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

Abstract

The goal of this study is to experimentally compare the performance of an Organic Rankine Cycle (ORC) system equipped with a radial-inflow turbine for two working fluids: R245fa and R1233zd. The radial-inflow turbine is a small-scale prototype designed to convert the waste heat from the exhaust gases of a truck combustion engine and was developed mainly using components of truck turbochargers. It is directly connected to a high-speed synchronous generator. The bearings system of the turbine and the generator have the innovative particularity to be respectively lubricated and cooled down by the working fluid so no additional lubricant or coolant is needed. The experimental comparison is carried out over a test-rig equipped with the radial turbine. The heat wasted by the truck through the exhaust gases is simulated using an electric oil boiler coupled to the ORC loop. The electrical power supplied by the turbine, limited to a maximum of 3.5kWel by the generator, is then dissipated in a load bank composed of truck fans while the condenser is cooled by a water loop. Measurements in steady-state are performed in order to evaluate the performance of the turbine-generator set when varying the pressure ratio, the rotational speed, the inlet temperature and the mass flow rate of the turbine and the lubrication flow rate of the bearings for various oil temperatures and mass flow rates. In order to identify the most suitable fluid for the Waste Heat Recovery (WHR) application, three comparison methods are proposed and discussed based on the measurements. Finally, because the turbine-generator set is the first oil-free prototype developed by the manufacturer, potential sources of improvements are discovered and discussed.