The organic Rankine cycle (ORC) is a promising method of recovering the exhaust heat of the internal combustion engine (ICE). However, the off-design exhaust conditions and the negative effects (such as increased backpressure and added weight) of the ORC installation onto vehicles greatly deteriorate the performance of ORC applied on mobile vehicles. In this paper, the ORC thermodynamic model with an integrated plate heat exchanger model is developed to evaluate the effects of sizing the heat exchanger and designing the ORC operating conditions on the thermodynamic performance of the ORC system. Considering various major exhaust conditions and the negative impacts of ORC system installation on vehicles, an optimal ORC system design strategy is proposed to maximize the net output power. The optimum geometric parameters of heat exchangers and ORC operating conditions are simultaneously designed through a mixed integer nonlinear programming problem. The proposed design strategy is compared with the design method without considering negative effects and the design method only based on one major engine operating point. The comparison results indicate that the proposed design strategy increases the weighted net output power and the proposed design strategy can ensure that the ORC works normally in various exhaust conditions. Among all the operating parameters, the size of the heat exchanger (two geometric parameters) is the major factor affecting the performance of ORC. These findings highlight the importance of considering various exhaust conditions and the negative impacts of vehicle-mounted ORC during the design procedure.

有机朗肯循环（ORC）是一种有前景的回收内燃机（ICE）废热的方法。但是，设计不良的排气条件以及ORC安装到车辆上的负面影响（例如增加的背压和增加的重量）大大降低了应用于移动车辆的ORC的性能。在本文中，开发了具有集成板式换热器模型的ORC热力学模型，以评估换热器的尺寸和设计ORC操作条件对ORC系统的热力学性能的影响。考虑到各种主要的排气条件以及ORC系统安装对车辆的负面影响，提出了一种最优的ORC系统设计策略，以使净输出功率最大化。通过混合整数非线性规划问题，可以同时设计热交换器的最佳几何参数和ORC操作条件。将所提出的设计策略与不考虑负面影响的设计方法进行比较，并将设计方法仅基于一个主要发动机工作点进行比较。比较结果表明，所提出的设计策略增加了加权净输出功率，所提出的设计策略可以保证ORC在各种排气条件下都能正常工作。在所有运行参数中，热交换器的大小（两个几何参数）是影响ORC性能的主要因素。这些发现凸显了在设计过程中考虑各种排气条件以及车载ORC的负面影响的重要性。