Waste heat recovery system and turbine expander thereof

Abstract

A waste heat recovery system for recovering waste heat of an internal combustion engine includes a turboexpander. The turboexpander includes turbine blades, a shaft coupled to and rotatable by the turbine blades, and a nozzle assembly. The nozzle assembly includes a nozzle block disposed about the shaft and adjacent to the turbine blades, a first nozzle component coupled to the nozzle block, and a second nozzle component coupled to the nozzle block. The first nozzle component defines a first nozzle having a first geometric configuration. The second nozzle component defines a second nozzle having a second geometric configuration different from the first geometric configuration. The waste heat recovery system further includes a flow control device in fluid communication with the turboexpander. The waste heat recovery system further includes a controller in communication with the flow control device.

Description

[0001] This application is a divisional application of the invention patent application entitled "Waste Heat Recovery System and Turbine Expander Thereof", filed on February 27, 2019, with application number 201910144972.0. Technical Field

[0002] This invention generally relates to a waste heat recovery system for recovering waste heat from internal combustion engines. Background Technology

[0003] Internal combustion engines (ICEs) generate thrust and / or power during operation and release heat as a byproduct. In the automotive industry, waste heat recovery systems typically utilize this waste heat to generate electricity, which can then be used to power the electronic components of motor vehicles.

[0004] Conventional waste heat recovery systems include a turbine expander, a flow control device, and a controller. The turbine expander outputs power based on a working fluid. Specifically, in a conventional waste heat recovery system, the turbine expander includes: turbine blades rotatable by the working fluid; a shaft coupled to and rotatable by the turbine blades and extending along a longitudinal axis; and a nozzle assembly for directing the working fluid to the turbine blades to rotate them.

[0005] A conventional nozzle assembly includes a nozzle block, a first nozzle component, and a second nozzle component. The nozzle block is disposed around a shaft and adjacent to a turboexpander. The first nozzle component is integral with the nozzle block to accelerate the working fluid and define a first nozzle, while the second nozzle component is integral with the nozzle block to accelerate the working fluid and define a second nozzle. In a conventional nozzle assembly, the first and second nozzles have the same geometric configuration.

[0006] Conventional waste heat recovery systems utilize the Organic Rankine Cycle (ORC). ORC is named for its use of a high-molecular-weight organic working fluid, whose liquid-to-vapor phase change occurs at temperatures below the water-to-vapor phase change. The working fluid can include at least one of ethanol, methanol, kerosene, gasoline, diesel, propanol, butanol, water, benzene, toluene, methane, ethane, propane, butane, acetone, or liquid hydrogen. The heat from the ICE waste heat heats the working fluid, causing it to undergo a liquid-to-vapor phase change. In the vapor state, the working fluid is more suitable for rotating turbine blades.

[0007] In recent years, there has been a strong desire to improve the efficiency and overall performance of waste heat recovery systems. There has also been a desire to expand the operational scope and improve controllability to help enhance the efficiency and overall performance of waste heat recovery systems. For conventional waste heat recovery systems, the working fluid must flow at appropriate pressure and mass flow rate to rotate the turbine blades.

[0008] However, in conventional waste heat recovery systems where the first and second nozzles have the same geometry, only a narrow window of working fluid pressure and mass flow rate allows the waste heat recovery system to operate. Specifically, the heat generated by the ICE varies based on the ICE's speed and load. Therefore, in certain operating states of the ICE (e.g., startup), the heat generated by the ICE can cause the working fluid pressure and mass flow rate to fall outside the narrow window that allows the waste heat recovery system to operate. When the working fluid is outside this narrow window of pressure and mass flow rate, the working fluid must bypass the turbine expander or the turbine expander must be shut down to prevent working fluid condensation from damaging the turbine blades.

[0009] Furthermore, conventional nozzle assemblies are difficult to manufacture. Specifically, due to the size of the nozzle block, defining the nozzle integrally with the nozzle block in the nozzle assembly requires extensive precision machining, which increases manufacturing time and cost.

[0010] Therefore, there is still a need to provide an improved waste heat recovery system. Summary of the Invention

[0011] A waste heat recovery system for recovering waste heat from an internal combustion engine includes a turboexpander to output power based on a working fluid. The turboexpander includes: turbine blades rotatable by the working fluid; a shaft coupled to and rotatable by the turbine blades and extending along a longitudinal axis; and a nozzle assembly for directing the working fluid to the turbine blades to rotate them. The nozzle assembly includes: a nozzle block disposed around the shaft and adjacent to the turbine blades; a first nozzle component coupled to the nozzle block to accelerate the working fluid; and a second nozzle component coupled to the nozzle block to accelerate the working fluid. The first nozzle component defines a first nozzle having a first geometric configuration. The second nozzle component defines a second nozzle having a second geometric configuration different from the first geometric configuration. The waste heat recovery system also includes a flow control device in fluid communication with the turboexpander to direct the working fluid to at least one of the first and second nozzles or bypass the turboexpander. The waste heat recovery system also includes a controller connected to the flow control device and adapted to control the flow control device to direct the working fluid to at least one of the first and second nozzles or bypass the turboexpander.

[0012] A waste heat recovery system for recovering waste heat from an internal combustion engine includes a turboexpander to output power based on a working fluid. The turboexpander includes: turbine blades rotatable by the working fluid; a shaft coupled to and rotatable by the turbine blades and extending along a longitudinal axis; and a nozzle assembly for directing the working fluid to the turbine blades to rotate them. The nozzle assembly includes a nozzle block disposed around the shaft and adjacent to the turbine blades, wherein the nozzle block defines an orifice. The nozzle assembly also includes a nozzle component removably coupled to the nozzle block such that the nozzle component is selectively disposed in the orifice to accelerate the working fluid. The nozzle component defines a nozzle. The waste heat recovery system further includes a flow control device fluidly in communication with the turboexpander to direct the working fluid to the nozzle or bypass the turboexpander. The waste heat recovery system also includes a controller in communication with the flow control device and adapted to control the flow control device to direct the working fluid to the nozzle or bypass the turboexpander. In the turboexpander described above, at least a portion of the nozzle block may be disposed between the nozzle and the turbine blades.

[0013] Therefore, the waste heat recovery system with first and second nozzles having different geometric configurations allows the working fluid to pass through each of the first and second nozzles at different working fluid pressures and mass flow rates, thereby expanding the operating range of the waste heat recovery system. Moreover, the first and second nozzles provide a series of incremental steps for working fluid pressure and mass flow rate, which allows for greater controllability of the waste heat recovery system. Furthermore, the waste heat recovery system with nozzle components that can be removably coupled to the nozzle block reduces the manufacturing complexity of the waste heat recovery system. Specifically, the nozzles of the nozzle components can be machined independently of the nozzle block, thereby reducing manufacturing time and costs. Attached Figure Description

[0014] Other advantages of the invention will be readily apparent, as these advantages can be better understood by referring to the following detailed description when considered in conjunction with the accompanying drawings, wherein:

[0015] Figure 1 This is a schematic diagram of a waste heat recovery system, which includes a turbine expander, a flow control device, a controller, an evaporator, a condenser, a sensor, and a pump.

[0016] Figure 2 This is a perspective view of a turboexpander;

[0017] Figure 3 yes Figure 2A perspective view of a turboexpander, wherein the turboexpander includes: turbine blades rotatable by a working fluid; a shaft coupled to and rotatable by the turbine blades; and a nozzle assembly for directing the working fluid to the turbine blades to rotate the turbine blades.

[0018] Figure 4 yes Figure 2 A top view of a turbine expander, with the turbine housing removed and the turbine blades and shaft shown in dashed lines;

[0019] Figure 5 yes Figures 2 to 4 A top view of a nozzle assembly, wherein the nozzle assembly includes: a nozzle block; a first nozzle component connected to the nozzle block and defining a first nozzle shown in dashed lines; a second nozzle component connected to the nozzle block and defining a second nozzle shown in dashed lines; a third nozzle component connected to the nozzle block and defining a third nozzle shown in dashed lines; and a fourth nozzle component connected to the nozzle block and defining a fourth nozzle shown in dashed lines.

[0020] Figure 6A It is along Figure 5 A cross-sectional view of the first nozzle component taken from line 6A-6A;

[0021] Figure 6B It is along Figure 5 A cross-sectional view of the second nozzle component taken from line 6B-6B;

[0022] Figure 6C It is along Figure 5 A cross-sectional view of the third nozzle component taken from line 6C-6C;

[0023] Figure 6D It is along Figure 5 A cross-sectional view of the fourth nozzle component taken from the 6D-6D line;

[0024] Figure 7A It is along Figure 6A A cross-sectional view of the first throat of the first nozzle, taken along line 7A-7A in the diagram;

[0025] Figure 7B It is along Figure 6B A cross-sectional view of the second throat of the second nozzle, taken by line 7B-7B in the diagram;

[0026] Figure 7C It is along Figure 6C A cross-sectional view of the third throat of the third nozzle, taken along line 7C-7C;

[0027] Figure 7D It is along Figure 6D A cross-sectional view of the fourth throat of the fourth nozzle, taken by line 7D-7D in the diagram;

[0028] Figure 8 yes Figures 2 to 5 A perspective view of an alternative embodiment of the nozzle assembly, wherein a nozzle block defines a first hole, a second hole, a third hole, and a fourth hole, wherein the first, second, third, and fourth nozzle components are removably coupled to the nozzle block, the first, second, third, and fourth nozzles are shown in dashed lines, and the first, second, third, and fourth nozzle components are respectively disposed in the first, second, third, and fourth holes;

[0029] Figure 9 yes Figure 8 A perspective view of the nozzle assembly, wherein the first, second, third and fourth nozzle components are removed from the first, second, third and fourth holes, respectively;

[0030] Figure 10 yes Figure 2 A perspective view of a turboexpander, which also includes multiple fluid connectors coupled to first, second, third and fourth nozzle components;

[0031] Figure 11 yes Figure 10 A perspective view of a turboexpander, in which multiple fluid-connected connectors are removed from the first, second, third, and fourth nozzle components. Detailed Implementation

[0032] Referring to the accompanying drawings, where the same numbers indicate the same parts in several views, Figure 1 The diagram schematically illustrates a waste heat recovery system 20 for recovering waste heat from an internal combustion engine (ICE). The waste heat recovery system 20 includes a turboexpander 22 for outputting power based on working fluid, a flow control device 24 in fluid communication with the turboexpander 22, and a controller 26 in communication with the flow control device 24.

[0033] refer to Figure 3 The turbine expander 22 includes turbine blades 28 capable of rotating through a working fluid. For example... Figure 2 As best shown, the turboexpander 22 also includes a shaft 30 coupled to and rotatable by the turbine blades 28. The shaft 30 extends along a longitudinal axis A. The working fluid causes the turbine blades 28 to rotate about the longitudinal axis A of the shaft 30.

[0034] Continue to refer to Figure 2The turbine expander 22 also includes a nozzle assembly 32 to direct working fluid to the turbine blades 28 to rotate the turbine blades 28. The nozzle assembly 32 includes a nozzle block 34 disposed around the shaft 30 and adjacent to the turbine blades 28. Typically, the nozzle block 34 has an annular configuration. However, the nozzle block 34 can have any configuration suitable for directing working fluid to the turbine blades 28. The nozzle block 34 may have a first face 36 facing the turbine blades 28 (e.g., ...). Figure 4 (best shown in the middle) and the second side 38 facing the first side 36 (as shown in the middle) Figure 2 (best shown in the middle).

[0035] Continue to refer to Figure 2 The nozzle assembly 32 also includes a nozzle component 40, which is coupled to the nozzle block 34 to accelerate the working fluid. For example... Figure 5 and 6A As shown, nozzle component 40 defines nozzle 42. In one embodiment, nozzle component 40 is integral with nozzle block 34 (i.e., one-piece), as... Figure 2 As shown in the diagram. In another embodiment, as described in further detail below, the nozzle component 40 may be separate from the nozzle block 34 (i.e., not integral).

[0036] Nozzle 42 has a geometric configuration. This geometric configuration can be a converging configuration, a diverging configuration, or a delaval (converging-diverging) configuration. Typically, the geometric configuration is as follows: Figure 5 and 6A The Delaware configuration shown.

[0037] like Figure 6A As best shown, when the geometry of nozzle 42 is a Delaware configuration, nozzle 42 may have a working fluid inlet 44, a converging portion 46, a diverging portion 48, a throat 50 separating the converging portion 46 and the diverging portion 48, and a working fluid outlet 52. When present, the converging portion 46 extends from the working fluid inlet 44 to the throat 50. With the converging portion 46 present, the cross-sectional area of ​​nozzle 42 gradually decreases from the working fluid inlet 44 to the throat 50. With the diverging portion 48 present, it extends from the throat 50 to the working fluid outlet 52. With the diverging portion 48 present, the cross-sectional area of ​​nozzle 42 gradually increases from the throat 50 to the working fluid outlet 52. With the throat 50 present, the throat 50 is the location of the minimum cross-sectional area of ​​nozzle 42. In the context of this invention, the minimum cross-sectional area of ​​nozzle 42 is referred to as the throat cross-sectional area 54, as... Figure 7A It is best shown in the middle.

[0038] The working fluid is delivered to the throat 50 through the converging portion 46 of the nozzle 42. If the working fluid has suitable pressure and mass flow rate, the working fluid velocity is suppressed at the throat 50. Whether the working fluid has suitable pressure and mass flow rate for suppressing the working fluid velocity at the throat 50 is based on the throat cross-sectional area 54. The working fluid then expands in the diverging portion 48, causing the working fluid velocity to increase to supersonic speeds. In this way, the nozzle 42 accelerates the working fluid to supersonic speeds.

[0039] As described above, the nozzle component 40 can be integrally formed with the nozzle block 34. In other embodiments, the nozzle component 40 can be fixed to the nozzle block 34, for example, by welding. Figure 8 and 9 As shown, the nozzle component 40 can be removably coupled to the nozzle block 34. When the nozzle component 40 is removably coupled to the nozzle block 34, the nozzle block 34 can define an orifice 56 to selectively receive the nozzle component 40. In this way, the nozzle component 40 can be selectively disposed in the orifice 56. Advantageously, when the nozzle component 40 is removably coupled to the nozzle block 34, the manufacturing complexity of the waste heat recovery system 20 is reduced. Specifically, the nozzle 42 of the nozzle component 40 can be machined and / or cast independently of the nozzle block 34, thereby reducing manufacturing time and manufacturing costs. Due to the interchangeability of the nozzle component 40, the removably coupled nozzle component 40 also allows for greater customizability of the waste heat recovery system 20.

[0040] When the nozzle component 40 is removably coupled to the nozzle block 34, the nozzle component may include threads. The nozzle block 34 may also include threads, allowing the nozzle component to be removably coupled to the nozzle block 34. In other embodiments, the nozzle component 40 may be removably coupled to the nozzle block 34 via an interference fit or a transition fit.

[0041] In some embodiments, when the nozzle component 40 is removably coupled to the nozzle block 34, at least a portion of the nozzle block 34 is disposed between the nozzle 42 and the turbine blade 28, such as Figure 8 and 9 As shown in the diagram. In other embodiments, the nozzle block 34 is entirely disposed between the nozzle 42 and the turbine blade 28. In some embodiments, no part of the nozzle block 34 is disposed between the nozzle 42 and the turbine blade 28.

[0042] Nozzle component 40 may also be defined as a first nozzle component 40, and nozzle 42 may also be defined as a first nozzle 42. Furthermore, each portion of the nozzle 42 may be further defined as a first portion (e.g., a first throat 50, a first throat cross-sectional area 54, etc.).

[0043] refer to Figure 2The nozzle assembly 32 may further include a second nozzle component 58, which is coupled to the nozzle block 34 to accelerate the working fluid. For example... Figure 5 and 6B As shown, when present, the second nozzle component 58 defines the nozzle 60. In such a case... Figure 2 In one embodiment best illustrated, the second nozzle component 58 is integral with the nozzle block 34 (i.e., one-piece). In another embodiment, as described in further detail below, the second nozzle component 58 may be separate from the nozzle block 34 (i.e., not integral).

[0044] The second nozzle 60 has a second geometric configuration. This second geometric configuration can be a converging configuration, a diverging configuration, or a delaval (converging-diverging) configuration. Typically, the second geometric configuration is as follows: Figure 5 and 6B The Delaware configuration is shown in the diagram. When the second geometry is a Delaware configuration, the second nozzle 60 may have a second working fluid inlet 62, a second converging portion 64, a second diverging portion 66, a second throat 68 separating the second converging portion 64 and the second diverging portion 66, and a second working fluid outlet 70. Figure 7B As best shown, the minimum cross-sectional area of ​​the second nozzle 60 is referred to as the second throat cross-sectional area 72. It should be understood that the description of the first working fluid inlet 44, the first converging portion 46, the first diverging portion 48, the first throat 50, and the first working fluid outlet 52 also applies to the second working fluid inlet 62, the second converging portion 64, the second diverging portion 66, the second throat 68, and the second working fluid outlet 70.

[0045] In one embodiment, the second geometry of the second nozzle 60 (when present) differs from the first geometry of the first nozzle 42. In some embodiments, the first and second geometries can be different types of configurations. For example, the first geometry can be a converging configuration, while the second geometry can be a delaval configuration. In other embodiments, such as Figure 5 As shown, the first and second geometric configurations can be of the same type but have corresponding parts that differ from each other. For example, when the first and second geometric configurations are Delaware configurations, at least one of the first working fluid inlet 44, the first converging portion 46, the first throat 50, the first diverging portion 48, and the first working fluid outlet 52 of the first nozzle 42 differs from the corresponding second working fluid inlet 62, the second converging portion 64, the second throat 68, the second diverging portion 66, and the second working fluid outlet 70 of the second nozzle 60.

[0046] In some embodiments, when the first and second geometric configurations are delaval configurations, the cross-sectional area 72 of the second throat differs from the cross-sectional area 54 of the first throat, such as... Figure 7A and7B As shown in the diagram. As described above, whether the velocity of the working fluid is suppressed at the first throat 50 and the second throat 68 is determined by the cross-sectional area 54 of the first throat and the cross-sectional area 72 of the second throat, as well as the working fluid pressure and mass flow rate. Because the cross-sectional areas 54 and 72 of the first throat are different, the working fluid pressure and mass flow rate can be adapted to one of the first nozzle 42 and the second nozzle 60 to accelerate the working fluid to supersonic speeds, but not to the other of the first nozzle 42 and the second nozzle 60. Furthermore, during ICE operation, the heat recovered by the waste heat recovery system 20 can change the working fluid pressure and mass flow rate, such that both the first nozzle 42 and the second nozzle 60 can accelerate the working fluid to supersonic speeds. In this way, the first nozzle 42 and the second nozzle 60 extend the operating range of the waste heat recovery system 20. Specifically, the first nozzle 42 and the second nozzle 60 extend the range of working fluid mass flow rates that the waste heat recovery system 20 can operate at a specific working fluid pressure. This advantageously allows the waste heat recovery system 20 to maintain maximum cycle efficiency and power output over a wider range of ICE operating conditions, as described in further detail below.

[0047] like Figure 2 As shown and as described above, the second nozzle component 58 can be integrally formed with the nozzle block 34. In other embodiments, the second nozzle component 58 can be fixed to the nozzle block 34, for example, by welding. Figure 8 and 9 As shown, in yet another embodiment, the second nozzle component 58 is removably coupled to the nozzle block 34. When the second nozzle component 58 is removably coupled to the nozzle block 34, the nozzle block may define a second orifice 74 to selectively receive the second nozzle component 58. In this way, the second nozzle component 58 can be selectively disposed in the second orifice 74.

[0048] When the second nozzle component 58 is removably coupled to the nozzle block 34, the second nozzle component may include threads. The nozzle block 34 may also include threads, allowing the second nozzle component 58 to be removably coupled to the nozzle block 34. In other embodiments, the second nozzle component 58 may be removably coupled to the nozzle block 34 via an interference fit or a transition fit.

[0049] In some embodiments, when the second nozzle component 58 is removably coupled to the nozzle block 34, at least a portion of the nozzle block 34 is disposed between the second nozzle 60 and the turbine blade 28, such as Figure 8 and 9 As shown in the diagram. In other embodiments, the nozzle block 34 is entirely disposed between the second nozzle 60 and the turbine blade 28. In some embodiments, no part of the nozzle block 34 is disposed between the second nozzle 60 and the turbine blade 28.

[0050] In some embodiments, the first nozzle component 42 and the second nozzle component 60 may be circumferentially spaced apart about a longitudinal axis A. In other embodiments, the first nozzle component 42 and the second nozzle component 60 may be equidistant and circumferentially spaced apart about a longitudinal axis A.

[0051] Refer again Figure 2 The nozzle assembly 32 may further include a third nozzle component 76 coupled to the nozzle block 34 to accelerate the working fluid. When present, the third nozzle component 76 defines a third nozzle 78. Figure 2 In one embodiment best illustrated, the third nozzle component 76 is integral with the nozzle block 34 (i.e., one-piece). In another embodiment, as described in further detail below, the third nozzle component 76 may be separate from the nozzle block 34 (i.e., not integral).

[0052] The third nozzle 78 has a third geometric configuration. This third geometric configuration can be a converging configuration, a diverging configuration, or a delaval (converging-diverging) configuration. Typically, the third geometric configuration is as follows: Figure 5 and 6C The delaval configuration is shown in the diagram. When the third geometry is a delaval configuration, the third nozzle 78 may have a third working fluid inlet 80, a third converging portion 82, a third diverging portion 84, a third throat 86 separating the third converging portion 82 and the third diverging portion 84, and a third working fluid outlet 88. Figure 7C As shown, the minimum cross-sectional area of ​​the third nozzle 78 is referred to as the third throat cross-sectional area 90. It should be understood that the description of the first working fluid inlet 44, the first converging portion 46, the first diverging portion 48, the first throat 50, and the first working fluid outlet 52 also applies to the third working fluid inlet 80, the third converging portion 82, the third diverging portion 84, the third throat 86, and the third working fluid outlet 88.

[0053] When present, the third geometry of the third nozzle 78 differs from at least one of the first and second geometries of the first nozzle 42 and the second nozzle 60. In some embodiments, the third geometry may be a configuration of a different type from at least one of the first and second geometries. For example, the first geometry may be a converging configuration, the second geometry may be a delaval configuration, and the third geometry may be a delaval configuration. In other embodiments, such as Figure 5As shown, the first, second, and third geometric configurations can be of the same type but have corresponding parts that differ from each other. For example, when the first, second, and third geometric configurations are Delaware configurations, at least one of the third working fluid inlet 80, third converging portion 82, third diverging portion 84, third throat 86, third diverging portion 84, and third working fluid outlet 88 of the third nozzle 78 differs from the corresponding first working fluid inlet 44, first converging portion 46, first diverging portion 48, first throat 50, and first working fluid outlet 52 of the first nozzle 42 and / or the second working fluid inlet 62, second converging portion 64, second diverging portion 66, second throat 68, and second working fluid outlet 70 of the second nozzle 60.

[0054] In some embodiments, when the first, second, and third geometric configurations are a delaval configuration, the cross-sectional area 90 of the third throat is different from at least one of the cross-sectional area 54 of the first throat and the cross-sectional area 72 of the second throat. In other embodiments, when the first, second, and third geometric configurations are a delaval configuration, the cross-sectional areas 54 of the first throat, 72 of the second throat, and 90 of the third throat are different from each other, such as... Figures 7A to 7C As shown in the image.

[0055] When the nozzles have different geometric configurations, the number of nozzle combinations that the working fluid can pass through before the turbine blades 28 rotate is 2n-1, where n is the number of nozzles included in the nozzle assembly 32.

[0056] When the first, second, and third geometries differ from each other, the working fluid passes through seven different combinations of the first nozzle 42, second nozzle 60, and third nozzle 78 based on the working fluid pressure and mass flow rate before the turbine blade 28 rotates. Specifically, the working fluid may pass through the first nozzle 42 alone, through the second nozzle 60 alone, through the third nozzle 78 alone, through the first nozzle 42 and the second nozzle 60 alone, through the first nozzle 42 and the third nozzle 78 alone, through the second nozzle 60 and the third nozzle 78 alone, and through the first nozzle 42, the second nozzle 60, and the third nozzle 78.

[0057] When the first, second, and third geometries are Delaware configurations and the first cross-sectional area 54, the second cross-sectional area 72, and the third throat cross-sectional area 90 are different from each other, whether the velocity of the working fluid is suppressed at the first throat 50, the second throat 68, and the third throat 86 is determined by the first cross-sectional area 54, the second cross-sectional area 72, and the third throat cross-sectional area 90, as well as the working fluid pressure and mass flow rate. Because the first cross-sectional area 54, the second cross-sectional area 72, and the third throat cross-sectional area 90 are different, the working fluid pressure and mass flow rate can be adapted to one of the first nozzle 42, the second nozzle 60, and the third nozzle 78 to accelerate the working fluid to supersonic speeds, but not to the others. Furthermore, during ICE operation, the heat recovered by the waste heat recovery system 20 can change the working fluid pressure and mass flow rate, allowing different combinations of the first nozzle 42, the second nozzle 60, and the third nozzle 78 to accelerate the working fluid to supersonic speeds. In this way, the first nozzle 42, the second nozzle 60, and the third nozzle 78 extend the operating range of the waste heat recovery system 20. Specifically, the first nozzle 42, the second nozzle 60, and the third nozzle 78 extend the range of working fluid mass flow rates that the waste heat recovery system 20 can operate at specific working fluid pressures. This advantageously allows the waste heat recovery system 20 to maintain maximum cycle efficiency and power output over a wider range of ICE operating conditions, as described in further detail below.

[0058] like Figure 2 As shown and as described above, the third nozzle component 76 can be integrally integrated with the nozzle block 34. In other embodiments, the third nozzle component 76 can be fixed to the nozzle block 34, for example, by welding. Figure 8 and 9 As shown, in another embodiment, the third nozzle component 76 is removably coupled to the nozzle block 34. When the third nozzle component 76 is removably coupled to the nozzle block 34, the nozzle block can define a third orifice 92 to selectively receive the third nozzle component 76. In this way, the third nozzle component 76 can be selectively disposed in the third orifice 92.

[0059] When the third nozzle component 76 is removably coupled to the nozzle block 34, the third nozzle component 76 may include threads. The nozzle block 34 may also include threads, allowing the third nozzle component 76 to be removably coupled to the nozzle block 34. In other embodiments, the third nozzle component 76 may be removably coupled to the nozzle block 34 via an interference fit or a transition fit.

[0060] In some embodiments, when the third nozzle component 76 is removably coupled to the nozzle block 34, at least a portion of the nozzle block 34 is disposed between the third nozzle 78 and the turbine blade 28, such as Figure 8 and 9 As shown in the diagram. In other embodiments, the nozzle block 34 is entirely disposed between the third nozzle 78 and the turbine blade 28. In some embodiments, no part of the nozzle block 34 is disposed between the third nozzle 78 and the turbine blade 28.

[0061] In some embodiments, the first nozzle component 40, the second nozzle component 58, and the third nozzle component 76 may be circumferentially spaced around a longitudinal axis A. In other embodiments, the first nozzle component 40, the second nozzle component 58, and the third nozzle component 76 may be equidistantly and circumferentially spaced around a longitudinal axis A.

[0062] Refer again Figure 2 The nozzle assembly 32 may further include a fourth nozzle component 94 coupled to the nozzle block 34 to accelerate the working fluid. When present, the fourth nozzle component 94 defines a fourth nozzle 96. Figure 2 In one embodiment best illustrated, the fourth nozzle component 94 is integral with the nozzle block 34 (i.e., one-piece). In another embodiment, as described in further detail below, the fourth nozzle component 94 may be separate from the nozzle block 34 (i.e., not integral).

[0063] The fourth nozzle 96 has a fourth geometric configuration. This fourth geometric configuration can be a converging configuration, a diverging configuration, or a delaval (converging-diverging) configuration. Typically, the fourth geometric configuration is as follows: Figure 5 and 6D The Delaware configuration is shown in the diagram. When the fourth geometry is a Delaware configuration, the fourth nozzle 96 may have a fourth working fluid inlet 98, a fourth converging portion 100, a fourth diverging portion 102, a fourth throat 104 separating the fourth converging portion 100 and the fourth diverging portion 102, and a fourth working fluid outlet 106. Figure 7C As shown, the minimum cross-sectional area of ​​the fourth nozzle 96 is referred to as the fourth throat cross-sectional area 108. It should be understood that the description of the first working fluid inlet 44, the first converging portion 46, the first diverging portion 48, the first throat 50, and the first working fluid outlet 52 also applies to the fourth working fluid inlet 98, the fourth converging portion 100, the fourth diverging portion 102, the fourth throat 104, and the fourth working fluid outlet 106.

[0064] When present, the fourth geometric configuration of the fourth nozzle 96 differs from at least one of the first, second, and third geometric configurations of the first nozzle 42, the second nozzle 60, and the third nozzle 78. In some embodiments, the fourth geometric configuration may be a configuration of a different type from at least one of the first, second, and third geometric configurations. For example, the first geometric configuration may be a converging configuration, the second geometric configuration may be a delaval configuration, the third geometric configuration may be a delaval configuration, and the fourth geometric configuration may be a diverging configuration. In other embodiments, such as Figure 5 As shown, the first, second, third, and fourth geometric configurations can be of the same type but have corresponding parts that differ from each other. For example, when the first, second, third, and fourth geometric configurations are Delaware configurations, at least one of the fourth working fluid inlet 98, fourth converging portion 100, fourth diverging portion 102, fourth throat 104, and fourth working fluid outlet 106 of the fourth nozzle 96 is different from the corresponding first working fluid inlet 44, first converging portion 46, first diverging portion 48, first throat 50, and first working fluid outlet 52 of the first nozzle 42, the second working fluid inlet 62, second converging portion 64, second diverging portion 66, second throat 68, and second working fluid outlet 70 of the second nozzle 60, and / or the third working fluid inlet 80, third converging portion 82, third diverging portion 84, third throat 86, and third working fluid outlet 88 of the third nozzle 78.

[0065] In some embodiments, when the first, second, third, and fourth geometric configurations are a Delaware configuration, the cross-sectional area 108 of the fourth throat is different from at least one of the cross-sectional areas 54, 72, and 90 of the first throat. In other embodiments, when the first, second, third, and fourth geometric configurations are a Delaware configuration, the cross-sectional areas 54, 72, 90, and 108 of the first throat are different from each other, such as... Figures 7A to 7D As shown in the image.

[0066] When the first, second, third, and fourth geometries are different from each other, the working fluid passes through fifteen different combinations of the first nozzle 42, the second nozzle 60, the third nozzle 78, and the fourth nozzle 96 based on the working fluid pressure and mass flow rate before the turbine blade 28 rotates. Specifically, the working fluid can pass through the first nozzle 42 alone, the second nozzle 60 alone, the third nozzle 78 alone, the fourth nozzle 96 alone, the first nozzle 42 and the second nozzle 60 alone, the first nozzle 42 and the third nozzle 78 alone, the first nozzle 42 and the fourth nozzle 96 alone, the second nozzle 60 and the third nozzle 78 alone, the second nozzle 60 and the fourth nozzle 96 alone, the third nozzle 78 and the fourth nozzle 96 alone, the first nozzle 42, the second nozzle 60 and the third nozzle 78 alone, the first nozzle 42, the second nozzle 60 and the fourth nozzle 96 alone, the first nozzle 42, the third nozzle 78 and the fourth nozzle 96 alone, the second nozzle 60, the third nozzle 78 and the fourth nozzle 96 alone, and the first nozzle 42, the second nozzle 60, the third nozzle 78 and the fourth nozzle 96 alone.

[0067] When the first, second, third, and fourth geometric configurations are Delaware configurations and the first cross-sectional area 54, the second cross-sectional area 72, the third throat cross-sectional area 90, and the fourth throat cross-sectional area 108 are different from each other, whether the velocity of the working fluid is suppressed at the first throat 50, the second throat 68, the third throat 86, and the fourth throat 104 is determined by the first cross-sectional area 54, the second cross-sectional area 72, the third throat cross-sectional area 90, and the fourth throat cross-sectional area 108, as well as the working fluid pressure and mass flow rate. Because the first cross-sectional area 54, the second cross-sectional area 72, the third throat cross-sectional area 90, and the fourth throat cross-sectional area 108 are different, the working fluid pressure and mass flow rate can be adapted to one of the first nozzle 54, the second nozzle 72, the third nozzle 90, and the fourth nozzle 108 to accelerate the working fluid to supersonic speeds, but not to the others of the first nozzle 54, the second nozzle 72, the third nozzle 90, and the fourth nozzle 108. Furthermore, during ICE operation, the heat recovered by the waste heat recovery system 20 can alter the working fluid pressure and mass flow rate, allowing different combinations of the first nozzle 42, second nozzle 60, third nozzle 78, and fourth nozzle 96 to accelerate the working fluid to supersonic speeds. In this way, the first nozzle 42, second nozzle 60, third nozzle 78, and fourth nozzle 96 extend the operating range of the waste heat recovery system 20. Specifically, the first nozzle 42, second nozzle 60, third nozzle 78, and fourth nozzle 96 extend the range of working fluid mass flow rates that the waste heat recovery system 20 can operate at specific working fluid pressures. This advantageously allows the waste heat recovery system 20 to maintain maximum cycle efficiency and power output over a wider range of ICE operating conditions, as described in further detail below.

[0068] like Figure 2 As shown and as described above, the fourth nozzle component 94 can be integrally integrated with the nozzle block 34. In other embodiments, the fourth nozzle component 94 can be fixed to the nozzle block 34, for example, by welding. Figure 8 and 9 As shown, in another embodiment, the third nozzle component 76 is removably coupled to the nozzle block 34. When the fourth nozzle component 94 is removably coupled to the nozzle block 34, the nozzle block 34 may define a fourth orifice 110 to selectively receive the third nozzle component 76. In this way, the fourth nozzle component 94 can be selectively disposed in the fourth orifice 110.

[0069] When the fourth nozzle component 94 is removably coupled to the nozzle block 34, the fourth nozzle component 94 may include threads. The nozzle block 34 may also include threads, allowing the fourth nozzle component 94 to be removably coupled to the nozzle block 34. In other embodiments, the fourth nozzle component 94 may be removably coupled to the nozzle block 34 via an interference fit or a transition fit.

[0070] In some embodiments, when the fourth nozzle component 94 is removably coupled to the nozzle block 34, at least a portion of the nozzle block 34 is disposed between the fourth nozzle 96 and the turbine blade 28, such as Figure 8 and 9 As shown in the diagram. In other embodiments, the nozzle block 34 is entirely disposed between the fourth nozzle 96 and the turbine blade 28. In some embodiments, no part of the nozzle block 34 is disposed between the fourth nozzle 96 and the turbine blade 28.

[0071] In some embodiments, the first nozzle component 40, the second nozzle component 58, the third nozzle component 76, and the fourth nozzle component 94 may be circumferentially spaced around the longitudinal axis A. Figure 4 In other embodiments shown, the first nozzle component 40, the second nozzle component 58, the third nozzle component 76, and the fourth nozzle component 94 may be equidistantly and circumferentially spaced around the longitudinal axis A.

[0072] It should be understood that the nozzle assembly 32 may also include any number of additional nozzle components, and the description of the first nozzle component 40 applies to any additional nozzle component. It should be further understood that any geometric configuration of any nozzle defined by an additional nozzle component will differ from that of at least one nozzle included in the nozzle assembly. In this way, the operational range of the waste heat recovery system 20 can be further extended by including additional nozzle components beyond the first nozzle component 40, second nozzle component 58, third nozzle component 76, and / or fourth nozzle component 94 described herein. For example, the nozzle assembly 32 may include five, six, seven, or eight nozzle components. However, it should be understood that the nozzle assembly 32 may have more than eight nozzle components.

[0073] like Figure 2 and 3 As shown, the turbine expander 22 may include a turbine housing 112. When the turbine housing 112 is present, the turbine blades 28 may be disposed within the turbine housing 112.

[0074] Refer again Figure 1 The waste heat recovery system 20 includes a flow control device 24 in fluid communication with the turboexpander 22 to direct the working fluid to or around at least one of the first nozzle 42, second nozzle 60, third nozzle 78, and / or fourth nozzle 96 included in the turboexpander 22. The flow control device 24 may be a valve or any other suitable working fluid flow control device. The flow control device 24 is typically located upstream of the turboexpander 22.

[0075] In some embodiments, the flow control device 24 may include a plurality of valves corresponding to each nozzle included in the turboexpander 22. For example, if the turboexpander 22 includes two nozzles, the flow control device 24 includes two valves. Each valve is movable between an open position in which working fluid can flow to the corresponding nozzle and a closed position in which working fluid flow to the corresponding nozzle is restricted. When the flow control device 24 includes a plurality of valves corresponding to each nozzle included in the turboexpander, the flow control device 24 may also include a bypass valve that allows working fluid to bypass the turboexpander 22. In other embodiments, the flow control device may include a switching valve adapted to selectively direct working fluid to one or more nozzles included in the turboexpander 22, or to bypass the turboexpander 22. It should be understood that any valve of the flow control device 24 may be movable between a closed position, an open position, and an intermediate position in which the flow rate of the working fluid is metered.

[0076] Continue to refer to Figure 1 The waste heat recovery system 20 includes a controller 26 which is in communication with the flow control device 24 and is adapted to control the flow control device 24 to direct the working fluid to at least one of the first nozzle 42, the second nozzle 60, the third nozzle 78 and / or the fourth nozzle 96 included in the turboexpander 22 or to bypass the turboexpander 22.

[0077] Controller 26 may include one or more processors or microprocessors to process instructions stored in memory to control the operation of flow control device 24. Such instructions may be any of the functions, algorithms, or techniques described herein that are executed by controller 26. Alternatively or additionally, controller 26 may include one or more microcontrollers, field-programmable gate arrays, systems-on-a-chip, discrete circuitry, and / or other suitable hardware, software, or firmware capable of performing the functions described herein.

[0078] Typically, the working fluid is an organic high-molecular-weight working fluid, and its liquid-vapor phase change occurs at a temperature below that of the water-vapor phase change. The working fluid may include at least one of ethanol, methanol, kerosene, gasoline, diesel, propanol, butanol, water, benzene, toluene, methane, ethane, propane, butane, acetone, or liquid hydrogen. During operation of the waste heat recovery system, the working fluid is in either a liquid or vapor state. In its vapor state, the working fluid is more suitable for rotating turbine blades.

[0079] like Figure 1As shown, the waste heat recovery system 20 may further include an evaporator 114 in fluid communication with the flow control device 24 and the turbine expander 22. The evaporator 114 transfers the heat from the ICE waste heat to the working fluid, thereby changing the working fluid from a liquid state to a vapor state. When present, the evaporator 114 is located upstream of the flow control device 24.

[0080] The waste heat recovery system 20 may further include a condenser 116 in fluid communication with the turbine expander 22 and the flow control device 24. After the working fluid passes through the turbine expander 22, the condenser 116 condenses the working fluid from a vapor state to a liquid state. The condenser 116 is located downstream of the turbine expander 22. In some embodiments, when the waste heat recovery system 20 includes an evaporator 114, the condenser 116 is located downstream of the turbine expander 22 and upstream of the evaporator 114.

[0081] The waste heat recovery system 20 may also include at least one sensor 118 communicating with the controller 26. The at least one sensor 118 is adapted to detect the characteristics of the working fluid. When present, the at least one sensor 118 is positioned upstream of the flow control device 24 and the turbine expander 22, such that the at least one sensor 118 can detect the characteristics of the working fluid before it passes through the flow control device 24. Figure 1 As shown, when the evaporator 114 is included in the waste heat recovery system 20, at least one sensor 118 is positioned upstream of the flow control device 24 and downstream of the evaporator 114. However, the at least one sensor 118 may be positioned upstream of the evaporator 114 or at any other location suitable for detecting the characteristics of the working fluid. The at least one sensor 118 is also adapted to send a signal to the controller 26 indicating the characteristics of the working fluid detected by the at least one sensor 118. The characteristics of the working fluid detected by the at least one sensor 118 may be working fluid pressure, working fluid mass flow rate, working fluid temperature, working fluid mass, and combinations thereof. In some embodiments, the at least one sensor 118 detects the working fluid temperature and the working fluid pressure.

[0082] In some embodiments, at least one sensor 118 may be two sensors. When at least one sensor 118 is two sensors, each sensor may detect one characteristic of the working fluid. Alternatively, each sensor may detect a combination of the characteristics of the working fluid. In some embodiments, one sensor detects the working fluid temperature, while the other sensor detects the working fluid pressure.

[0083] To ensure maximum cycle efficiency and power output of the waste heat recovery system 20, the combination of the working fluid passing through the first nozzle 42, the second nozzle 60, the third nozzle 78, and / or the fourth nozzle 96 before the turbine blades 28 rotate is based on the working fluid pressure and the working fluid mass flow rate. As described above, the heat discarded by the ICE is recovered by the waste heat recovery system 20 to heat the working fluid, causing the working fluid to undergo a liquid-vapor phase change. The heat discarded by the ICE varies based on the ICE speed and load (i.e., operating state). Therefore, under certain operating states of the ICE (e.g., start-up, acceleration, etc.), to maintain maximum cycle efficiency and power output of the waste heat recovery system 20, the heat discarded by the ICE and recovered by the waste heat recovery system 20 may cause the working fluid pressure to be unsuitable for one or more of the first nozzle 42, the second nozzle 60, the third nozzle 78, and / or the fourth nozzle 96. As described below, at least one sensor 118 is connected to the controller 26 to direct fluid to at least one of the first nozzle 42, the second nozzle 60, the third nozzle 78 and / or the fourth nozzle 96 included in the turboexpander 22 to ensure maximum cycle efficiency and power output of the waste heat recovery system 20 in a wider range of operating conditions of the ICE.

[0084] When at least one sensor 118 is included in the waste heat recovery system 20, the controller 26 may be adapted to control the flow control device 24 to direct the working fluid to one of the first nozzle 42, second nozzle 60, third nozzle 78, and / or fourth nozzle 96 included in the turboexpander 22, or bypass the turboexpander 22, based on the characteristics of the working fluid detected by the at least one sensor 118. In one embodiment, when the controller 26 receives a signal indicating the characteristics of the working fluid detected by the at least one sensor 118, the controller 26 may compare the detected characteristics of the working fluid with a threshold corresponding to the geometric configuration of each of the first nozzle 42, second nozzle 60, third nozzle 78, and / or fourth nozzle 96 included in the turboexpander. After comparing the detected characteristics of the working fluid with the threshold, the controller then controls the flow control device 24 to direct the working fluid to each of the first nozzle 42, second nozzle 60, third nozzle 78, and / or fourth nozzle 96 where the detected characteristics of the working fluid exceed the corresponding threshold. If the controller 26 determines that the detected characteristics of the working fluid do not exceed a corresponding threshold, the controller 26 controls the flow control device 24 to guide the working fluid around the turbine expander 22. In this way, the different geometric configurations of the first nozzle 42, the second nozzle 60, the third nozzle 78, and / or the fourth nozzle 96 advantageously extend the operating range of the waste heat recovery system 20 by accelerating the working fluid to supersonic speeds over a wider range of working fluid pressures, mass flow rates, temperatures, etc. Furthermore, due to the variations in working fluid pressure and / or mass flow rate during ICE operation, the waste heat recovery system 20 advantageously allows for incremental increases in the working fluid flow rate to the turbine blades 28.

[0085] For example, during ICE startup, the working fluid mass flow rate can be low to ensure that the heat wasted by the ICE is transferred to the working fluid to the maximum extent. To ensure maximum cycle efficiency and power output of the waste heat recovery system 20, the working fluid pressure is typically higher than when the engine is in other operating conditions (such as steady-state operation). Based on the higher working fluid pressure, the controller 26 controls the flow control device 24 to direct the working fluid to at least one of the nozzles with the smaller throat cross-sectional area among the first nozzle 42, the second nozzle 60, the third nozzle 78, and / or the fourth nozzle 96.

[0086] In another example, during acceleration, the heat generated by the ICE fluctuates continuously. To ensure maximum cycle efficiency and power output of the waste heat recovery system 20, the controller 26 can control the flow control device 24 to direct the working fluid to one, two, three, and / or four of the following nozzles: first nozzle 42, second nozzle 60, third nozzle 78, and / or fourth nozzle 96, such that the working fluid pressure remains relatively constant despite the fluctuations in the heat generated by the ICE. In other words, the number of nozzles to which the working fluid is directed can vary with the changes in the heat generated by the ICE.

[0087] In some embodiments, at least one sensor 118 may be adapted to detect at least one of the working fluid temperature and working fluid pressure upstream of the turboexpander 22. The controller 26 controls the flow control device 24 to direct the working fluid to at least one of the first nozzle 42, second nozzle 60, third nozzle 78, and / or fourth nozzle 96 included in the turboexpander 22, or to bypass the turboexpander 22, based on at least one of the working fluid mass flow rate and working fluid pressure detected by the at least one sensor 118.

[0088] Refer again Figure 1 The waste heat recovery system 20 may also include a working fluid circuit 120 for circulating the working fluid. The working fluid circuit 120 is fluidly connected to the turbine expander 22, the flow control device 24, the evaporator 114, and / or the condenser 116. The working fluid circuit 120 may include multiple fluid conduits.

[0089] like Figure 10 and 11 As shown, when the working fluid circuit 120 includes a plurality of fluid conduits, the turbo expander 22 may include one or more fluid connectors 122 to removably connect a fluid conduit to each of the first nozzle component 40, the second nozzle component 58, the third nozzle component 76 and / or the fourth nozzle component 94 included in the turbo expander 22.

[0090] In some embodiments, the working fluid circuit 120 may include a bypass circuit that fluidly connects the flow control device 24 directly to the condenser 116, thereby bypassing the working fluid passage through the turbine expander 22.

[0091] Refer again Figure 1The waste heat recovery system 20 may further include a pump 124 adapted to adjust the flow rate of the working fluid through the waste heat recovery system 20 at one or more speeds. The pump 124 may be any suitable pump, such as a piston pump or a diaphragm pump. In some embodiments, when the waste heat recovery system 20 includes an evaporator 114 and a condenser 116, the pump 124 may be positioned upstream of the evaporator 114 and downstream of the condenser 116. In some embodiments, when at least one sensor 118 is present, the pump 124 may be in communication with a controller 26, and the controller 26 may control the pump 124 to adjust the flow rate of the working fluid based on the characteristics of the working fluid detected by the at least one sensor 118.

[0092] The vehicle may include a waste heat recovery system 20 as described herein. In some embodiments, the shaft 30 of the turboexpander 22 may be coupled to a generator. When the shaft 30 is coupled to the generator, the waste heat generated by the ICE can be converted into electricity that can be stored or used by the vehicle.

[0093] The invention has been described in an illustrative manner, and it should be understood that the terminology used is intended to be descriptive rather than limiting. In view of the foregoing teachings, many modifications and variations of the invention are possible, and the invention may be practiced in ways other than those specifically described.

Claims

1. A waste heat recovery system for recovering waste heat of an internal combustion engine, the waste heat recovery system comprising: a turboexpander for outputting power based on a working fluid, the turboexpander comprising: a turbine blade rotatable by the working fluid, a shaft coupled to and rotatable by the turbine blade, wherein the shaft extends along a longitudinal axis, and a nozzle assembly for directing the working fluid to the turbine blade to rotate the turbine blade, the nozzle assembly comprising: a nozzle block disposed about the shaft and adjacent to the turbine blade, a first nozzle component coupled to the nozzle block to accelerate the working fluid, wherein the first nozzle component defines a first nozzle having a first geometric configuration, a second nozzle component coupled to the nozzle block to accelerate working fluid, wherein the second nozzle component defines a second nozzle having a second geometric configuration different from the first geometric configuration; a third nozzle component coupled to the nozzle block to accelerate the working fluid, wherein the third nozzle component defines a third nozzle having a third geometric configuration different from at least one of the first geometric configuration and the second geometric configuration; and a fourth nozzle component coupled to the nozzle block to accelerate the working fluid, wherein the fourth nozzle component defines a fourth nozzle having a fourth geometric configuration different from at least one of the first geometric configuration, the second geometric configuration, and the third geometric configuration; and wherein at least a portion of the nozzle block is disposed between any one of the first nozzle, the second nozzle, the third nozzle, the fourth nozzle and the turbine blade; a flow control device in fluid communication with the turboexpander to direct the working fluid to at least one of the first nozzle, the second nozzle, the third nozzle, the fourth nozzle or bypass the turboexpander; a controller in communication with the flow control device and adapted to control the flow control device to direct the working fluid to at least one of the first nozzle, the second nozzle, the third nozzle, the fourth nozzle or bypass the turboexpander; and at least one sensor adapted to detect at least one of a working fluid temperature and a working fluid pressure of the working fluid upstream of the turboexpander; wherein the nozzle block further defines a first bore and a second bore, wherein the first nozzle component is removably coupled to the nozzle block such that the first nozzle component is selectively disposed in the first bore, and wherein the second nozzle component is removably coupled to the nozzle block such that the second nozzle component is selectively disposed in the second bore.

2. The waste heat recovery system of claim 1, wherein the first geometric configuration of the first nozzle is a De Laval configuration having a first throat cross-sectional area, and wherein the second geometric configuration of the second nozzle is a De Laval configuration having a second throat cross-sectional area different from the first throat cross-sectional area.

3. The waste heat recovery system of claim 1, wherein the first nozzle component and the second nozzle component are spaced apart circumferentially about the longitudinal axis.

4. The waste heat recovery system of claim 1, wherein the first nozzle component, the second nozzle component, the third nozzle component, and the fourth nozzle component are spaced apart circumferentially about the longitudinal axis.

5. The waste heat recovery system of claim 1, wherein the controller controls the flow control device to direct the working fluid to at least one of the first nozzle, the second nozzle, the third nozzle, the fourth nozzle, or bypass the turboexpander based on at least one of the working fluid temperature and the working fluid pressure detected by the at least one sensor.

6. The waste heat recovery system of claim 1, wherein the first geometric configuration of the first nozzle is a De Laval configuration having a first throat cross-sectional area, wherein the second geometric configuration of the second nozzle is a De Laval configuration having a second throat cross-sectional area, wherein the third geometric configuration of the third nozzle is a De Laval configuration having a third throat cross-sectional area, and wherein the fourth geometric configuration is a De Laval configuration having a fourth throat cross-sectional area, and wherein each of the first throat cross-sectional area, the second throat cross-sectional area, the third throat cross-sectional area, and the fourth throat cross-sectional area are different.

7. A waste heat recovery system for recovering waste heat of an internal combustion engine, the waste heat recovery system comprising: a turboexpander for outputting power based on a working fluid, the turboexpander comprising: a turbine blade rotatable by the working fluid, a shaft coupled to and rotatable by the turbine blade, wherein the shaft extends along a longitudinal axis, and a nozzle assembly for directing the working fluid to the turbine blade to rotate the turbine blade, the nozzle assembly comprising: a nozzle block disposed about the shaft and adjacent to the turbine blade, a first nozzle component coupled to the nozzle block to accelerate the working fluid, wherein the first nozzle component defines a first nozzle having a first geometric configuration, a second nozzle component coupled to the nozzle block to accelerate working fluid, wherein the second nozzle component defines a second nozzle having a second geometric configuration different from the first geometric configuration; a third nozzle component coupled to the nozzle block to accelerate the working fluid, wherein the third nozzle component defines a third nozzle having a third geometric configuration different from at least one of the first geometric configuration and the second geometric configuration; and a fourth nozzle component coupled to the nozzle block to accelerate the working fluid, wherein the fourth nozzle component defines a fourth nozzle having a fourth geometric configuration different from at least one of the first geometric configuration, the second geometric configuration, and the third geometric configuration; and wherein at least a portion of the nozzle block is disposed between any one of the first nozzle, second nozzle, third nozzle, fourth nozzle and the turbine blade; a flow control device in fluid communication with the turboexpander to direct the working fluid to at least one of the first nozzle, second nozzle, third nozzle, fourth nozzle or bypass the turboexpander; a controller in communication with the flow control device and adapted to control the flow control device to direct the working fluid to at least one of the first nozzle, second nozzle, third nozzle, fourth nozzle or bypass the turboexpander; and at least one sensor adapted to detect at least one of a working fluid temperature and a working fluid pressure of the working fluid upstream of the turboexpander; wherein the nozzle block further defines a first bore and a second bore, wherein the first nozzle component is integral with the nozzle block, and wherein the second nozzle component is integral with the nozzle block.

8. A turboexpander for a waste heat recovery system that outputs power based on a working fluid, the turboexpander comprising: a turbine blade rotatable by the working fluid; a shaft coupled to the turbine blade and rotatable by the turbine blade, wherein the shaft extends along a longitudinal axis; and a nozzle assembly for directing the working fluid to the turbine blade to cause the turbine blade to rotate, the nozzle assembly comprising: a nozzle block disposed about the shaft and adjacent to the turbine blade, a first nozzle component coupled to the nozzle block to accelerate the working fluid, wherein the nozzle component defines a first nozzle having a first geometric configuration, a second nozzle component coupled to the nozzle block to accelerate working fluid, wherein the second nozzle component defines a second nozzle having a second geometric configuration different from the first geometric configuration; a third nozzle component coupled to the nozzle block to accelerate the working fluid, wherein the third nozzle component defines a third nozzle having a third geometric configuration different from at least one of the first geometric configuration and the second geometric configuration; and a fourth nozzle component coupled to the nozzle block to accelerate the working fluid, wherein the fourth nozzle component defines a fourth nozzle having a fourth geometric configuration different from at least one of the first geometric configuration, the second geometric configuration, and the third geometric configuration; and wherein at least a portion of the nozzle block is disposed between any one of the first nozzle, second nozzle, third nozzle, fourth nozzle and the turbine blade; and at least one sensor adapted to detect at least one of a working fluid temperature and a working fluid pressure of the working fluid upstream of the turboexpander; wherein the nozzle block further defines a first bore and a second bore, wherein the first nozzle component is removably coupled to the nozzle block such that the first nozzle component is selectively disposed in the first bore, and wherein the second nozzle component is removably coupled to the nozzle block such that the second nozzle component is selectively disposed in the second bore.

9. The turboexpander of claim 8, wherein the first geometric configuration of the first nozzle is a De Laval configuration having a first throat cross-sectional area, and wherein the second geometric configuration of the second nozzle is a De Laval configuration having a second throat cross-sectional area that is different than the first throat cross-sectional area.

10. The turboexpander of claim 8, wherein the first geometric configuration of the first nozzle is a De Laval configuration having a first throat cross-sectional area, wherein the second geometric configuration of the second nozzle is a De Laval configuration having a second throat cross-sectional area, wherein the third geometric configuration of the third nozzle is a De Laval configuration having a third throat cross-sectional area, and wherein the fourth geometric configuration is a De Laval configuration having a fourth throat cross-sectional area, and wherein each of the first, second, third, and fourth throat cross-sectional areas are different.

11. The turboexpander of claim 8, wherein the first nozzle component and the second nozzle component are circumferentially spaced about the longitudinal axis.

12. The turboexpander of claim 10, wherein the first, second, third, and fourth nozzle components are circumferentially spaced about the longitudinal axis.

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