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WORKING FLUID SELECTION AND DESIGN OF SMALL-SCALE WASTE HEAT RECOVERY SYSTEMS BASED ON ORGANIC RANKINE CYCLES

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WORKING FLUID SELECTION AND DESIGN OF SMALL-SCALE WASTE HEAT RECOVERY SYSTEMS BASED ON ORGANIC RANKINE CYCLES ( working-fluid-selection-and-design-small-scale-waste-heat-re )

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3.3 Computational fluid dynamics 41 on the flow field predicted by the CFD simulations as well as on the changes made in the process design. The constraints that were used in the radial turbine design for the experi- mental setup in evaluating feasible turbine dimensions and working parameters are listed in Table 3.5. The relative velocity at the turbine rotor inlet was limited to be subsonic to reduce the losses related to the supersonic flow as well as to simplify the rotor design. In addition, a subsonic absolute velocity was designed at the turbine rotor outlet to reduce the losses. The stator throat width was designed to be more than 1 mm and the blade height at the rotor inlet and in the stator flow channel was designed to be more than 1.5 mm because smaller dimension were estimated to lead in difficulties in manufacturing the turbine wheel and stator flow channels as well as to low turbine efficiency. Table 3.5: Constraints used in the design of radial turbine for the ORC prototype. bst >1mm Maw1 <1 t1 > 1.5 mm Mac2 <1 3.3 Computational fluid dynamics The turbine CFD simulations presented in this study were performed for a small-scale, high expansion ratio radial turbine that was designed for an experimental setup. The CFD simulations were carried out by using the Navier-Stokes flow solver Finflo, which is a multi-grid solver developed at the Aalto University School of Science and Technology, and some modifications and additions have been implemented to the code at the Lappeen- ranta University of Technology. More detailed information about Finflo and different numerical methods can be found for example in a paper of Siikonen (Siikonen, 1995). Finflo has been used as a flow solver in the modelling of different types of turbomachinery flows, such as in the flow modelling of centrifugal compressors (Turunen-Saaresti, 2004; Tang, 2006; Jaatinen, 2009), ORC turbines (Hoffren et al., 2002; van Buijtenen et al., 2003), and supersonic axial turbines (Gro ̈nman, 2010; Gro ̈nman et al., 2013). Gro ̈nman et al. (2013) modelled a transonic turbine cascade and demonstrated the reliability of the modelling with Finflo in a case where shock waves occur. In addition, the results ob- tained by using Finflo were compared to the results obtained by two other flow solvers in modelling high-expansion ratio real-gas flows in supersonic ORC turbine stator (Harinck, 2010). In general, the results obtained with different flow solvers were in a good agree- ment showing small differences mainly in a predicted shock wave strength as well as on the wake dissipation. It should be noted, that due to the lack of available experimental data on real gas flows occurring in the so-called dense gas region, the used CFD code has not been validated with real gas flow measurements. Based on the experimental results obtained in the measurements for a commercial 160 kW ORC, a reasonably good perfor- mance prediction for the turbine was estimated by using Finflo in the turbine design (van

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