Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications
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1 Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications Giuseppe Bianchi 1, Stuart Kennedy 3, Obadah Zaher 2, Savvas A. Tassou 1, Jeremy Miller 2, Hussam Jouhara 1 Milan, 13/09/2017
2 I-ThERM Project aim is to Investigate, design, build and demonstrate innovative plug and play waste heat recovery solutions to facilitate optimum utilisation of energy in selected applications with high replicability and energy recovery potential in the temperature range This project has received funding from the European Union s Horizon 2020 research and innovation programme under grant agreement No Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 2
3 The opportunity [elaborations from Eurostat database + Forman et al. 2016] Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 3
4 TFC vs ORC Single phase heat recovery High exergetic efficiency High mass flow rate Two-phase expansion High isentropic efficiency Large density changes Multi-phase heat recovery Compact heater (evaporator) Worse heat utilization Single phase expansion Safer blade environment Realistic expansion ratios Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 4
5 Outline Potential for low grade waste heat to power conversion through TFC systems Modelling approach Input data for twin-screw machines Test case Parametric analyses Next challenges Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 5
6 Modelling approach (mass flux, velocity, mass fraction fluxes, etc.) (pressure, temperature, density, internal energy, enthalpy, etc.) One-dimensional formulation of Navier-Stokes equations Staggered grid spatial discretization Leakage paths as orifices x 1 x vap liq Thermo-physical properties from REFPROP v9.1 Explicit Runge-Kutta scheme Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 6
7 Input data Geometrical data from pre-processor or CAD drawings Rotor Diameter 127 mm Aspect Ratio (L/D) 1.65 Built-in Volume ratio 5 Male / Female rotor lobes 4/6 Suction / Discharge ports arrangement Revolution speed range Tip speed range Weight axial / axial RPM m/s 220 kg Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 7
8 GT-SUITE model Expander cell Scaling procedure SF 360 / sim real Z sim Zmale ceil 360 Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 8
9 Test case TATA Steel UK Stream Flowrate (kg/s) Inlet/max Pressure (bar) Outlet/min Pressure (bar) Inlet Temperature ( o C) Outlet Temperature ( o C) Waste heat stream R245fa stream Condensing water stream MW thermal design power output 120 kw electrical pilot test rig (1:10) at Spirax Sarco UK Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 9
10 Simulation results Inlet pressure Inlet quality Revolution speed Outlet pressure 8 bar a RPM 1.3 bar a Indicator diagram (p-v) Quality-angle diagram Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 10
11 Constant inlet quality upstream the expander Variable revolution speed Inlet pressure 8bar Parametric analyses Greater revolution speeds Increase the expansion in the manifold Lower the volumetric efficiency Increase the indicated power, but not proportionally vol V m Z suc suc male 60 real real Pind Zmale pdv 60 Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 11
12 Constant revolution speed Inlet quality is set upstream the expander Inlet pressure 8bar Parametric analyses (cont d) A greater inlet quality Lowers the mass flow rate Increases the volumetric efficiency Reduces the indicated power vol m V Z suc suc male 60 real real Pind Zmale pdv 60 Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 12
13 Conclusions Potential of low grade heat to power conversion assessed Similarities and differences between TFC and ORC outlined Modelling procedure for twin-screw machines in GT-SUITE developed A twin-screw expander for TFC applications modelled Pre-expansion in the intake manifold highly affects the expander performance Actual expansion ratio of the Trilateral Flash Cycle is significantly influenced by the expander operation Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 13
14 Next challenges Upscaling the prototype unit Testing in real industrial environment Model setup on large size expanders Validation Transient modelling of the whole TFC system Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 14
15 Acknowledgements This project has received funding from the European Union s Horizon 2020 research and innovation programme under grant agreement No Project No Grant No. EP/P510294/1 Grant No. EP/K011820/1 Follow us on Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications 15
16 Two-phase chamber modelling of a twin-screw expander for Trilateral Flash Cycle applications Giuseppe Bianchi 1, Stuart Kennedy 3, Obadah Zaher 2, Savvas A. Tassou 1, Jeremy Miller 2, Hussam Jouhara 1 Milan, 13/09/2017
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