GT-SUITE as a Modelling Tool

for Expanders and Pumps

in Waste Heat Recovery applications

Dr. Giuseppe Bianchi Dr. Apostolos Pesyridis Prof. Savvas A. Tassou

Institute of Energy Futures

Brunel University London

Uxbridge, Middlesex, UB8 3PH, UK

www.brunel.ac.uk

E giuseppe.bianchi@brunel.ac.uk

T +44 (0)1895 267707

M +44 (0)7401 358947

Frankfurt, 09/10/2017

EUROPEAN GT CONFERENCE 2017

Marek Lehocky

Jonathan Harrison

Gamma Technologies

G. Bianchi

Outline

Automotive ORC potential and industrial interest

GT-SUITE ORC modelling approach

Pump modelling

• Centrifugal

• Positive displacement (sliding vane)

Expander modelling

• Radial turboexpander

• Positive displacement (sliding vane, twin-screw)

Lessons learned

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 2

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ICE engine waste heat recovery potential

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 3

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GT-SUITE template for ORC modelling

System integration

Diversified fluid and component libraries

Control implementation

Low computational effort

❖ Large number of input data required

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 4

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Modelling approaches and available templates

Operating maps (experimental or from datasheets)

Detailed component modelling (no turbomachinery)

✓ Gear

✓ Gerotor

✓ Swashplate

✓ Piston

✓ Scroll (ongoing)

✓ Screw

✓ Vane

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 5

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Centrifugal pump

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 6

Input data

• Revolution speed

• Pressure rise

• Power consumption

Process data

• Interpolation of the curves in a range between 1800 and 3000 rpm

• Extrapolation of the curves for lower velocities

Process data

• Calculation of isentropic efficiencies for each point of the performance map

Performance Maps

• plot the performance and the isentropic efficiency maps of the centrifugal pump

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Sliding vane pump

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 7

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Sliding vane pump

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 8

Angular pressure profile Performance map

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Turboexpander

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 9

Radial Turbine Design

RTD

oRotor

oStator

oVolute

o Losses

Radial TurbineOptimisation

RTO

Advanced numerical methods for optimization:

oObjective function

oDoE

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Turboexpander

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 10

The optimum geometry was imported in an in-house code to generate an

off-design turbine map

Standard NASA loss model was utilized being calibrated on the design

point from RTD

Turbine map was generated by running the code at various pressure

ratios and rotational speeds

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Twin-screw two-phase expander

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360

malesim

ZZ ceil

Scaling procedure

360 / sim realSF

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Twin-screw two-phase expander

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Indicator diagram (p-V) Quality-angle diagram

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Sliding vane expander

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GT-SUITE - 3D CFD - experiments

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Conclusions

ORC is a suitable technology for heavy-duty vehicles and stationary engines

GT-SUITE allows the modelling of ORC components and systems, including

controls

Turbomachinery modelling needs operating maps

• Methodology for radial turbo-expander with backsweep design presented

Detailed machine modelling is available for most of the positive displacement

technologies (some of the models do not account for friction yet)

• Modelling approach in two-phase twin-screw machines presented

• Focus on sliding vane machines (pump and expander cases presented)

• GT-SUITE model results are in good agreement with experiments as well as with 3D CFD

simulations

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 15

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Acknowledgements

Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 16

This project has received funding from the European Union’s Horizon 2020 research and

innovation programme under grant agreement No. 680599

Project No. 61995-431253 Grant No. EP/P510294/1

Grant No. EP/K011820/1

G. Bianchi

About us

Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 17

Centre for Advanced Powertrain and

Fuels Research (CAPF)

➢ 13 Engine test cells – one of the largest, academic

powertrain research centres in UK

➢ Multi-cylinder engines

• 7.2 litre Diesel bus engine

• 2.0litre HSDI CR diesel engine, I4 & V6 prototype GDI

engines

• EPSRC Centre of Excellence in Optical Diagnostics

➢ Single cylinder engines

• 3 Ricardo Hydra Single cylinder optical engine testbeds

➢ Analysers

• Full Gas analysers, fast FID, fast sampling valve,

Smoke/PM analysers

➢ Optical Systems

• 2 Nd:YAG Lasers, a Dye laser, an Excimer laser, a

Copper Vapour laser

• Detectors: 2 Gated ICCDs, high-speed colour video

camera (60K fps)

➢ Techniques

• LDA, PIV, LIF (fuel, OH, CH2O ), LIEF, SRS, LII.

➢ Engine simulation

• Phenomenological, gas dynamics, and CFD (KIVA3v)

Centre for Sustainable Energy Use in

Food Chains (CSEF)

➢ Thermal management

• Refrigeration (4 climatic chambers, single stage and multi-

stage CO2 and HFO systems)

• Heat pump technology (experimental facilities for CO2 and

HFO systems)

• Thermal energy storage (phase change materials)

➢ Heat recovery

• Cold and hot low pressure wind tunnels for fundamental

research

• Full-scale heat exchanger testing

• Heat pipe technology expertise

➢ Heat to power conversion

• ORC rig on a CHP unit

• ORC rig on heavy-duty engine

• sCO2 rig for high temperature industrial heat recovery

➢ Numerical simulation

• Multi-core computational facilities

• Commercial and customised model development

G. Bianchi

Selected references

1) J. Ringler et al., Rankine Cycle for Waste Heat Recovery of IC Engines, SAE Int. J. Engines 2(1):67-76, 2009,

DOI:10.4271/2009-01-0174.

2) M. Karvonen et al., Technology competition in the internal combustion engine waste heat recovery: a patent landscape

analysis, Journal of Cleaner Production, Volume 112, 2016, Pages 3735-3743, ISSN 0959-6526,

DOI:10.1016/j.jclepro.2015.06.031.

3) G. Bianchi, Exhaust Waste Heat Recovery in Internal Combustion Engines - Development of an ORC-based power unit using

Sliding Vane Rotary Machines, 2015, ISBN 978-88-87182-69-9, DOI: 10.13140/RG.2.1.4095.7282 (PhD thesis)

4) R. Cipollone et al., Development of an Organic Rankine Cycle system for exhaust energy recovery in internal combustion

engines, Proceedings of the 33rd UIT (Italian Union of Thermo-fluid-dynamics) Heat Transfer Conference, Journal of Physics:

Conference Series, Volume 655, 2015, pp. 012015, DOI:10.1088/1742-6596/655/1/012015

5) G. Bianchi et al., Design and analysis of a sliding vane pump for waste heat to power conversion systems using organic fluids,

Applied Thermal Engineering, Volume 124, 2017, Pages 1038-1048, ISSN 1359-4311,

DOI:10.1016/j.applthermaleng.2017.06.083.

6) M. Marchionni et al., Dynamic modelling and optimization of an ORC unit equipped with plate heat exchangers and

turbomachines, 4th ORC seminar, Milan, 2017

7) G. Bianchi et al., Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications, 4th ORC

seminar, Milan, 2017

8) A. Karvountzis-Kontakiotis et al., “Design of Radial Turbine Expanders for Organic Rankine Cycle, Waste Heat Recovery in

High Efficiency, Off-Highway Vehicles”, 3rd Annual Engine ORC Consortium Workshop, Queens University Belfast, UK, 14-16

September 2016.

9) A. Karvountzis-Kontakiotis et al., “Variable Geometry Turbine Design for Off-Highway Vehicle Organic Rankine Cycle Waste

Heat Recovery”, Conference Proceedings of THIESEL 2016, Valencia, Spain 13-16 September 2016.

GT-SUITE as a Modelling Tool for Expanders and Pumps for Waste Heat Recovery 18