Eaton : Showcasing Waste Heat Recovery System Concepts to Improve Fuel Economy, Reduce Emissions

HANNOVER, GERMANY … Power management company Eaton is displaying multiple Waste Heat Recovery (WHR) system concepts that utilize different technical approaches to provide choices for customers that need to improve fuel economy and reduce emissions under stricter government regulations. The systems are being shown here at the 66th IAA Commercial Vehicles Show.

The concepts include Eaton's Indirect systems, which are based on the Organic Rankine Cycle, and its Direct system, which uses an electrified approach. The Indirect systems use organic fluids from the after-treatment system or engine to convert energy normally lost in the form of heat into useful power for Commercial Vehicles. Through simulations, the Indirect systems have shown fuel economy improvements in the range of 5 percent.

The Direct system uses Eaton's Electrically Assisted Variable Speed Supercharger (EAVSS) and Electric Waste Heat Recovery Device to deliver precise air flow control to the engine, optimize EGR flow, and control the breathing of the engine. This system has shown through simulation more than a 20 percent improvement in fuel economy while also reducing emissions and NOX.

'With the demand increasing for technical innovations that deliver improved fuel economy while lowering emissions, Eaton is looking at a variety of solutions including several Waste Heat Recovery options that help meet these challenges in an efficient and affordable manner,' said Gerard Devito, chief technology officer, Eaton's Vehicle Group. 'Based on preliminary modeling and simulation work on working prototypes, we feel both of these solutions have merit and can be commercially viable in the near term.'

Eaton's Indirect WHR systems are innovative concepts that combine engine exhaust waste heat recovery with emissions reduction on heavy-duty diesel engines. The system delivers value to customers, including:

1. Better fuel economy (targeted at a five percent improvement);
2. Lowers Green House Gas emissions;
3. Meets future European emissions standards;
4. Requires no added driver intervention; and,
5. Is more cost effective and delivers better performance than having two independent systems.

With Eaton's patented combination of Waste Heat Recovery and advanced aftertreatment in one system, no additional fuel is required to meet future cleaner emission standards. Targeted applications are heavy-duty diesel engines.

Eaton's Direct WHR concept features an electrified intake and exhaust engine flow management system, which offers control for advanced combustion schemes and EGR, immediate response time to torque, and energy recovery of both kinetic as well as exhaust heat energy. The system is comprised of two components -- a highly efficient Roots expander that is coupled an electric generator to enable WHR, and Eaton's EAVSS. Eaton's EAVSS uses a single motor and enables Start/Stop, functions in place of the Alternator, enables Electric Boosting and Brake Regeneration. Targeted applications include light- and medium-duty diesel engines.

Eaton is a power management company with 2015 sales of $20.9 billion. Eaton provides energy-efficient solutions that help our customers effectively manage electrical, hydraulic and mechanical power more efficiently, safely and sustainably. Eaton has approximately 96,000 employees and sells products to customers in more than 175 countries. For more information, visit www.eaton.com.