The recuperator has the potential to enhance engine performance, reduce fuel consumption, and lower pollutant emissions, making it a promising technology for promoting environmental sustainability. This study investigates the impact of a Gyroid recuperator on the performance of a four-stroke internal combustion engine. Experimental analyses compared engine performance at various set points of rotational speeds before and after recuperator installation. The results validate the effectiveness of the Gyroid recuperator in recovering waste heat, thereby leading to improvements in fuel efficiency. The optimal performance, characterized by an 832.31 J/s increase in recovered combustion heat energy, was observed at 7000 RPM. Additionally, the Gyroid recuperator achieved a maximum overall heat transfer coefficient of 7.9215 W/m2 K at 8000 RPM. The performance of the Gyroid recuperator was further analyzed using the log mean temperature difference method, which yielded a peak value of 114.4 °C at 7000 RPM. The effectiveness-number of transfer units’ method was also employed to assess its effectiveness. These results show that the recuperator can efficiently transmit and recover heat under certain working circumstances. The analysis suggests higher heat energy losses at lower speeds than high speeds, indicating a more efficient energy conversion process at higher engine speeds. The possibilities of the Gyroid recuperator to improve engine performance and its suitability for internal combustion engines are highlighted in this study. This technology offers a promising solution for improving vehicle efficiency and promoting environmental sustainability.
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