Generation of 3D Turbine Blades for Automotive Organic Rankine Cycles: Mathematical and Computational Perspectives

Fuhaid Alshammari,Mohamed Elashmawy,Apostolos Pesyridis

doi:10.3390/math9010050

Fuhaid Alshammari, Mohamed Elashmawy + Show 1 more

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https://doi.org/10.3390/math9010050

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Abstract

Organic Rankine cycle technology is gaining increasing interest as one of potent future waste heat recovery potential from internal combustion engines. The turbine is the component where power production takes place. Therefore, careful attention to the turbine design through mathematical and numerical simulations is required. As the rotor is the main component of the turbine, the generation of the 3D shape of the rotor blades and stator vanes is of great importance. Although several types of commercial software have been developed, such types are still expensive and time-consuming. In this study, detailed mathematical modelling was presented. To account for real gas properties, REFPROP software was used. Moreover, a detailed 3D CFD numerical analysis was presented to examine the nature of the flow after generating the 3D shapes of the turbine. Moreover, finite element analysis was performed using various types of materials to obtain best-fit material for the current application. As the turbine is part of a larger system (i.e., ORC system), the effects of its performance on the whole ORC system were discussed. The results showed that the flow was smooth with no recirculation at the design point except at the last part of the suction surface where strong vortices were noticed. Despite the strong vortices, the mathematical model proved to be an effective and fast tool for the generation of the 3D shapes of turbine blades and vanes. The deviations between the 1D mean-line and 3D CFD in turbine efficiency and power output were 2.28% and 5.10%, respectively.

Highlights

Since the late 19th century, the average temperature on Earth has risen by approximately 0.9 ◦ C because of the increased carbon dioxide (CO2 ) and other man-made emissions to the atmosphere [1]
Results at Off-DesignToPoints evaluate the performance of the turbine at off-design conditions, the pressure ratio is varied from 3 to 6.9, and the turbine inlet temperature is varied from 400 K to 471.55 K, To evaluate the performance of the turbine at off-design conditions, the pressure ratio is varied for two-speed lines (30,000 rpm and 40,000 rpm)
From 450 to 471.55 K, the rate of increase in heat input is 4.07% compared to 5.80% of net power

Summary

Introduction

Since the late 19th century, the average temperature on Earth has risen by approximately 0.9 ◦ C because of the increased carbon dioxide (CO2 ) and other man-made emissions to the atmosphere [1]. Besides the potential effects of CO2 on global climate, transportation contributes to air pollution through mono-nitrogen oxides (NOx) and particulate matter (PM) emissions [2]. Transportation contributes to global warming through CO2 emissions which pose serious threats to public health. With the improvement of people’s living standards, fuel consumption by the transportation sector will increase significantly [6]. These concerns necessitate the development of more efficient combustion engines to reduce fuel consumption and CO2 emissions. In this regard, waste heat recovery (WHR) technology is one of the promising technologies in recovering the wasted fuel energy

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