Research Paper
Research Paper
Research Paper
A R T I C L E I N F O A B S T R A C T
Keywords: A small-scale radial expansion turbine is distinguished by its ease of production, higher efficiency, and reliability.
Nitrogen turboexpander Such turbines have been successfully used in cryogenic turboexpander systems for refrigeration and liquefaction
Sobol sensitivity of the process gas. This paper presents a methodology for design optimization, numerical, and experimental
Experimental and numerical analysis
investigation of a radial turbine and nozzle (turboexpander), the most necessary and extortionate component of a
Claude cycle
nitrogen liquefaction system based on Claude cycle. The initial investigation starts with the preliminary design of
a turboexpander using an in-house developed Matlab® code. Then, a Sobol method-based optimization approach
has been proposed to determine the normalized sensitivity index and optimal range of major non-dimensional
and geometrical variables for the better off-design performance of the turboexpander. After that, different los
ses of the turbine have been determined using an optimum set of loss correlations which is incorporated into the
preliminary design process. This approach can overcome the optimization issues caused by the high sensitive
design parameters, which may not be addressed through conventional methods, and ameliorates the off-design
performance of the turboexpander (improves power output, total-to-static efficiency, and diminishing the turbine
losses by 14.28%, 3.89%, and 9.61% respectively) as compared to the initial design. Based on this, three tur
boexpander systems are designed and a comparative numerical study has been conducted to study the flow field
phenomenon and their thermodynamic performance at three operating pressure and cryogenic temperature (16
bar & 150 K, 8 bar & 120 K, and 4.5 bar & 95 K) using ANSYS CFX®. Finally, the Claude cycle-based experi
mental facility has been established to determine the thermal performance of the turboexpander at various
operating pressure (16 and 8 bar), rotational speeds (120,612, 102,419, and 80,914 rpm), inlet temperatures
(150 and 120 K), and mass flow rates (0.01–0.10 kg/s). The results illustrate that the predicted performance from
the numerical simulation shows good agreement with the experimental results. Additionally, error analysis of
experimental parameters has also been discussed.
1. Introduction nozzle (turboexpander) are the key components for such types of
refrigeration and liquefaction cycles which can be used as an expansion
To accomplish the emerging demand for cryogenic fluids, it is widely device in many applications, such as gas turbines, organic Rankine cy
accepted that the cryogenic turboexpander-based gas liquefaction cycles cles, air separation, and liquefaction systems [1,2,41]. Generally, these
would be the mainstream for various industrial and research appliances. turboexpanders have been designed to operate in a gaseous state for
It has been a promising alternative to traditional cryogenic systems to durable and safe operation. The performance of the gas liquefaction
generate ultra-low temperature and gas liquefaction. Radial turbine and system depends on the efficient design of such turboexpander.
* Corresponding author.
E-mail addresses: [email protected], [email protected] (M. Kumar), [email protected] (S.K. Behera), [email protected] (R.K. Sahoo), sandip@
vecc.gov.in (S. Pal).
https://doi.org/10.1016/j.icheatmasstransfer.2022.106185
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M. Kumar et al. International Communications in Heat and Mass Transfer 136 (2022) 106185
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M. Kumar et al. International Communications in Heat and Mass Transfer 136 (2022) 106185
1[ ( ) ]2
Δhincidence = W4 sin β4 − β4,opt (8)
2
The incidence loss is minimized by decreasing the relative flow angle
(β4) between incoming flow and turbine inlet angle whereas the turbine
exit losses can be controlled by increasing the exit flow area.
The passage loss is obtained due to a combination of viscous and
secondary flow loss within the blade passage. Generally, this type of loss
has been strongly influenced by Coriolis and centripetal forces. The
shape of flow passage and fluid density at design conditions (tempera
ture and pressure) are also responsible for such losses [32]. Wasswe
bauer and Glassman [33] proposed that this loss would be computed by
averaging the inlet and outlet relative velocity. The passage loss is
calculated as: (Eq. (9)).
( )
Δhpassage = 0.5K W32 cos2 i + W42 (9)
U43 Zr ( √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ )
Δhtip = Kx εx Cx + Kr εr Cr + Kx,r εx εr Cx Cr (10)
8π
where Cx (axial) and Cr (radial) are the coefficients which are
calculated from Eqs. (11) and (12) respectively.
r4,sh
1−
(11)
r3
Cx =
Cm3 b3
(r ) Z − b
(12)
4,sh r 3
Cr =
4 Cm4 r4 b4
The tip leakage loss is related to the tip gaps from which mass flow Fig. 2. Flowchart of the one-dimensional design methodology.
rate is reduced in between the blade passages. It is also associated with
turboexpander geometry. This loss has been curtailed by minimizing the
radial clearance at the turboexpander outlet.
The exit energy loss appears because of energy conversion at the
turboexpander exit. Such losses generally introduce swirls. Since that
kinetic energy is unworkable, it is considered as a loss. The exit energy
loss is calculated as (Eq. (13)):
1
Δhexit = C42 (13)
2
It is considered that the fluid density does not affect this loss. How
ever, it has been minimized by increasing the cross-sectional area at the
turboexpander exit.
These losses have been integrated with the preliminary design code
to update the initial prediction of total-to-static efficiency (ηts) (Eq. (14))
[34].
ΔhTotal,loss = Δhincidence + Δhpassage + Δhtip + Δhexit + ΔhTEL + ΔhO (14)
Lastly, the mass flow rate at the turboexpander outlet is calculated Fig. 3. Various losses of the turbine.
using Eq. (16) and compared with the assumed value at the nozzle inlet.
The new mass flow rate is updated and the procedure is continued till velocity diagram. Fig. 2 represents the flowchart of preliminary design
convergence. optimization procedure used in the present study. The additional details
of the design procedure for other components are described in our
m4 = ρ4 Cm4 A4 (16)
previous study [8].
Fig. 1 represents the schematic diagram of turboexpander and its
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M. Kumar et al. International Communications in Heat and Mass Transfer 136 (2022) 106185
Table 2 Table 3
Normalized sensitivity index of important design parameters and their optimum Input parameters of a radial expansion turbine.
range. Design variables Unit Range
Non-dimensional Normalized Normalized Optimum
Inlet total pressure bar 4–17
design variables sensitivity index sensitivity index range
Outlet static pressure bar 1.2–8.2
(ηts) (Total loss)
Inlet total temperature K 90–180
Pressure ratio (rp) 0.72 0.69 2.68–3.96 Mass flow rate kg/s 0.01–0.10
Rh/R3 0.62 0.74 0.25–0.28 Specific speed (ns) – 0.48–0.60
Rs/R3 0.44 0.51 0.86–0.92 Specific diameter (ds) – 2.81–3.38
Static head 0.17 0.14 0.79–0.88 Rotational speed rpm 0.6–1.8 (×105)
coefficient Ψ) Tip clearance mm 0.1–0.5
Blade speed ratio 0.87 0.43 0.65–0.69 Flow coefficient (ϕ) – 0.82–0.96
(vs) Stage loading (ψ) – 0.72–0.88
Flow coefficient (ϕ) 0.21 0.13 0.23–0.34 Number of blades (Turbine) – 7–17
Number of blades 0.58 0.64 10–13 Number of blades (Nozzle) – 15–31
(Z) Turbine inlet flow angle degree 70–83
Specific speed (ns) 0.29 0.22 0.48–0.55 Turbine outlet flow angle degree − 2.8 to − 3.8
Hub radius ratio – 0.20–0.32
Shroud radius ratio – 0.74–0.96
2.2. Loss analysis
Fig. 3 represents the details of different losses obtained for high- Table 4
pressure turboexpander (HPT), medium pressure turboexpander Specifications of designed turbine.
(MPT), and low-pressure turboexpander (LPT). It is noticed that passage Parameters High- Medium Low-
loss (approximately 40%), tip clearance loss (approximately 23%), and pressure pressure pressure
incidence loss (approximately 7%) contribution to HPT is higher.
Flow coefficient (ϕ) 0.32 0.28 0.26
However, exit energy loss (approximately 28%) and trailing edge loss Specific speed (ns) 0.55 0.53 0.52
(approximately 15%) are maximum for LPT. This may happen because Rotational speed (ω) (krpm) 180 160 130
of higher kinetic energy loss at the exit of LPT as compared to MPT and Turbine inlet diameter (d3) (mm) 24.76 26.89 28.74
HPT. It is also observed that among all the losses, passage loss contrib Turbine outlet diameter (d4) 15.42 16.20 17.96
(mm)
utes the maximum for all the turboexpanders. This may happen due to Blade height (turbine inlet) (b3) 1.68 2.41 2.63
higher secondary loss contribution inside the blade passages. However, (mm)
the tip clearance, exit energy, trailing edge, and incidence losses Blade height (turbine outlet) (b4) 0.84 1.26 1.38
contribute in the decreasing order for HPT, MPT, and LPT respectively. (mm)
Mach number at turbine inlet 0.89 0.85 0.80
The other losses for HPT, MPT, and LPT are approximately 4, 3, and 5%
(M3)
respectively. Blade speed (U3) (m/s) 273.85 250.22 224.80
Absolute velocity (C3) (m/s) 194.49 181.12 175.50
Axial velocity (W3) (m/s) 86.62 82.64 76.09
2.3. Sensitivity analysis Absolute velocity angle (α3) 80 80 78
(degree)
Sobol method is a model-independent sensitivity analysis technique Head coefficient (ψ) 0.85 0.82 0.80
to measure the total output variances of input parameters. It can solve Absolute flow angle (β3) (degree) − 55.89 − 61.13 − 61.01
Number of blades (Z) 13 13 11
the non-linear and non-monotonic functions efficiently. The relation is Mass flow rate (m.) (kg/s) 0.08 0.06 0.05
expressed in functional form as Eq. (17): Total losses (Lt) 0.23 0.20 0.19
( ) Total-to-static efficiency (ηts) 81.21 79.42 77.31
Y = f (X) = f X1 , …..,Xp (17) Power (kW) 5.41 4.51 3.81
where f0 is a constant which is approximately equal to the expected Table 2 illustrates the normalized sensitivity indices and optimal
value (output). ranges of important non-dimensional and geometrical design parame
The variance decomposition has been expressed as (Eq. (19)): ters of the turboexpander. It is observed that the blade speed ratio (vs),
pressure ratio (rp), number of blades (Z), Rh/R3, and Rs/R3 have a
maximum sensitivity index to total-to-static efficiency (ηts) and total
p
∑ p− 1 ∑
∑ p
V(Y) = Vi + Vij + ….. + V1,…..p (19)
i=1 i=1 j=1+1 loss. Therefore, the value of these parameters has been updated in the
preliminary design process. Based on these ranges, three turboexpanders
Following the aforementioned procedure, the total output variance (High, medium, and low-pressure) are developed. Major preliminary
of each parameter has been determined in terms of sensitivity indices design parameters and obtained results of the designed turboexpanders
(ratio of partial to total variance). are mentioned in Tables 3 and 4.
First-order sensitivity index (Eq. (20)):
Vi 3. Experimental techniques
Si = (20)
V
The experimental test rig has been developed using different indoor
Second-order sensitivity index (Eq. (21)):
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Table 5 Table 8
Specifications of experimental turboexpander. Node allocations in different sections (HPT / MPT / LPT).
Turbine inlet diameter (mm) 24.90 Inlet block Passage block Outlet block
Turbine outlet diameter (mm) 15.60
Streamwise Blade-to- Streamwise Blade-to- Streamwise Blade-to-
Number of nozzles 21
blade blade blade
Nozzle pitch circle diameter (mm) 40.17
Nozzle outlet diameter (mm) 25.54 Turbine 30 / 30 / 30 64 /64 / 54 / 52 / 52 82 / 82 / 30 / 30 / 28 60 / 60 /
Shaft diameter (mm) 16.08 60 80 60
Number of turbine blades (Z) 13 Nozzle 25 / 25 / 25 60 / 60 / 64 / 64 / 60 52 / 52 / 25 / 25 /25 44 / 42 /
60 50 44
Table 6 ADAM®. The mass flow rate is measured using rotameter. The specifi
Specifications of measuring instruments. cations of the measuring devices are mentioned in Table 6.
Instrument Company Range Accuracy Additionally, the four important dimensionless parameters are
Temperature sensor ADAM 70–800 K – calculated from experimental results. The error analysis has been con
Flow meter Alflow 1–30 m3/h ± 2.5% ducted to analyze the effect of measurement errors on performance
Speed sensor Emerson 0.07–2500 Hz ± 0.005% (dimensionless) parameters. Table 7 represents the uncertainty analysis
Oscilloscope Tektronix 20–100 MHz ± 2% which clearly shows that the isentropic efficiency, specific speed, pres
Digitel caliper Mitutoyo 150 mm 0.013 mm
Pressure gauge Swagelok 0–25 bar ± 0.2%
sure ratio, and blade speed ratio have maximum uncertainty of 5.41%,
Pressure transducer Endevco 0–35 bar ± 0.05% 5.17%, 3.22%, and 8.22% respectively.
4. Numerical procedure
Table 7
Error propagation analysis (experimental). 4.1. Grid generation
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Table 10
Boundary conditions (HPT / MPT / LPT).
Total Total Rotational Flow
pressure temperature speed (rpm) regime
(bar) (K)
Table 11
Grid independence analysis (HPT / MPT / LPT).
Nozzle (in Turbine (in ηis Power output CPU time
Fig. 7. Computational domain in CFX® pre. million) million) (kW) (hrs)
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Fig. 9. Variation of isentropic efficiency and mass flow rate with pressure ratio
(a) Isentropic efficiency with pressure ratio.
(b) Mass flow rate with pressure ratio.
to be no-slip, adiabatic, and hydraulically smooth. Since the simulations 5. Results and discussions
are carried out using a single turboexpander domain, the cyclic peri
odicity has been imposed along the circumferential direction to decrease 5.1. Experimental results
the computational cost. The additional details of boundary conditions
have been mentioned in Table 10. In this section, the experimental and numerical results are presented
and discussed with proper validation. The important basic parameters
4.4. Grid sensitivity analysis used to describe the performance of a turboexpander system includes
rotational speed, pressure ratio, mass flow rate, power output, and
The isentropic efficiency and power output of the turboexpander isentropic efficiency. The pressure ratio (rp), specific speed (ns), and
have been compared for five different grid resolutions to check the blade speed ratio (vs) have been used as independent variable while
reliability of the numerical simulations for all turboexpander systems as isentropic efficiency (ηi), mass flow rate, and power output are depen
revealed in Table 11 and Fig. S1. It shows that the fourth and fifth rows dent variables.
have a very small variation of output power and isentropic efficiency Fig. 9 represents a comparison between isentropic efficiency and
(maximum variation <1%) however, the computational time is rela mass flow rate with respect to pressure ratio at three different rotational
tively higher. Therefore, the grid resolution of the fourth row of Table 11 speeds (80,914 rpm, 102,419 rpm, and 120,612 rpm). It is noticed that
provides satisfactory results and has been considered for all the nu the isentropic efficiency increases with an increase in pressure ratio
merical simulations as shown in Fig. 8. reach its maximum value and then decreases. The highest isentropic
efficiency has been achieved for a pressure ratio of 1.84, 2.70, and 3.75
Fig. 10. Isentropic efficiencies as a function of (a) specific speed (ns) (b) Blade speed ratio (vs).
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M. Kumar et al. International Communications in Heat and Mass Transfer 136 (2022) 106185
Fig. 11. Variations of (a) rotational speed (b) temperature drop with power output.
Fig. 12. (a) Pressure (b) Mach number (c) Temperature (d) Static entropy contours at 50% blade height.
(a) Pressure contours.
(b) Mach number contours.
(c) Temperature contours.
(d) Static entropy contours.
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M. Kumar et al. International Communications in Heat and Mass Transfer 136 (2022) 106185
at 80,914 rpm, 102,419 rpm, and 120,612 rpm respectively. At low isentropic efficiency as a function of blade speed ratio and specific
rotational speed, the isentropic efficiency is highest at a pressure ratio of speed. It shows that the highest efficiency has been obtained for specific
1.8–2.0 whereas it is highest for medium and high rotational speed for a speeds in the range of 0.52–0.58 (approximately 0.54). Fig. 10 (b) rep
pressure ratio of 2.4–2.8 and 3.5–4.0 respectively. It is also noticed that resents that the maximum efficiency has been obtained for LPT, MPT,
the maximum efficiency is obtained at a lower rotational speed. It may and HPT when the blade speed ratio is 0.58, 0.64, and 0.67 respectively.
happen because minimum losses are obtained at this speed. However, at Fig. 11 represents the variation of rotational speed and temperature
high-pressure ratios where isentropic efficiency decreases, the losses are drop with respect to power output. It is prominent that the power output
higher which diminishes the efficiency of the turboexpander. increases with increase in rotational speed of the turboexpander. It
Fig. 9 (b) represents the variation of pressure ratio with mass flow happens because of work done by the fluid on the turboexpander blade.
rate at different rotational speeds. It is obvious that the pressure ratio In this process, the kinetic energy of the fluid has been transformed into
increases with mass flow rate as it is directly related to square of the the rotational energy of the turboexpander blade, consequently, tem
mass velocity under turbulent flow conditions. It is noticed that the perature decreases. It is distinguished that the highest power output has
pressure ratio increases with increase in mass flow rate, reaches its been obtained at a rotational speed of 1.21 × 105 and 1.02 × 105 rpm for
maximum value at a specific mass flow rate. Further, an increase in mass which approximately 25 and 20 K temperature drop occurs for high
flow rate decreases the pressure ratio. It can be seen that the specific (HPT) and medium (MPT) pressure turboexpander respectively.
mass flow rate and pressure ratio for LPT, MPT, and HPT (from nu The results conclude that the HPT has better performance (ηis, P, and
merical analysis) are approximately 0.09 kg/s and 3.65, 4.00, and 4.30 temperature drop) as compared to MPT and LPT. However, the LPT has
respectively. However, the experimental results show the specific mass higher efficiency at low-pressure ratio ranges (approximately
flow rate and corresponding pressure ratio for LPT, MPT, and HPT are 1.80–2.10).
0.85 kg/s for rp = 2.45, 0.86 kg/s for rp = 3.25, and 0.82 kg/s for rp =
3.60 respectively. The difference in numerical and experimental results 5.2. Numerical results
appears due to limitation of the experimental facility.
The performance of turboexpander can also be represented in terms Fig. 12 represents the area-averaged contours of thermophysical
of specific speed and blade speed ratio. Fig. 10 illustrates the variation of characteristics such as pressure, Mach number, temperature, and static
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M. Kumar et al. International Communications in Heat and Mass Transfer 136 (2022) 106185
Fig. 13. (a) Density variation (area-averaged) along the streamwise location (b, c) Variation of different properties inside the turboexpander.
entropy for all the turboexpander at mid-span (50% blade height). The higher at the pressure surface (up to 1.30 streamwise distance from the
expansion of the process fluid throughout the flow passage results in leading edge) in contrast to that of the suction surface. It may happen by
pressure drop and corresponding increase in kinetic energy of the fluid. striking of the high kinetic energy expanded fluid imminent to the
In this process, the rotational speed of the turbine has been increased leading edge. After 1.30 streamwise location, the kinetic energy di
which is the prime reason for increase in Mach number and corre minishes and Mach number decreases and finally stabilized. However,
sponding enthalpy and temperature drop. In all the cases, the flow is there is some instantaneous increase in Mach number near the trailing
smoothly accelerated on the first half of the pressure side because of an edge. This happens due to sudden contraction in the flow passage area
increase in Mach number (near the turbine leading edge). However, the and static pressure drop in these regions.
suction side experiences a local increase in Mach number at the trailing Fig. 12 (c) represents the temperature contours at 50% blade height.
edge. It may happen because of instantaneous pressure drop in these The temperature drop for HPT is more coherent than other cases. It is
regions or rotation of the turbine blade. It is noticed that the pressure noticed that the temperature decreases along the flow passages and
drop in the turbine blade passages are higher up to 1.40 streamwise becomes minimum at the turbine outlet. It happens because of contin
location thereafter the variation is smooth which shows the designed uous pressure drop along the flow passage. It is also observed that the
models (HPT, MPT, and LPT) are adequate. instantaneous temperature drop occurs near the trailing edge of the
Fig. 12 (b) represents the Mach number contours at 50% blade height turboexpander because of the static pressure drop in these regions. After
which shows that the fluid flow throughout the turboexpander is in the that, the kinetic energy of the fluid decreases, as a result, the pressure
subsonic regime. The maximum Mach number of HPT, MPT, and LPT are energy increases, and finally a small increase in temperature (approxi
0.86, 0.80, and 0.77 respectively, which occur near the leading edge of mately 2 K) takes place. It is observed that the maximum temperature
the turbine blade. It is noticed that the intensity of Mach number is drop (24 K) takes place for high-pressure turboexpander. In medium and
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M. Kumar et al. International Communications in Heat and Mass Transfer 136 (2022) 106185
Fig. 14. Velocity vector at different blade heights (spans) for high-pressure turboexpander.
low-pressure turboexpander, 20 and 16 K temperature drop takes place. Fig. 13 (c) represents the temperature Vs static entropy variation to
This happens because of higher enthalpy drop in HPT (Fig. 13 (b)). In understand the thermodynamic conditions (expansion process) of the
MPT and LPT, the decrease in temperature drop may happen due to inlet fluid inside the turboexpander. For an ideal process, the line should be
fluid temperature advancing towards its boiling point. Under these vertical (isentropic process), but for a real process, it deviates. The in
conditions, the thermodynamic properties of fluid-like density, molec crease in inclination shows that the entropy generation during the
ular viscosity, etc. have severe changes that may affect the corre expansion process inside the turboexpander. It is observed that the
sponding enthalpy drop inside the turboexpander. maximum entropy generation takes place inside the turbine where
Fig. 12 (d) characterizes the static entropy contours at 50% blade higher temperature gradients have been obtained.
height. It shows that the increase in entropy inside the nozzle is mini
mum whereas it increases at the leading edge of the turbine due to
passage vortices and boundary layer separation in these regions 5.3. Internal flow field analysis
(Figs. 14-16). Additionally, the increase in shear strain of the fluid
because of the blending of flow stream from pressure and suction side The streamline anatomy of the turbine blade profile and boundary
may also be responsible for increase in entropy in these regions. It is layer formation near the leading and trailing edge, and hub and shroud
visualized that; the static entropy is highest at the outlet of the turbine. layers are responsible for secondary flow (especially passage and
This may happen due to viscous dissipation, flow reversal, and other scraping flow vortices). Also, the meridional curvature has been
non-ideal conditions in these regions. responsible for those flow patterns (vortices) at pressure and suction
Fig. 13 (a) demonstrates the variation of density (area-averaged) surfaces, which globally form the boundary layers in those regions.
inside the turboexpander along the streamwise location. It depicts the These types of flow behaviors have prevailed inside the turbine flow
density variation is strongly influenced by the pressure drop of the fluid. passage. Therefore, the fluid flow structures of turbines of HPT, MPT,
Fig. 13 (b) depicts the pressure variation with static enthalpy (p-h dia and LPT have been represented and explained in detail.
gram) throughout the turboexpander. The diagram indicates the static Figs. 14-16 represents the velocity vectors at 10, 50, and 90% blade
enthalpy drop for corresponding change in pressure inside the tur height. It is interesting to observe that the secondary flow regime has
boexpander, which gives the refrigerating capacity of the system. It has been obtained at the pressure surface of the turbine blade passage
been distinguished that the HPT has maximum enthalpy drop, as a because of the pressure gradient induced by the rotation of the turbine.
result, a higher temperature drop occurs (Fig. 12 (c)). For all the designed turboexpanders, it is noted that the fluid flows
steadily and there are few regions where flow separation exists. The
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M. Kumar et al. International Communications in Heat and Mass Transfer 136 (2022) 106185
Fig. 15. Velocity vector at different blade heights (spans) for medium pressure turboexpander.
secondary flow appears near the blade wall because of Coriolis accel which further transforms into the passage vortices. These vortices have
eration and dominance of the radial pressure gradient of the fluid. An been generated mostly at the pressure side (PS) (50% blade height) at
analogous phenomenon has been observed and explained in our previ the leading edge which disappears after mixing with the mainstream
ous study [39]. However, the appearance of such flow characteristics flow and rotation of the turbine blade. However, at the pressure side
near the pressure side is because of pressure non-uniformities in these (90% blade height), scraping flow exists on the leading edge which
regions. Moreover, at higher blade heights, a relatively weak secondary disappears at higher streamwise locations (between 1.50 and 1.60) and
flow exists at the suction surface which mixes with the mainstream flow may be the reason for flow separation in these regions. Similarly, the tip
at higher span and then disappeared. These flow characteristics increase leakage flow exists adjacent to the suction side (SS) adjacent to the mid-
the entropy of the fluid which diminishes the performance of the tur section of the turbine blade passage. The passage vortices appear at 50%
boexpander (Fig. 12 (d)). It is also noticed that the velocity vectors are blade height along the leading edge on the pressure side of the flow
directed towards the suction side for all the cases. This happens because passage. Along the further downstream direction, the passage vortices
of difference in magnitude of velocity vectors is greater along the disappeared by mixing with the mainstream (fully developed) flow.
pressure side. Also, a relatively higher pressure has been obtained near In Fig. 15, the passage vortices have been obtained at 10 and 50%
the tip regions induces tip leakage flow mostly near the suction side of blade height near the leading edge which further changes into the
all the turbines. scraping flow at a higher span. The intensity of passage vortices and
In Fig. 14, the flow separation occurs adjacent to the leading edge at scraping flow have been decreased at higher streamwise locations (50
10% blade height. The induced pressure gradient in the flow passage is and 90% blade height). However, at 10% blade height, the scraping flow
the main reason for flow separation along the downstream direction appears at a higher streamwise location (at PS between 1.35 and 1.75).
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Fig. 16. Velocity vector at different blade heights (spans) for low-pressure turboexpander.
Table 12
Comparison of 1-D, numerical simulation and experimental results.
(1-D / numerical / HPT MPT LPT
experiment)
Flow separation appears near the pressure side (10% blade height)
because of the adverse pressure gradient which mixes with the main
stream flow and transformed into scraping flow on higher streamwise
location. Additionally, tip leakage flow exists at pressure surface of 50%
blade height. It occurs because of pressure differences along the down
stream direction.
In Fig. 16, the flow separation occurs adjacent to the leading edge of
the turbine blade for 10% blade heights and at the leading and trailing
edge for 50% blade height. At 90% blade heights, scraping flow exists
adjacent to the leading edge of the turbine blade.
Fig. 17 represents the area-averaged turbulence kinetic energy (TKE)
variation inside the turboexpander. It is noticed that the TKE increases
after 0.80 streamwise location inside the nozzle. After that, the intensity
Fig. 17. Area-averaged TKE distribution along the streamwise location. of TKE increases reaches its maximum value at 1.30, 1.20, and 1.10
streamwise location for HPT, MPT, and LPT respectively. The main
reason for the sudden increase of TKE is highly turbulent flow inside the
turbine governed by the blade curvature.
The performance parameters of all the turboexpanders from
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M. Kumar et al. International Communications in Heat and Mass Transfer 136 (2022) 106185
[25] Subrata K. Ghosh, Ranjit K. Sahoo, Sunil K. Sarangi, Experimental performance Nomenclature
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