Solutions

Waste Heat Recovery

Design and optimize waste heat recovery systems with GT-SUITE. Predict performance and reduce prototyping through simulation-driven engineering.

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Solution Overview

Heat Exchanger Design Optimization

Various technologies are being explored to make use of the hot exhaust gases from engines. Two of these technologies that can be modeled in GT-SUITE are Rankine cycle and TEG (Thermo Electric Generator) systems. These systems can be integrated with a GT-POWER engine model to predict energy recovery across a wide range of operating conditions.

Using GT-SUITE’s proven two-phase approach used in modeling air conditioning systems with fluid properties from NIST Refprop, Rankine cycle models are simulated to explore fuel savings and investigate advanced control strategies. Complex layouts including multiple heat exchanger stages and valving systems are supported.

Studies using TEGs include investigating new advanced Peltier-effect materials and different layouts for maximizing the amount of power generation between the hot and cold streams. Companies using GT-SUITE can reduce physical testing by finding optimal designs in simulation instead of trail-and-error testing.

Vehicle Exhaust Waste Heat Recovery (WHR) System

Application Highlights

From Components to Complete Systems

Model all Rankine/TEG system components individually or as a complete system
Fluid properties calculated from built-in NIST REFPROP
Spatially resolved condenser and evaporator models to capture phase change
Automatic calibration of all components – heat exchangers, expander, etc
Robust solver based on Navier-Stokes equations allows arbitrary initial state and zero flow
Fast simulation (faster than real-time)

Advanced WHR Simulation Capabilities

Model, analyze, and optimize waste heat recovery systems with advanced simulation tools that capture component behavior, system interactions, and real-world operating conditions.

Advanced Controls Optimization

Develop and validate control strategies that maximize energy recovery across all engine operating conditions. Simulation-driven development cuts calibration time and speeds deployment of production-ready systems.

Seamless GT-POWER Engine Integration

Connect WHR models directly to existing GT-POWER engine circuits to capture full engine and recovery system interaction. Predict fuel savings and system-level performance accurately, without rebuilding models from scratch.

Geometry-Based Heat Exchanger Scaling

Quantify how heat exchanger geometry changes, including scaling for different system sizes, affect performance without new test data. Supports rapid design iteration and early component selection.

Reliable Results, Every Stage

GT-SUITE models the full recovery cycle in detail, capturing how the working fluid heats, vaporizes, and cools through the system. From quick concept studies to detailed performance checks, results reflect real-world behavior and give you confidence before hardware is built.

Multi-Configuration System Layout Optimization

Evaluate and compare WHR system architectures, including complex layouts with multiple heat exchanger stages and valving, to identify the best-performing configuration for your application. Find optimal designs in simulation and reduce costly physical prototyping.

Any Fluid, Ready Instantly

GT-SUITE supports a wide range of refrigerants and working fluids out of the box, and accepts custom supplier fluid data files automatically, with no conversion or setup required. Work with the exact fluids your system uses from day one.