Optimization of a Scroll Expander Applied to an Ammonia/Water Combined Cycle System for Hydrogen Production - Paper No. 1645

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Optimization of a Scroll Expander Applied to an Ammonia/Water Combined Cycle System for Hydrogen Production - Paper No. 1645 ( optimization-scroll-expander-applied-an-ammonia-water-combin )

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producing saturated ammonia vapor and relatively weak concentration ammonia-water saturated liquid. The weak solution leaves the vapor generator at state 4 and rejects heat to the high concentration stream before it is throttled to the system low pressure and sprayed into the absorber. The rectifier cools the saturated ammonia vapor to condense out any remaining water. The vapor is then superheated to state 7 and expanded to produce work. The sub-ambient exhaust vapor (state 8) provides refrigeration before returning to the absorber where it is re-absorbed into the weak solution. The heat of condensation is rejected to the low-temperature source and the cycle repeats. using unique expansion methods exist throughout industry. These designs can be organized into two categories, positive-displacement and turbo-machinery, based on the method of fluid displacement. Positive-displacement expanders Positive-displacement machines such as reciprocating and rotary piston, rotary vane, and screw operate by expanding a fixed volume of fluid per oscillation. Torque pulsation is a common phenomenon due to the inherent discontinuity associated with the finite number of pistons or lobes and fixed displacement. Reliability is an issue with positive-displacement machines because of a greater number of moving parts (i.e. piston linkages, sliding vanes); and in the case of pistons, a lubrication system to reduce leakage encountered in the gap between the moving seals and volute. Turbo-machinery Turbo-machinery, comprised of axial and radial flow turbines, utilizes the pressure differential across a series of radial blades to provide a “lift” force to turn the rotor, thereby producing shaft work. In this manner, a continuous power output is provided. Reliability is improved over positive-displacement expanders because the rotor is the only moving part. Turbines are designed with a clearance between the blade tips and the volute to allow free rotation; however, leakage at the tips (windage loss) is the primary cause of irreversibility in the expansion process. Blade tip clearances remain approximately constant for varying turbine size. As turbine size is decreased, the loss due to windage as a percentage of the work output becomes increasingly significant. For this reason, positive-displacement expanders are more suited for small-scale operations. The amount that the blade tip clearances can be reduced is limited by the centrifugal force and/or thermal expansion of the blade material. Typical turbine operating speeds range from a few thousand up to tens of thousands RPM. Centrifugal force is dependent on blade tip speed, which is function of the RPM and the rotor diameter. As a result, larger turbines suffer greater radial blade deformation and are less suited for blade tip clearance reduction. Scroll compressor/expander The scroll compressor was first invented by Lèon Creux in 1905 (Gravesen and Henriksen, 2001). Commercial interest in the technology was not strong until the introduction of computer numerically controlled (CNC) machines in the 1970s. CNC machines provided the basis for machining the precise elements needed for a scroll compressor to operate efficiently and quietly (Copeland corp., 2001). A scroll compressor consists of two identical spiral elements assembled with a 180° phase difference. During operation, one scroll remains stationary and the other is attached eccentrically to a motor shaft. This configuration allows the scroll to rotate in an orbiting Figure 4.3 Combined cycle flow diagram The power output and cooling capacity of the cycle under given operating parameters is highly dependent on the expander efficiency. Irreversibilties due to friction and leakage decrease the amount of work extracted from the fluid. Because less work is extracted, the expander exhaust temperature is higher and the cooling capacity is reduced. Losses in the expander have the greatest impact on the overall cycle efficiency (Tamm etal., 2003), so it is important to select an optimal design. The main criteria for expander selection are operating pressures and temperatures, flow rate of ammonia vapor and material compatibility with ammonia. Ammonia is a corrosive substance that reacts with metals such as copper, brass, and bronze, all of which are commonly used as bearing or bushing material. The expander selected for use in the combined cycle must be sized correctly for the flow rate and for the operating pressure ratio for maximum power production and refrigeration capacity. It must also be constructed out of steel, aluminum, or any other material compatible in an ammonia environment. Expander Design An expansion device extracts mechanical energy from a fluid by expanding it from a high to a low pressure and converting it into shaft work. Various expander designs

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