Sajjad Zakeralhoseini

Design, computational and experimental investigation of a small-scale turbopump for organic Rankine cycle systems

Jürg Alexander Schiffmann, Sajjad Zakeralhoseini

The hydraulic design, computational analysis, and experimental investigations of a high-speed small-scale turbopump for mobile waste heat recovery applications based on organic Rankine cycle systems are presented in this paper. Such applications demand high-pressure rise, lightweight, and compact pumping systems with simple construction. The investigated turbopump features an unshrouded 37.75 mm tip diameter single-stage centrifugal pump equipped with eight radial blades, eight splitters blades, and a rectangular axisymmetric volute. The pump should deliver 0.28 kg/s of mass flow rate with a pressure rise of 20 bar at a designed rotational speed of 25,000 rpm. Due to uncertainties observed in employing state-of-the-art 1-d methods that are valid for much larger machines, computational fluid dynamics is utilized to obtain a design meeting the specifications. The pump’s performance is evaluated experimentally at different rotational speeds, mass flow rates, and impeller tip clearances. The excellent agreement between experimental data and predictions from computational fluid dynamics validates the design methodology and computational results. The turbopump’s characteristics are then utilized to estimate the possible performance improvement of a target organic Rankine cycle using the novel turbopump instead of a commercial multi-stage centrifugal pump. The comparison suggests that the novel turbopump increases the efficiency of the target organic Rankine cycle by 0.3 % points and decreases its back-work ratio by nearly 50 %. The novel turbopump is approximately ten times more compact compared to commercial systems.

2023

Small-scale turbopumps for waste heat recovery applications based on an organic Rankine cycle: a study from pre-design to experimental validation

Sajjad Zakeralhoseini

The organic Rankine cycle (ORC) system is among the technologies applied to exploit waste heat in vehicles. Since common organic fluids have lower latent heat than water, higher mass flow rates are required to convert the same waste heat, considerably increasing the pump size and energy usage. The weight and size of standard pumps can significantly penalize the benefits of installing waste heat recovery on vehicles. Hence, efficient and compact pumps, such as small-scale turbopumps, would be very welcome for mobile applications. Numerical investigations are conducted on extensive parameter ranges to study their effects on the performance of small-scale turbopumps. A fully parameterized tool is developed to generate a wide range of turbopumps and their fluid domains to carry out three-dimensional computations across the impeller stage and the entire pump. Investigations are conducted under different operating conditions, and the accomplished results are analyzed to characterize the performance under design and off-design conditions. First off, the effect of tip clearance in small-scale turbopumps is studied. The slip factor is suggested to decrease linearly with increasing the flow rate. In addition, the tip clearance ratio influences the slip factor, and its effect is non-linear. The head rise decreases as the tip clearance ratios increase. The numerical data is employed to infer reduced-order models for considering the tip clearance effect in the early-phase design process of small-scale turbopumps. The models predict the CFD data with an average relative deviation of 3.6% and 5.8% for the slip factor and the head loss coefficient, respectively. Likewise, the effects of splitter blades and meridional profiles are studied. The splitters can increase impeller head coefficient and slip factors by 10%-24% depending on the blade outlet angle. At the same time, the total efficiency is not influenced significantly. For an unshrouded impeller with a tip clearance ratio of 0.10, a higher head rise is observed for a placement closer to the suction side of the main blade. Moreover, meridional profiles with a sharper change in the cross-sectional area in the vicinity of the inlet rather than a linear change from inlet to the outlet are found to be more advantageous. The optimization of the splitter blade deviating from the main blade profile is less successful than the optimization of meridional profiles in mitigating the effects of tip clearance, as only a 2.43% improvement in total efficiency is achieved. In a further step, the specific speed-specific diameter diagrams are extended to small-scale high-speed pumps. The CFD computations are conducted across the entire pump stage, and the results are analyzed to characterize the performance of turbopumps in terms of nq, ds, and efficiency. The good agreement between experimental performance characteristics and CFD predictions validates the computational results and reduced-order models.Finally, a high-speed turbopump with a specific speed of 8.9 is studied experimentally. The pump should deliver 0.28 kg/s of mass flow rate with a pressure rise of 20 bar. The turbopump's characteristics are utilized to estimate the possible performance improvement of a target ORC. The comparison suggests that the pump increases the efficiency of the ORC by 0.3% and decreases its back-work ratio by nearly 50%. The pump is approximately ten times more compact compared to commercial systems.

EPFL2023

The influence of splitter blades and meridional profiles on the performance of small-scale turbopumps for ORC applications; analysis, neural network modeling and optimization

Jürg Alexander Schiffmann, Sajjad Zakeralhoseini

This work presents the influence of splitters on the performance of small-scale turbopumps for organic Rankine cycle applications numerically. Different design parameters, such as impeller diameter at the outlet, number of blades, blade angle at the trailing edge, and the length and location of the splitter blades, are studied for both shrouded and unshrouded impellers at tip clearance ratios of 0.05 and 0.10 (relative to blade height). The results suggest that splitter blades can increase impeller head coefficient and slip factors up to 10%–24% depending on the blade outlet angle. At the same time, the total efficiency is not influenced significantly. The CFD calculations predict that the placement of splitters in the middle of the blade channel leads to the maximum head coefficient for shrouded impellers. In contrast, for the tip clearance ratio of 0.10, a higher head coefficient is observed for placement closer to the suction side of the main blade. After that, different meridional profiles are studied to investigate their influence on the performance characteristics and mitigation of tip clearance effects. Profiles with a sharper change of cross-section area at the inlet rather than a linear change are found more advantageous, as higher head rise, total efficiency, and static efficiency are observed. In the end, the splitter blade profiles are optimized through techniques of design of experiments, leading to a 2.43% improvement in total efficiency. In contrast, the head rise remains constant, and static efficiency decreases by 0.49% for an impeller with a tip clearance ratio of 0.05.

2023

The effects of the tip clearance on the performance of small-scale turbopumps for ORC applications; analysis and modeling

Jürg Alexander Schiffmann, Sajjad Zakeralhoseini

In this paper, the influence of tip clearance on the performance of small-scale turbopumps is studied numerically on extensive parameter ranges suitable for organic Rankine cycle applications. A novel and fully parameterized design model is developed and used to generate a wide range of turbopumps and their fluid domains to carry out three-dimensional computations across the impeller stage. Impellers are investigated at different operating conditions and the accomplished results are analyzed to characterize the performance at design and off-design conditions. The CFD calculations demonstrate that the slip factor is dependent not only on its geometrical parameters as considered by most correlations but also on its operating conditions. The slip factor decreased almost linearly as the flow rate increased. In addition, the tip clearance ratio influences the slip factor and its influence is non-linear. The head rise decreases as the tip clearance ratios increased, however, for radial impellers, the higher head rise was observed for small tip clearance ratios.

Technical University of Munich2021

Small-scale turbopumps for waste heat recovery applications based on an organic Rankine cycle: a study from pre-design to experimental validation

Sajjad Zakeralhoseini

EPFL2023