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Design methodology for radial turbo expanders in mobile organic Rankine cycle applications

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  • Costall, A.W.
  • Gonzalez Hernandez, A.
  • Newton, P.J.
  • Martinez-Botas, R.F.

Abstract

Future vehicles for clean transport will require new powertrain technologies to further reduce CO2 emissions. Mobile organic Rankine cycle systems target the recovery of waste heat in internal combustion engines, with the exhaust system identified as a prime source. This article presents a design methodology and working fluid selection for radial turbo expanders in a heavy-duty off-road diesel engine application. Siloxanes and Toluene are explored as the candidate working fluids, with the latter identified as the preferred option, before describing three radial turbine designs in detail. A small 15.5kW turbine design leads to impractical blade geometry, but a medium 34.1kW turbine, designed for minimum power, is predicted to achieve an isentropic efficiency of 51.5% at a rotational speed of 91.7kmin-1. A similar 45.6kW turbine designed for maximum efficiency yields 56.1% at 71.5kmin-1. This emphasizes the main design trade-off – efficiency decreases and rotational speed increases as the power requirement falls – but shows reasonable radial turbine efficiencies and thus practical turbo expanders for mobile organic Rankine cycle applications are realizable, even considering the compromised flow geometry and high speeds imposed at such small scales.

Suggested Citation

  • Costall, A.W. & Gonzalez Hernandez, A. & Newton, P.J. & Martinez-Botas, R.F., 2015. "Design methodology for radial turbo expanders in mobile organic Rankine cycle applications," Applied Energy, Elsevier, vol. 157(C), pages 729-743.
  • Handle: RePEc:eee:appene:v:157:y:2015:i:c:p:729-743
    DOI: 10.1016/j.apenergy.2015.02.072
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    2. Morgan, Robert & Dong, Guangyu & Panesar, Angad & Heikal, Morgan, 2016. "A comparative study between a Rankine cycle and a novel intra-cycle based waste heat recovery concepts applied to an internal combustion engine," Applied Energy, Elsevier, vol. 174(C), pages 108-117.
    3. Zou, Aihong & Chassaing, Jean-Camille & Persky, Rodney & Gu, YuanTong & Sauret, Emilie, 2019. "Uncertainty Quantification in high-density fluid radial-inflow turbines for renewable low-grade temperature cycles," Applied Energy, Elsevier, vol. 241(C), pages 313-330.
    4. Bamorovat Abadi, Gholamreza & Kim, Kyung Chun, 2017. "Investigation of organic Rankine cycles with zeotropic mixtures as a working fluid: Advantages and issues," Renewable and Sustainable Energy Reviews, Elsevier, vol. 73(C), pages 1000-1013.
    5. Guillaume, Ludovic & Legros, Arnaud & Desideri, Adriano & Lemort, Vincent, 2017. "Performance of a radial-inflow turbine integrated in an ORC system and designed for a WHR on truck application: An experimental comparison between R245fa and R1233zd," Applied Energy, Elsevier, vol. 186(P3), pages 408-422.
    6. Ambra Giovannelli & Erika Maria Archilei & Coriolano Salvini, 2020. "Two-Stage Radial Turbine for a Small Waste Heat Recovery Organic Rankine Cycle (ORC) Plant," Energies, MDPI, vol. 13(5), pages 1-17, February.
    7. Fuhaid Alshammari & Apostolos Karvountzis-Kontakiotis & Apostolos Pesyridis & Muhammad Usman, 2018. "Expander Technologies for Automotive Engine Organic Rankine Cycle Applications," Energies, MDPI, vol. 11(7), pages 1-36, July.
    8. White, Martin T. & Read, Matthew G. & Sayma, Abdulnaser I., 2020. "Making the case for cascaded organic Rankine cycles for waste-heat recovery," Energy, Elsevier, vol. 211(C).
    9. Shao, Long & Ma, Xinling & Wei, Xinli & Hou, Zhonglan & Meng, Xiangrui, 2017. "Design and experimental study of a small-sized organic Rankine cycle system under various cooling conditions," Energy, Elsevier, vol. 130(C), pages 236-245.
    10. Da Lio, Luca & Manente, Giovanni & Lazzaretto, Andrea, 2017. "A mean-line model to predict the design efficiency of radial inflow turbines in organic Rankine cycle (ORC) systems," Applied Energy, Elsevier, vol. 205(C), pages 187-209.
    11. Uusitalo, Antti & Honkatukia, Juha & Turunen-Saaresti, Teemu, 2017. "Evaluation of a small-scale waste heat recovery organic Rankine cycle," Applied Energy, Elsevier, vol. 192(C), pages 146-158.
    12. Liu, Peng & Shu, Gequn & Tian, Hua & Wang, Xuan & Yu, Zhigang, 2018. "Alkanes based two-stage expansion with interheating Organic Rankine cycle for multi-waste heat recovery of truck diesel engine," Energy, Elsevier, vol. 147(C), pages 337-350.
    13. Al Jubori, Ayad M. & Al-Dadah, Raya K. & Mahmoud, Saad & Daabo, Ahmed, 2017. "Modelling and parametric analysis of small-scale axial and radial-outflow turbines for Organic Rankine Cycle applications," Applied Energy, Elsevier, vol. 190(C), pages 981-996.
    14. Khalil, Khalil M. & Mahmoud, S. & Al- Dadah, R.K., 2020. "Experimental and numerical investigation of blade height effects on micro-scale axial turbines performance using compressed air open cycle," Energy, Elsevier, vol. 211(C).
    15. Marenco-Porto, Carlos A. & Fierro, José J. & Nieto-Londoño, César & Lopera, Leonardo & Escudero-Atehortua, Ana & Giraldo, Mauricio & Jouhara, Hussam, 2023. "Potential savings in the cement industry using waste heat recovery technologies," Energy, Elsevier, vol. 279(C).
    16. Manente, Giovanni & Da Lio, Luca & Lazzaretto, Andrea, 2016. "Influence of axial turbine efficiency maps on the performance of subcritical and supercritical Organic Rankine Cycle systems," Energy, Elsevier, vol. 107(C), pages 761-772.
    17. Martin T. White & Abdulnaser I. Sayma, 2018. "A Generalised Assessment of Working Fluids and Radial Turbines for Non-Recuperated Subcritical Organic Rankine Cycles," Energies, MDPI, vol. 11(4), pages 1-26, March.
    18. Sun, Hongchuang & Qin, Jiang & Hung, Tzu-Chen & Huang, Hongyan & Yan, Peigang, 2019. "Performance analysis of low speed axial impulse turbine using two type nozzles for small-scale organic Rankine cycle," Energy, Elsevier, vol. 169(C), pages 1139-1152.
    19. Zhonghe Han & Peng Li & Xu Han & Zhongkai Mei & Zhi Wang, 2017. "Thermo-Economic Performance Analysis of a Regenerative Superheating Organic Rankine Cycle for Waste Heat Recovery," Energies, MDPI, vol. 10(10), pages 1-23, October.
    20. Kaczmarczyk, Tomasz Z. & Żywica, Grzegorz & Ihnatowicz, Eugeniusz, 2017. "The impact of changes in the geometry of a radial microturbine stage on the efficiency of the micro CHP plant based on ORC," Energy, Elsevier, vol. 137(C), pages 530-543.
    21. Lei, Biao & Wang, Wei & Wu, Yu-Ting & Ma, Chong-Fang & Wang, Jing-Fu & Zhang, Lei & Li, Chuang & Zhao, Ying-Kun & Zhi, Rui-Ping, 2016. "Development and experimental study on a single screw expander integrated into an Organic Rankine Cycle," Energy, Elsevier, vol. 116(P1), pages 43-52.
    22. Da Lio, Luca & Manente, Giovanni & Lazzaretto, Andrea, 2016. "Predicting the optimum design of single stage axial expanders in ORC systems: Is there a single efficiency map for different working fluids?," Applied Energy, Elsevier, vol. 167(C), pages 44-58.
    23. Grelet, Vincent & Reiche, Thomas & Lemort, Vincent & Nadri, Madiha & Dufour, Pascal, 2016. "Transient performance evaluation of waste heat recovery rankine cycle based system for heavy duty trucks," Applied Energy, Elsevier, vol. 165(C), pages 878-892.
    24. Enhua Wang & Ningjian Peng, 2023. "A Review on the Preliminary Design of Axial and Radial Turbines for Small-Scale Organic Rankine Cycle," Energies, MDPI, vol. 16(8), pages 1-20, April.

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