sensors to create a virtual pump torque sensor and a virtual expander torque sensor, and uses these sensors to provide an accurate net torque output from the WHR system.

Abstract: The disclosure describes a non-condensable gas collection, detection, and removal system for a WHR system that helps to maintain cycle efficiency of the WHR system across the life of an engine system associated with the WHR system. A storage volume is configured to collect non-condensable gas received from the working fluid circuit, and a release valve is configured to selectively release non-condensable gas contained within the storage volume.