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79 6 Radial turbine design for a micro-ORC test setup In this chapter, the design of a small-scale radial turbine designed for an ORC experi- mental setup based on high speed turbogenerator technology is presented and discussed. Based on the turbine design consideration and on the thermodynamic analysis for differ- ent fluids presented in the previous chapters, MDM was selected as the working fluid for an experimental setup, designed to recover exhaust gas heat from a diesel engine. The estimated power output of the turbine is about 13 kW and a high speed turbogenerator is used in the system. The selection of the working fluid was a compromise taking into account the cycle efficiency, process design, and turbine design. MDM was selected since it allows to design a turbine with a significantly lower rotational speed and larger tur- bine wheel, when compared to the hydrocarbons and fluorocarbons and siloxane MM. In addition, the blade height at the rotor inlet is higher with MDM when compared to the hydrocarbons. The disadvantages of using MDM as the working fluid are the relatively high expansion ratio over the turbine, which leads to a large variation on the rotor blade height between the rotor inlet and outlet; the high volumetric flow rate at the turbine out- let, which leads to the use of large sized heat exchangers and process piping at the low pressure side of the process; low speed of sound; and moderate cycle efficiency when compared to more complex siloxanes, such as D4 or hydrocarbons, with a high critical temperature. 6.1 Design and flow analysis of the turbine In this section, the design and CFD-simulation results for the turbine are presented. The simulations were performed for different stator and rotor geometries. The design data used as an input in the turbine design are presented in Table 6.1 and the main specifi- cations of the designed turbine in Table 6.2. The velocity triangles obtained in the 1D turbine design at the turbine rotor inlet and rotor outlet are presented in Figure 6.1. The design was an iterative process in which several changes were made into the process de- sign according to the changes made in the turbine design and the input data used in the turbine design was changed according to the changes made in the process design and me- chanical design. The final turbine geometry was a compromise between the aerodynamic design and mechanical design, taking into account the limitation for mechanical stresses and vibrations, as well as the limitations for the axial force caused by the pressure differ- ence over the turbine wheel. In addition, the process design set limitations, such as the condensing pressure, was limited to be above 0.03 bar. Thus, the turbine outlet pressure of 0.07 bar is used in the turbine design because slightly higher condensing temperature is adopted in the experimental setup when compared to the condensing temperature used in the Case1 in Chapter 5. In addition, the pressure losses between the turbine and the condenser increase the turbine outlet pressure and were taken into account in the turbine design. The degree of reaction lower than 0.5 and the turbine inlet pressure significantly lower than the fluids critical pressure were used in the final turbine design to increase the blade height at the rotor inlet and in the stator flow channels. In additon, the turbine rotor have curved blades at the rotor inlet instead of straight blades. The used turbine designPDF Image | WORKING FLUID SELECTION AND DESIGN OF SMALL-SCALE WASTE HEAT RECOVERY SYSTEMS BASED ON ORGANIC RANKINE CYCLES
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