BorgWarner Organic Rankine Cycle (ORC) Waste Heat Recovery Systems

Tailpipe and EGR evaporators, exhaust flap bypass valves, turbine expander/generator/pumps & power electronics and heat exchanger/condensers recover part of the 50% of fuel energy wasted in heat rejection to improve fuel economy, reduce emissions.

Orc Group 590346a474513
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BorgWarner's Organic Rankine Cycle (ORC) waste heat recovery products and systems convert wasted exhaust heat into usable electrical energy.

Tailpipe and EGR Evaporators

  • +60% tailpipe evaporator efficiency
  • +80% EGR evaporator efficiency
  • Thermally decoupled tube-shell construction
  • Compact, modular design for ease of packaging and low cost

Exhaust Flap Bypass Valve

  • Bypasses exhaust around tailpipe evaporator when required
  • Two types: exhaust flap valve and throttle valve
  • CAN-based eActuators for fast, precise proportional control
  • May be installed upstream or downstream of evaporator
  • Low pressure drop minimizes impact on engine performance

Turbine Expander/Generator/Pump

  • 48V output
  • 7 kW nominal, 13 kW max output
  • 65% peak turbine efficiency
  • Very low weight < 10 kg mass, compact package
  • Integrated high pressure pump
  • No oil lubrication required

Turbine Expander Power Electronics

  • Bidirectional high speed motor controller
  • For 48V vehicle systems
  • Weighs less than 6 kg, compact package
  • Water cooled
  • Capable of up to 25 kW (can be scaled down)

Heat Exchanger/Condenser

  • EGR Cooler technology yields compact, high efficiency design
  • Stacked brazed plate and fin construction maximizes efficiency
  • Proprietary brazing materials ensure long-term reliability
  • Stainless steel provides compatibility for corrosive working fluids (e. g. ethanol)

ORC Waste Heat Recovery System

  • Proprietary software tools enable rapid specification to a customer’s engine requirements
  • System-level Simulations, Controls, and Testing have resulted in numerous design enhancements
  • BorgWarner ORC components have run hundreds of hours on proprietary ORC system test rigs
  • A broad product portfolio and system-level approach allow BorgWarner to maximize overall performance and durability at the lowest cost
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