Combined Supercritical CO₂ Brayton Cycle and Organic Rankine Cycle for Exhaust Heat Recovery

In order to reduce energy consumption and related CO₂ emissions, waste heat recovery is considered a viable opportunity in several economic sectors, with a focus on industry and transportation. Among different proposed technologies, thermodynamic cycles using suitable organic working fluids seem to be promising options, and the possibility of combining two different cycles improves the final recovered energy. In this paper, a combination of Brayton and Rankine cycles is proposed: the upper cycle has supercritical carbon dioxide (sCO₂) as its working fluid, while the bottomed Rankine section is realized by an organic fluid (organic Rankine cycle (ORC)). This combined unit is applied to recover the exhaust energy from the flue gases of an internal combustion engine (ICE) for the transportation sector. The sCO₂ Brayton cycle is directly facing the exhaust gases, and it should dispose of a certain amount of energy at lower pressure, which can be further recovered by the ORC unit. A specific mathematical model has been developed, which uses experimental engine data to estimate a realistic final recoverable energy. The model is able to evaluate the performance of each recovery subsection, highlighting interactions and possible trade-offs between them. Hence, the combined system can be optimized from a global point of view, identifying the most influential operating parameters and also considering a regeneration stage in the ORC unit.