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Design of an Organic Rankine Cycle for Waste Heat Recovery From a Portable Diesel Generator

[+] Author Affiliations
Frederick J. Cogswell, David W. Gerlach, Timothy C. Wagner, Jarso Mulugeta

United Technologies Research Center, East Hartford, CT

Paper No. IMECE2011-65489, pp. 707-716; 10 pages
  • ASME 2011 International Mechanical Engineering Congress and Exposition
  • Volume 4: Energy Systems Analysis, Thermodynamics and Sustainability; Combustion Science and Engineering; Nanoengineering for Energy, Parts A and B
  • Denver, Colorado, USA, November 11–17, 2011
  • Conference Sponsors: ASME
  • ISBN: 978-0-7918-5490-7
  • Copyright © 2011 by United Technologies Corp.


A 5-kW Organic Rankine Cycle (ORC) was designed for mobile 60-kW diesel engine waste heat recovery applications to provide additional electricity for powering air conditioners. The ORC uses a non-flammable, near-zero-global-warming-potential fluid (Novec649) in a supercritical cycle. The system conceptual design and some observations on the component specification are described. The system will utilize an advanced oil-free high speed direct drive turbine. The proposed power generation module has a volume of ∼3 ft3 and contains the turbine, generator, pump, recuperator, and electrical components. The heat rejection heat exchanger is located on the power generation module in a configuration similar to mini-split air conditioners. The heat recovery heat exchanger (supercritical heater) is attached to the diesel generator and placed in series before the OEM muffler. The supercritical heater must be carefully designed to prevent the refrigerant from overheating, while still maintaining a high effectiveness.

Copyright © 2011 by United Technologies Corp.



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