Our client developed a novel highly efficient thermal dynamic cycle for use in waste heat recovery systems. The system makes use of waste heat and converts it to electrical energy by driving a generator with a heat engine. The system was comprised of a heat engine, a generator, a containment vessel, two heat exchangers and a high pressure (725 psi) and high temperature (325 F) plumbing and valving system.
For the engine, we started with the short block of an inline four cylinder diesel engine (engine block, pistons, crankshaft and oil pump). All other stock components were removed and redesigned starting with a custom desmodromic valve train along with the cam drive, flywheel and engine starting system.
For this project, Exact Engineering provided the following services:
- Design of completely new cylinder head with novel metal seating poppet valves
- Design of novel desmodromic cam train including cams, rockers, camshaft, cam chain and cam block
- Cam train dynamic loads and life analysis
- Custom engine vibration isolators
- ASME certified pressure vessel for containment of heat engine
- Design of magnetic drive coupling with splined drive shaft feedthru and installation tooling
- Globe valve actuator with position sensor for speed control and emergency shutdown
- Generator drive train design
- Electrical hermetic feedthrus
- High pressure (725 psi) high temperature (325 F) plumbing
- Thermally isolated and hermetic high pressure fluid feethru
- Design and analysis of system space frame to house and support all mechanical components and generator (3500lbs total).
- Fabrication, assembly and testing of heat engine and integration into vessel
- Assembly of magnetic coupling and integration into vessel
- General system assembly and testing
