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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Mathematics 2020, 9, 50 2 of 30 Lately, organic Rankine cycle (ORC) systems have gained lots of attention for recov- ering waste heat from low to medium temperature heat sources [7]. Compared to other WHR technologies, ORC systems present high thermal efficiency under a wide range of operating conditions [8], relatively low cost and minor increase of pumping losses [9]. The implementation of ORC systems in internal combustion engines (ICEs) is found to significantly improve fuel consumption by up to 5% [9], while another study reported that engine exhaust emissions (especially NOx) drop as engine load is minimized [10]. More recent studies show the high potential of ORC systems as WHR technologies in ICEs. Karvountzis-Kontakiotis et al. [11] studied the effects of variable geometry turbine performance on the thermal cycle performance. Compared to fixed geometry turbines, the thermal efficiency of the cycle with variable geometry turbine variable was 32.2% better. Zhang et al. [12] developed an experimental system to recover wasted heat in the exhaust gas of a heavy-duty diesel engine. The results indicated that the maximum power output, ORC efficiency and overall system efficiency were respectively 10.38 kW, 6.48% and 43.8%. Guillaume et al. [13] used exhaust gases of a truck diesel engine as the heat source for their ORC system. They used a radial inflow turbine as the expansion machine and two working fluids: R245fa and R1233zd. The maximum electric power and turbine efficiency were 2.8 kW (using R245fa) and 32% (using R1233zd), respectively. Alshammari et al. [14,15] explored the potential of integrating an ORC as WHR technology in heavy-duty diesel engines. The authors used an intermediate thermal oil loop to ensure steady-state operation. Although operated at off-design conditions, electrical power of 9 kW was generated. Lion et al. [16] investigated different engine-ORC architectures using a large two-stroke marine diesel engine. The results proved the ability of ORC to reduce the engine fuel consumption by 5.4% at full load. Imran et al. [17] developed a multi-objective optimization model of an organic Rankine cycle system using the exhaust gas of a heavy-duty diesel engine at 40% load. At the design point, a net power output of 10.94 kW was obtained. Mat Nawi et al. [18] extracted the wasted heat in a 996 kW marine engine with an exhaust temperature of 573.15 K using an ORC system. The obtained system efficiency and net power were 2.28% and 5.10 kW. Ezoji and Ajarostaghi [19] performed thermodynamic-computational fluid dynamics (CFD) analysis to recover wasted heat from the coolant system (water jacket) in a six-cylinder homogeneous charge compression ignition (HCCI). Results in- dicate that the improvement in thermal performance of the hybrid system in the HCCI engine can be as high as 27.94%. Yue at al. [20] proposed a mathematical model for vehicle energy supply system using ORC system and various turbine inlet temperatures. The maximum thermal efficiency of 37.5% was obtained using cyclo-pentane as the working fluid. The results showed also that the maximal gasoline oil saving rate at 9.73 kg/h, and the minimal payback period at 769 h were achieved. Liao et al. [21] investigated the potential of recovering waste heat from a coal-fired plant. The results showed a maximum thermal efficiency of 16.37%. Liu et al. [22] developed a new system for harvesting wasted heat aiming at reducing fuel consumption and exhaust emissions of a 14-cylinder marine engine, by combining steam and organic Rankine cycles. The results showed that the thermal efficiency of the engine could be improved by 4.42% and the fuel consumption could be reduced by 9322 tons per year. Le Brun et al. [23] analyzed the feasibility and prospects of small-scale commercial combined ICE + ORC CHP systems. They concluded that the installation of 40 kWe ORC system e alongside a 400-kWe ICE-CHP system can lead to an increase in overall efficiency from 51.7% to 54.0%, and a reduction of 2% in carbon emissions. Ochoa et al. [24] studied the feasibility of integrating ORCs in internal combustion engines using advanced exergo-environmental modelling. The results showed that BSFC and CO2 emissions could be improved significantly using ORC systems. Among the components of the ORC system, the expansion machine is the most crucial because of its significant effects on the performance, size and cost of the overall cycle [25]. Radial inflow turbines appear as the main tool to improve the energy efficiency of automotive powertrain systems [26]. Although mean-line modelling consumes up to 50% of the total engineering time during radial turbine design [27,28], some conditions

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