Towards Centrifugal Compressor Stages Virtual Testing

Flow features inside centrifugal compressor stages are very complicated to simulate with numerical tools due to the highly complex geometry and varying gas conditions all across the machine. For this reason, a big effort is currently being made to increase the fidelity of the numerical models during the design and validation phases. Computational Fluid Dynamics (CFD) plays an increasing role in the assessment of the performance prediction of centrifugal compressor stages. Historically, CFD was considered reliable for performance prediction on a qualitatively level, whereas tests were necessary to predict compressors performance on a quantitatively basis. In fact "standard" CFD with only the flow-path and blades included into the computational domain is known to be weak in capturing efficiency level and operating range accurately due to the under-estimation of losses and the lack of secondary flows modeling. This research project aims to fill the gap in accuracy between "standard" CFD and tests data by including a high fidelity reproduction of the gas domain and the use of advanced numerical models and tools introduced in the author's OEM in-house CFD code. In other words, this thesis describes a methodology by which virtual tests can be conducted on single stages and multistage centrifugal compressors in a similar fashion to a typical rig test that guarantee end users to operate machines with a confidence level not achievable before. Furthermore, the new "high fidelity" approach allowed understanding flow phenomena not fully captured before, increasing aerodynamicists capability and confidence in designing high efficiency and high reliable centrifugal compressor stages.

Modelling of ORC components and systems for low-medium temperature heat recovery applications with reduced environmental impact

Although its great potential as low to medium temperature waste heat recovery (WHR) solution, the ORC technology presents open challenges that still prevent its diffusion in the market, which are different depending on the application and the size at stake. Focusing on the micro range power size and low temperature heat sources, the ORC technology is still not mature due to the lack of appropriate machines and working fluids. Considering instead the medium to large size, the technology is already available but the investment is still risky. The intention of this thesis is to address some of the topical themes in the ORC field, paying special attention in the development of reliable models based on realistic data and accounting for the off-design performance of the ORC system and of each of its components. Concerning the “Micro-generation” application, this work: i) explores the modelling methodology, the performance and the optimal parameters of reciprocating piston expanders; ii) investigates the performance of such expander and of the whole micro-ORC system when using Hydrofluorocarbons as working fluid or their new low GWP alternatives and mixtures; iii) analyzes the innovative ORC reversible architecture (conceived for the energy storage), its optimal regulation strategy and its potential when inserted in typical small industrial frameworks. Regarding the “Industrial WHR” sector, this thesis examines the WHR opportunity of ORCs, with a focus on the natural gas compressor stations application. This work provides information about all the possible parameters that can influence the optimal sizing, the performance and thus the feasibility of installing an ORC system. New WHR configurations are explored: i) a first one, relying on the replacement of a compressor prime mover with an ORC; ii) a second one, which consists in the use of a supercritical CO2 cycle as heat recovery system.