STUDIO NUMERICO SPERIMENTALE DI TuRBomacchine di piccola potenza

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1 Giornata di Studio sulle TURBOMACCHINE Bergamo 15 luglio 2016 STUDIO NUMERICO SPERIMENTALE DI TuRBomacchine di piccola potenza Rodolfo Bontempo Marcello Manna Raffaele Tuccillo Dipartimento di Ingegeria Industriale (D.I.I) Università di Napoli Federico II

2 Abstract The presentation deals with theoretical, numerical and experimental analysis of small sized turbomachines Ducted Rotors The classical actuator disk model is improved to take into account all nonlinear flow features. It is applied to the theoretical analysis and to the preliminary design of innovative devices like small ducted wind turbines. Turbochargers The steady and unsteady behaviour of automotive turbochargers are studied my experimental means. Some insights on the validity of the adiabatic flow assumption and on the statistical characterisation of the surge are provided. The analysis of turbochargers is further detailed showing the conceptual design of an innovative vaneless axial flow turbine. Finally, the design of a novel downstream volute for axial flow turbine is presented and discussed Radial flow turbine A similarity criteria approach is used to investigate the actual possibilities of adopting a radial flow turbine as an ORC expander. The results are validated by CFD. 2

3 References Bontempo, R., Manna, M., Solution of the flow over a non-uniform heavily loaded ducted actuator disk, Journal of Fluid Mechanics (728), pp , 2013 Bontempo, R., Manna, M., Performance analysis of open and ducted wind turbines, Applied Energy (136), pp , 2014 Bontempo, R., Manna, M., Effects of the duct thrust on the performance of ducted wind turbines, Energy (99), pp , 2016 Bontempo, R., Cardone, M., Manna, M., Vorraro, G., Steady and unsteady experimental analysis of a turbocharger for automotive applications, Energy Conversion and Management (99), pp , 2015 Cameretti M.C., Ferrara F., Gimelli A., and Tuccillo R., 2015, Combined MGT ORC solar hybrid system. PART B: Component Analysis and Prime Mover Selection, ENERGY PROCEDIA, vol. 81 (2015), pp , doi: /j.egypro Cameretti M.C., Ferrara F., Gimelli A., and Tuccillo R., 2015, "Employing Micro-Turbine Components in Integrated Solar MGT - ORC power plants", ASME paper GT Conceptual design of an axial flow turbine for advanced variable geometry turbochargers, 2016 (A. Saccomanno Dissertation, Superv. R. Tuccillo, a. Pesiridis) Fluid-Dynamic Design of an Innovative Turbine-Volute Layout for Turbochargers, 2016 (A. Ferrara Dissertation, Superv. R. Tuccillo, a. Pesiridis) 3

4 Summary The nonlinear actuator disk method as applied to ducted rotors UNINA Turbocharger Test Rig Conceptual design and analysis of a vaneless axialflow turbine for turbochargers Design and analysis of axial flow turbine with downstream volute for turbochargers Study of the ORC expander based on similarity criteria and CFD analysis 4

5 The nonlinear actuator disk method as applied to ducted rotors Ducted propellers Ducted Turbines The duct improves the propulsive efficiency The duct prevents the occurrence of the cavitation The duct improves the power coefficient ı ı (a ducted turbine can beat the Betz limit) 5

6 Assumptions Stationary Incompressible Inviscid Axisymmetric The rotor is modelled through an actuator disk Genesis of the method Nonlinear actuator disk Vortex Panel method Exact solution of the flow in an implicit form for a prescribed load distribution A semi-analytical and iterative procedure has been developed 6

7 Main advantages of the method The method naturally takes into account the contraction of the wake (very important for ducted and heavily loaded propellers) The method duly accounts for the nonlinear and mutual interaction between the duct and the rotor the rotor and duct flow fields are strongly coupled Non-uniform load distributions, rotor wake rotation and ducts of general shapes can be dealt with Low computational cost it is well suited to be integrated in the first stage of design systems based on the repeated analysis scheme of hierarchical type 7

8 Velocity contours Duct: NACA 4415; Parabolic Load Distribution; ı = ı. ı Dimensionless axial velocity ı ı /ı ı Dimensionless radial velocity ı ı /ı ı 8

9 Verification against CFD Duct: NACA 4415; Parabolic Load Distribution; ı = ı. ı SA CFD 9

10 CPU Time evaluation Ducted Wind Turbine: NACA

11 Ducted Wind Turbine Versus Open Wind Turbine Duct: NACA 5415; Parabolic Load Distribution open ducted Betz Limit 11

12 UNINA Turbocharger Test Rig Rig Layout 12

13 UNINA Turbocharger Test Rig VI Layout 13

14 UNINA Turbocharger Test Rig VI Layout 14

15 UNINA Turbocharger Test Rig Applications: Steady-State Performance Maps Compressor Map Turbine Map 15

16 UNINA Turbocharger Test Rig Applications: Evaluation of the heat transfer effects on the performance 16

17 UNINA Turbocharger Test Rig Applications: Surge Characterisation Surge N/N ref = 0.6 Surge N/N ref = 1 17

18 UNINA Turbocharger Test Rig Applications: Surge Characterisation ı ı ı ı ı ı Surge N/N ref = 0.6 Surge N/N ref = 1 18

19 UNINA Turbocharger Test Rig Applications: Surge Characterisation 19

20 Conceptual design and analysis of a vaneless axial-flow turbine for turbochargers Cooperation with Brunel University, London (Dr. A. Pesiridis) Engine 1D modelling Preliminary design 3D design CFD investigation Off-design and map generation 20

21 Engine 1D modelling Simulation at 100% of load Engine performance Simulation at 75% of load 150 Load 100% 150 Load 75% Engine Power [kw] Engine Torque [Nm] Axial turbine GT Engine Speed [rpm] Load 100% Axial turbine Engine Power [kw] Engine Torque [Nm] Axial turbine GT Engine Speed [rpm] 300 Load 75% Axial turbine GT1548 GT Engine Speed [rpm] Engine Speed [rpm]

22 Preliminary design Data from 1D engine simulation of a 1.6l Ford EcoBoost Engine Speed rpm (max. load) Mass flow kg/s 0,1140 0,1148 0,0926 0,0736 0,0446 rate Inlet bar 2,268 2,377 1,967 1,669 1,324 Total Pressure Outlet bar 1,375 1,463 1,283 1,170 1,077 Static Pressure Power kw 8,66 8,11 6,01 4,14 1,51 Speed rpm Inlet Total temperature K 1050, , , , ,06 22

23 Preliminary design Balje Diagram for axial turbines 23

24 Preliminary design Cordier diagram 24

25 Design of the volute nozzle axial flow rotor Rotor: BladeGen The fluid conditions at rotor inlet must be achieved by the volute nozzle system Nozzle: CFturbo Volute: CFturbo 25

26 Design of the volute nozzle axial flow rotor Rotor: BladeGen Nozzle: CFturbo q Due to the non- Volute: uniformity CFturbo of the q fluid condition at the nozzle outlet surface, a nonperiodic solution is carried out A MRF has been used for stationary part rotor interaction (FLUENT flow solver) 26

27 Grid Size Sensitivity Case # Stator (*10^3) Number of cells 1 rotor passage (*10^3) Total (*10^3) η T-T [-] Mesh sensitivity analysis η T-S [-] Mach Number ex [-] CFD resluts Tot Pressure ex [Pa] Mass flow [kg/s] Computational time [h] Case ,809 0,697 0, , Case ,818 0,704 0, , Case ,823 0,701 0, , Case ,824 0,700 0, , Case ,824 0,699 0, , Case ,824 0,698 0, , Case ,824 0,698 0, , ,116 0,1158 Case 2 Mass flow rate [kg/s] 0,1156 0,1154 0,1152 0,115 0,1148 Case 3 Case 4 Case 5 Case 6 Case 7 0,1146 0,1144 0,1142 Case Number of cells x

28 CFD analysis of the fixed part Free vortex distribution 28

29 CFD analysis of the fixed part Free vortex distribution 29

30 Rotor CFD investigation Results Power [W] Mass Flow [kg/s] η T-S η T-T Final Turbine , % 82,4% AxStream ,113 77,0% 86,0% HUB SECTION MEAN SECTION TIP SECTION 30

31 OFF DESIGN ANALYSIS 3 2,8 2,6 2,4 2,2 βt-s 2 1,8 1,6 1,4 1,2 Turbine Operating Map Tref=109 7K ; pref=2.35 bar 1 0,08 0,09 0,1 0,11 0,12 0,13 Corrected mass flow [kg/s] m (T/Tref)/((p/pref) Compressor pressure ratio [-] Turbine Speed [rpm] Total-to-static efficiency [-] 2, ,72 0, ,68 0, , ,62 Engine load Axial 75% turbine 0,6 GT Data at engine 3000 speed 4000[rpm] Data at Engine Speed [rpm] Total-to-total efficiency [-] Engine Turbine Matching Load 75% Load 75% 0,84 1,80 0,82 0,8 1,60 0,78 1,40 0,76 0,74 1,20 0,72 Axial turbine Engine load 75% 0,7 GT1548 1, Data Data at at Engine engine Speed speed [rpm] 31

32 OFF DESIGN ANALYSIS Turbine 280 Operating Map Load 75% Tref=109 7K ; pref=2.35 bar 2,8 2,6 2,4 2,2 2 1,8 Engine Torque [Nm] , ,4 120 Axial turbine GT1548 1, ,08 0,09 0,1 0,11 0,12 0,13 Corrected mass flow [kg/s] m (T/Tref)/((p/pref) Engine Speed [rpm] 32

33 Cooperation with Brunel University, London (Dr. A. Pesiridis) Fluid-Dynamic Design of an Innovative Turbine-Volute Layout for Turbochargers The solution proposed: Honeywell Axial Flow Turbine 33

34 v Kinetic energy recovery v Improved efficiency under steady and unsteady conditions due to the largely circumferential uniform flow. v Improved transient response due the shorter flow path and less exhaust manifold and turbine volute volume between the engine and the rotor. v Reduction of pulsating flow effects (phase shift) due to the shorter flow passage of the stator than that of a volute 34

35 Reduction of the discharge static pressure Static Pressure Outlet Turbine [bar] 1,45 1,39 Total to Static Efficiency [%] 74,07 73,01 Blade Speed [m/s] 294,1 294,1 Isentropic Velocity [m/s] 534,72 555,17 Blade Speed Ratio [-] 0,55 0,52 Rotor Mean Diameter [mm] 38,56 37,56 Rotor Blade Height [mm] 13,41 13,47 Stator Mean Diameter [mm] 38,56 37,56 Stator Blade Height [mm] 12,05 12 Maximum Rotor Diameter[mm] 51,97 51,03 Inlet Area [mm^2] 1623,6 1588,6 35

36 Stator Annulus Stator Profile, Hub Stator Profile, Mean Stator Profile, Tip Rotor Annulus Hub Profile Mean Profile Tip Profile Solidworks 3D representation 36

37 3D turbine representation from BladeGen Solidworks 3D representation 37

38 Different Configurations 11 Stator Blades/ 12 Rotor Blades/ Increased Thickness 19 Stator Blades/20 Rotor Blades Configuration Original New Δ% Total To Static Efficiency [%] 70,9 74 4,18 Total To Total Efficiency [%] 85,2 82,8 2,8 Power [kw] 14, ,61 Mass Flow Rate [kg/s] 0,134 0, ,58 38

39 Different Configurations MEAN 19 Stator Blades/20 Rotor Blades 39

40 Different Configurations HUB 19 Stator Blades/20 Rotor Blades 40

41 v Isentropic Flow v Free Vortex Law v Mass conservation The design of diffuser and volute Cross Sections Calculation: Free Vortex Law 41

42 The concept of a symmetric volute Use of two «semivolutes» to reduce the clutter of the last sections and accomodate the radial flow exiting the diffuser 42

43 Streamlines in the innovative volute 43

44 Different configurations of the innovative volute System Efficiency ,29 78,7 78,73 78, , ,59 77,19 77,38 77, % , VOLUTES Total to Static Efficiency 44

45 Mesh Sensitivity of the ultimate systems Innovative Volute System Elements Stator Rotor Diffuser Volute Classic Volute System Elements Stator Rotor Diffuser Volute

46 Performance Maps Classic Volute Innovative Volute ı ı ı ı ı ı ı,ı ı ı ı ı ı ı ı ı ı,ı ı ı ı ı ı ı ı ı ı ı ı ı,ı ı ı ı ı,ı ı ı ı ı ı ı ı ı ı ı ı ı,ı ı ı ı ı,ı ı ı 46

47 Turbine Speed [rpm] Data at Engine Speed [rpm] Turbine-Engine Matching Turbine with innovative volute Turbine with classic volute Compressor Pressure Ratio 2 1,9 1,8 1,7 1,6 1,5 1,4 Turbine with 1,3 innovative 1,2 volute 1,1 Turbine with classic 47 volute [rpm] Studio Numerico Data at Engine Sperimentale Speed di Turbomacchine di Piccola Potenza Turbine Power [kw] Turbine with innovative volute Turbine with classic volute [rpm] Data at Engine Speed

48 Effect of Turbine-Engine Matching 140 Engine Power (Maximum Load) Power [kw] Engine speed [rpm] Turbine with innovative volute Original Turbine Turbine with innovative 180 volute 170 Original Turbine Torque [Nm] Engine Torque (Maximum Load) Engine speed [rpm] 48

49 THE DOWN-SIZED RADIAL TURBINE AS AN ORC EXPANDER The radial flow turbine from the well consolidated technology of down-sized turbochargers appears to be worthy of particular attention as an effective ORC expander An analysis to investigate the actual possibilities of adapting the radial flow turbine to a different application: Similarity criteria CFD validation Working Fluids considered: R245fa (higher molecular mass compared with air and steam) R134a Ammonia (lighter working fluid ) 49

50 The changes in both rotational speed and mass flow rate are mainly governed by the molecular mass of the new working fluid, while the turbine pressure ratio varies in accordance with the isentropic exponent and the isentropic efficiency Reference conditions: Air expansion Total-to-static pressure ratio β ORC γ = γ ORC ref 1 γ ORC 1 1 γ 1 η ref γ ORC ORC β ref γ ref ηref Rotational speed N ORC = N ref SF ( m) ( m) ref ORC γ γ ORC ef T T ORC ref Expected mass flow rate m ORC = m ref SF 2 T T ref ORC p p ref ORC ( m) ( m) ref γ γ ORC ref ORC 50

51 Reference Conditions vpressure ratio = 4.1 vangular speed = rad/s. Rotor Geometry üexternal diameter = 47.8 mm üaxial displacement = 19.9 mm ü 9 swirled blades Three dimensional views of the radial flow turbine rotor The ORC condensing pressure was estimated at 40 C m / m ref The use of ammonia, even if more favourable in terms of cycle efficiency thanks to its higher superheating temperature, would imply an increase in rotor speed Operating Conditions and Properties of the several working fluids Air R245fa R134a Ammonia P 01 (bar) T 01 (K) P 2 (bar) β tt (expected) ω (rad /s) γ Inlet Sound Speed (m/s) µ (Pa s) 2.62 x x x x 10-5 ν (m 2 /s) 8.92 x x x x

52 Since the values of the mass flow delivered by the radial turbine should meet those resulting from the energy balance of the heat recovery boiler a further transformation has been also considered for this component by applying an appropriate scaling factor (SF) according to the well known relationships: SF m = ORC DORC Dref D 2 ORC 1 SF 2 2 ; ωorc ; H ωorcdorc For the T100-R245fa cases, a scaling factor of was established the C30-R134a case implied a reduction in mass flow rate that was obtained by applying a scaling factor of

53 53 A simultaneous reduction of these parameters can be obtained by means of an iterative procedure that leads to a decrease in the angular velocity (and, therefore, in the rotor flow capacity) and in the pressure ratio, in accordance with the additional relationship: = γ γ β η γ γ T R H

54 CFD analysis of the radial flow turbine The CFD analysis of the radial flow rotor was carried out in a threedimensional periodic sector of 40 with a tetrahedral mesh of elements (with an average volume of 1.89 x 10-2 mm 3 and an average edge size of 0.27 mm). Time marching solution of the transonic flow Reynolds stress (7 eqs.) model for the viscous flow 54

55 Averaged meridional contours of relative Mach number 55

56 A second step of this investigation was the off-design study that is discussed, as an example, for the C30-R245fa case that did not require any adjustment in terms of scaling factor. Characteristic curves of the radial flow rotor (Working fluid R245fa) It is worth-noting that the rotor appears to cover a wide range of mass flow rates, even if acceptable values of the efficiency can be found in a more restricted interval 56

57 Relative Mach number contours at mid-span (Working fluid R245fa) 57

58 Micro Gas Turbine Laboratory, Ce.S.M.A, Napoli, ITaly The MICRO GAS TURBINE CAPSTONE C30 Fossil and Biogas fuelling Matching with bottoming ORC 58

59 Thanks for your kind attention 59

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