Generation of 3D Turbine Blades for Automotive ORC

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Generation of 3D Turbine Blades for Automotive ORC ( generation-3d-turbine-blades-automotive-orc )

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􏰁􏰂􏰃 􏰅􏰆􏰇 􏰈􏰉􏰊􏰋􏰌􏰂􏰍 Abstract: Organic Rankine cycle technology is gaining increasing interest as one of potent future waste heat recovery potential from internal combustion engines. The turbine is the component where power production takes place. Therefore, careful attention to the turbine design through mathematical and numerical simulations is required. As the rotor is the main component of the turbine, the generation of the 3D shape of the rotor blades and stator vanes is of great importance. Although several types of commercial software have been developed, such types are still expensive and time-consuming. In this study, detailed mathematical modelling was presented. To account for real gas properties, REFPROP software was used. Moreover, a detailed 3D CFD numerical analysis was presented to examine the nature of the flow after generating the 3D shapes of the turbine. Moreover, finite element analysis was performed using various types of materials to obtain best-fit material for the current application. As the turbine is part of a larger system (i.e., ORC system), the effects of its performance on the whole ORC system were discussed. The results showed that the flow was smooth with no recirculation at the design point except at the last part of the suction surface where strong vortices were noticed. Despite the strong vortices, the mathematical model proved to be an effective and fast tool for the generation of the 3D shapes of turbine blades and vanes. The deviations between the 1D mean-line and 3D CFD in turbine efficiency and power output were 2.28% and 5.10%, respectively. Keywords: mathematical modelling; automotive organic rankine cycle; computational fluid dynam- ics (CFD); finite element analysis; radial inflow turbine; generation of backswept blades 1. Introduction Since the late 19th century, the average temperature on Earth has risen by approxi- mately 0.9 ◦C because of the increased carbon dioxide (CO2) and other man-made emissions to the atmosphere [1]. Besides the potential effects of CO2 on global climate, transportation contributes to air pollution through mono-nitrogen oxides (NOx) and particulate mat- ter (PM) emissions [2]. Transportation also contributes to global warming through CO2 emissions which pose serious threats to public health. Among fuel-based applications, transportation burns most of the world’s fuel, accounting for more than 28% of the total fuel consumption in the United States in 2018 [3] and more than 50% in the United King- dom [4]. In addition, fuel prices have continually increased, from 1.191$/gallon in 1990 to 2.578$/gallon in the US [5]. Additionally, with the improvement of people’s living stan- dards, fuel consumption by the transportation sector will increase significantly [6]. These concerns necessitate the development of more efficient combustion engines to reduce fuel consumption and CO2 emissions. In this regard, waste heat recovery (WHR) technology is one of the promising technologies in recovering the wasted fuel energy. mathematics Article Generation of 3D Turbine Blades for Automotive Organic Rankine Cycles: Mathematical and Computational Perspectives Fuhaid Alshammari 1 , Apostolos Pesyridis 2,3,* and Mohamed Elashmawy 1,4 Citation: Alshammari, F.; Pesyridis, A.; Elashmawy, M. Generation of 3D Turbine Blades for Automotive Organic Rankine Cycles: Mathematical and Computational Perspectives. Mathematics 2020, 9, 50. https://doi.org/10.3390/math9010050 Received: 17 September 2020 Accepted: 19 October 2020 Published: 29 December 2020 Publisher’s Note: MDPI stays neu- tral with regard to jurisdictional claims in published maps and institutional affiliations. Copyright: © 2020 by the authors. Li- censee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/ licenses/by/4.0/). 1 2 3 Mechanical Engineering Department, Engineering College, University of Hail, Hail 81481, Saudi Arabia; Fu.alshammari@uoh.edu.sa (F.A.); arafat_696@yahoo.com (M.E.) Alasala Colleges, King Fahad Bin Abdulaziz Rd., Dammam 31483, Saudi Arabia; a.pesyridis@alasala.edu.sa Department of Mechanical, Aerospace and Civil Engineering, Brunel University London, Centre of Advanced Powertrain and Fuels, Uxbridge UB8 3PH, UK 4 * Correspondence: a.pesyridis@brunel.ac.uk Mechanical Engineering Department, Engineering College, Suez University, Suez 43521, Egypt Mathematics 2020, 9, 50. https://doi.org/10.3390/math9010050 https://www.mdpi.com/journal/mathematics

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