High-Efficient Bladeless Expander Concept

Abstract

Tesla bladeless expanders are promising in energy harvesting and small-scale power generation applications due to their lower cost and simplicity in design. Although such expanders exhibit very high rotor efficiency (analytical total to static efficiency ~ 90%), it shows poor performance when coupled with a stator (experimental total to static efficiency ~30%) due to losses present in the stator and stator-rotor interaction. This paper presents the design and experiment of a novel, high-efficient Tesla bladeless expander concept. The concept arises from the loss phenomena in the stator-rotor interaction in conventional bladeless expanders, which are among the main causes of the low performance. This concept is believed to bring the bladeless expanders to the same performances as the traditional ones with vanes, compared to which however the bladeless machines boast greater simplicity, robustness, and the absence of performance decay as the size decreases, competing even in the contexts for traditional turbomachinery. The high-efficient bladeless expander prototype with water as a working fluid is designed and developed, representing the similitude case for a liquid butane heat pump. The available isentropic power across the throttling process in the butane case is 3.3 kW @10000 rpm. The turbine consists of 24 nozzles and 150 disks separated by 0.1 mm spacers. The turbine shaft is connected to the high-speed electric generator. The performance test on the expander is carried out at rotational speeds ranging from 3000 rpm to 6200 rpm and with differential pressure across the expander up to 14 bar. Experimental ventilation loss is characterised and its effect on the performance of the expander is discussed. The preliminary results of the expander under investigation showed satisfactory production of power with an acceptable efficiency range. It is also shown that the present concept is promising and able to address the major i.e., stator-rotor interaction which is the major source of loss in the traditional bladeless expander.