TEG and ORC Heat Recovery via Engine Coolant Diversion
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Solution Overview
Problem
The efficiency of Thermo-Electric Generators (TEGs) in power generation systems is limited by the need for high temperature differentials, which can be constrained by air cooling and physical space, and existing systems lack optimal management of waste heat from reciprocating engines for enhanced energy recovery.
Innovation Solution
The integration of a Thermo-Electric Generator (TEG) with an Organic Rankine Cycle (ORC) system, utilizing liquid cooling and a control module to manage heat transfer between the engine, TEG, and ORC, allowing for the efficient distribution and reuse of waste heat through various piping configurations and heat exchangers to optimize energy recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air cooling is used for TEG, then the system is simpler and requires less equipment, but the temperature differential is limited and energy output is reduced
Solution Approach 1:
The patent combines the TEG cooling system with the engine cooling system by integrating a heat exchanger that allows the engine coolant to cool the TEG's hot side. This merging of functions enables the TEG to achieve higher temperature differentials using the engine's waste heat, thereby increasing power output without adding a separate cooling system
Solution Approach 2:
The patent converts the engine's waste heat, which would otherwise be discarded through the exhaust or radiator, into a useful resource for cooling the TEG. By utilizing this waste thermal energy to maintain the temperature differential across the TEG, the system increases power generation efficiency while reducing overall heat waste
2Power
If liquid cooling is used for TEG to increase temperature differential, then energy output increases, but equipment size and system complexity increase
Solution Approach 1:
The patent makes the engine coolant serve multiple functions: it cools the engine cylinder head and simultaneously cools the TEG's hot side through the integrated heat exchanger. This multi-functionality allows liquid cooling of the TEG without requiring a separate cooling loop, thereby increasing power output while limiting the increase in system complexity
Solution Approach 2:
The system uses its own internal resources to solve the cooling requirement. The engine's own coolant, which must be circulated regardless, is utilized to provide the liquid cooling necessary for TEG operation. This self-service approach enables enhanced power generation without imposing additional system complexity or external cooling requirements
3Productivity
If waste heat from engine is not recovered, then system is simpler, but energy efficiency is reduced
Solution Approach 1:
The patent recovers waste heat from the engine that would otherwise be discarded. By capturing thermal energy from the engine coolant and exhaust gas and directing it through heat exchangers to generate additional power via the TEG and ORC system, the invention transforms wasted energy into useful output, thereby improving overall energy efficiency
Solution Approach 2:
The patent utilizes phase transitions of working fluids in the heat exchangers and ORC system to recover waste heat. The phase change processes enable efficient heat transfer from the engine waste heat sources to the power generation cycle, allowing energy recovery while managing the complexity of the heat management system
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration increases energy output from TEGs by enhancing temperature differentials and reduces equipment size, while improving the overall efficiency of the reciprocating engine, TEG, and ORC systems through effective heat management and reuse, enabling more efficient energy conversion and utilization.
Implementation Method 1
Thermo-electric Generator (TEG)... the number of applications is increasing... TEGs are typically used in engine exhaust heat recovery and that heat is then converted to electric power
Implementation Method 2
Organic Rankin Cycle (ORC) system... distributing waste heat from a reciprocating engines exhaust and cooling fluid between a Thermo-electric Generator (TEG) and an Organic Rankin Cycle (ORC) system
Implementation Method 3
By using the engines cooling fluid (or a separate thermal fluid cooling medium), both the reciprocating engine and the TEG can both benefit from improved operation and/or efficiency
Implementation Method 4
utilizing liquid cooling and a control module to manage heat transfer between the engine, TEG, and ORC
Data Source
AI summary
A heat recovery system that includes at least one an engine, a radiator, an Organic Rankine Cycle (ORC) and a thermo-electric generator (TEG). The radiator may be coupled to the reciprocating engine, and the ORC may be coupled to the reciprocating engine and to the TEG. A control module in the system is configured to divert reciprocating engine jacket water fluid through any of the radiator, ORC and TEG to increase the energy efficiency of the reciprocating engine through heat recovery caused by the diverted fluid.