Design and optimization of turbo-expanders for organic rankine cycles

In a world focused on the need to produce energy for a growing population, while reducing atmospheric emissions of carbon dioxide, organic Rankine cycles represent a solution to fulfil this goal. This study focuses on the design and optimization of axial-flow turbines for organic Rankine cycles. From the turbine designer point of view, most of this fluids exhibit some peculiar characteristics, such as small enthalpy drop, low speed of sound, large expansion ratio. A computational model for the prediction of axial-flow turbine performance is developed and validated against experimental data. The model allows to calculate turbine performance within a range of accuracy of ±3%. The design procedure is coupled with an optimization process, performed using a genetic algorithm where the turbine total-to-static efficiency represents the objective function. The computational model is integrated in a wider analysis of thermodynamic cycle units, by providing the turbine optimal design. First, the calculation routine is applied in the context of the Draugen offshore platform, where three heat recovery systems are compared. The turbine performance is investigated for three competing bottoming cycles: organic Rankine cycle (operating cyclopentane), steam Rankine cycle and air bottoming cycle. Findings indicate the air turbine as the most efficient solution (total-to-static efficiency = 0.89), while the cyclopentane turbine results as the most flexible and compact technology (2.45 ton/MW and 0.63 m3/MW). Furthermore, the study shows that, for organic and steam Rankine cycles, the optimal design configurations for the expanders do not coincide with those of the thermodynamic cycles. This suggests the possibility to obtain a more accurate analysis by including the computational model in the simulations of the thermodynamic cycles. Afterwards, the performance analysis is carried out by comparing three organic fluids: cyclopentane, MDM and R245fa. Results suggest MDM as the most effective fluid from the turbine performance viewpoint (total-to-total efficiency = 0.89). On the other hand, cyclopentane guarantees a greater net power output of the organic Rankine cycle (P = 5.35 MW), while R245fa represents the most compact solution (1.63 ton/MW and 0.20 m3/MW). Finally, the influence of the composition of an isopentane/isobutane mixture on both the thermodynamic cycle performance and the expander isentropic efficiency is investigated. Findings show how the mixture composition affects the turbine efficiency and so the cycle performance. Moreover, the analysis demonstrates that the use of binary mixtures leads to an enhancement of the thermodynamic cycle performance.

Numerical Analysis and Redesign of a High Speed Linear Cascade Wind Tunnel for Aircraft Gas Turbine Engines Testing

Linear cascade testing serves a fundamental role in the research, development, and design of turbomachines as it is a simple yet very effective way to compute the performance of a generic blade geometry. These kinds of experiments are usually carried out in specialized wind tunnel facilities. This thesis deals with the numerical characterization and subsequent partial redesign of the S-1/C Continuous High Speed Wind Tunnel of the Von Karman Institute for Fluid Dynamics. The current facility is powered by a 13-stage axial compressor that is not powerful enough to balance the energy loss experienced when testing low turning airfoils. In order to address this issue a performance assessment of the wind tunnel was performed under several flow regimes via numerical simulations. After that, a redesign proposal aimed at reducing the pressure loss was investigated. This consists of a linear cascade of turning blades to be placed downstream of the test section and designed specifically for the type of linear cascade being tested. An automatic design procedure was created taking as input parameters those measured at the outlet of the cascade. The parametrization method employed Bézier curves to produce an airfoil geometry that could be imported into a CAD software so that a cascade could be designed. The proposal was simulated via CFD analysis and proved to be effective in reducing pressure losses up to 41%. The same tool developed in this thesis could be adopted to design similar apparatuses and could also be optimized and specialized for the design of turbomachines components.