The current experimental ORC setups for long-haul Heavy Duty Diesel Engines (HDDE) are not reaching the desired fuel savings within the expected costs. Pathways to improve ORC performance and cost-effectiveness remain a major challenge facing the automotive sector. This paper presents the conceptual overview and simulation results (using Aspen HYSYS) of a novel ORC especially tailored for high temperature heat sources (300-400°C) in truck applications. With a fundamental revision of the expansion and heat transfer characteristics, the advantage of the proposed novel ORC included an equivalent performance to the conventional ORC despite a 20% reduction in the total heat transfer area and a 40% reduction in the size of the expansion machine. This resulted in a 15% improvement in the Cost/kW value of the system, whilst offering 5.1% improvement in engine thermal efficiency at highway driving conditions.
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