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The centrifugal turbine architecture is a promising solution for small-to-medium organic Rankine cycle (ORC) power systems. The inherent compactness of the multistage arrangement makes this configuration very attractive for dealing with the high volumetric flow ratios typical of ORC turbines. In absence of experimental evidence, a thorough assessment of the technology can be uniquely based on sufficiently accurate computational fluid dynamic (CFD) simulations. In the present work, the aerodynamic performance of a fixed and a rotating cascade of centrifugal turbine are investigated by applying a three-dimensional CFD model. Precisely, the study is focused on the sixth stage of the transonic centrifugal turbine proposed in Pini et al. (2013, “Preliminary Design of a Centrifugal Turbine for ORC Applications,” ASME J. Eng. Gas Turbines Power, 135(4), p. 042312). After recalling the blade design methodology, the blade-to-blade and secondary flow patterns are carefully studied for both stator and rotor. Results show that the centrifugal configuration exhibits distinctive features if compared to axial turbine layouts. The diverging shape of the bladed channel and the centrifugal force alter significantly the pressure distribution on the profile. Moreover, the Coriolis force induces a slip effect that should be properly included in the preliminary design phase. Provided that the flaring angle is limited, the almost uniform spanwise blade loading greatly augments the three-dimensional performance of the cascades compared to axial rows. In the rotor, the low inlet endwall vorticity and the Coriolis force further weaken the secondary flows, resulting in even lower secondary losses with respect to those predicted by loss models developed for axial turbines. Ultimately, the efficiency of the stage is found to be two points higher than that estimated at preliminary design level, demonstrating the high potential of the centrifugal turbine for ORC applications.

A blow-down wind tunnel for real-gas applications has been designed, validated by means of dynamic simulation, and then built. The facility is aimed at characterizing an organic vapor stream, representative of the expansion taking place in organic Rankine cycle (ORC) turbines, by independent measurements of pressure, temperature, and velocity. The characterization of such flows and the validation of design tools with experimental data, which are still lacking in the scientific literature, is expected to strongly benefit the performance of future ORC turbines. The investigation of flow fields within industrial ORC turbines has been strongly limited by the unavailability of calibration tunnels for real-gas operating probes, by the limited availability of plants, and by restricted access for instrumentation. As a consequence, it has been decided to design and realize a dedicated facility, in partnership with a major ORC manufacturer. The paper thoroughly discusses the design and the dynamic simulation of the apparatus, presents its final layout, and shows the facility “as built”. A straight-axis planar convergent-divergent nozzle represents the test section for early tests, but the test rig can also accommodate linear blade cascades. The facility implements a blow down operating scheme, due to high fluid density and operating temperature, which prevent continuous operation because of the prohibitive thermal power required. A wide variety of working fluids can be tested, with adjustable operating conditions up to maximum temperature and pressure of 400 °C and 50 bar, respectively. Despite the fact that the test rig operation is unsteady, the inlet nozzle pressure can be kept constant by a control valve. In order to estimate the duration of the setup and experimental phase, and to describe the time evolution of the main process variables, the dynamic plant operation, including the control system, has been simulated. Design and simulation have been performed with both lumped-parameter and 1D models, using siloxane MDM and hydrofluorocarbon R245fa as the reference working fluids, described by state-of-the-art thermodynamic models. Calculations show how experiments may last from 12 seconds up to several minutes (depending on the fluid and test pressure), while reaching the experimental conditions requires few hours, consistently with the performance of daily-based experiments. Moreover, the economic constraints have been met by the technical solutions adopted for the plant, allowing the construction of the facility.

A blow-down wind tunnel for real gas applications has been designed to characterize an organic vapour stream by independent measurements of pressure, temperature and velocity. Experiments are meant to investigate flow fields representative of expansions taking place in Organic Rankine Cycles (ORC) turbines. Strong real gas effects, high Mach numbers and approximations affecting the calculated properties of novel compounds, make the knowledge of ORC turbine blade passage flow field still rather limited. A significant enhancement of turbines efficiency is expected from detailed investigations on expansion streams. Despite Organic Cycles have attracted large research efforts in recent years, present days design tools still suffer from a lack of relevant experimental data. So far, ideal gas test cases and equilibrium measurements have supported separately CFD and thermodynamic model validations. These considerations prove the relevance of such a test rig. This paper discusses the design and the final layout of the facility, whose construction is currently in progress. A straight axis supersonic nozzle has been chosen as test section for early tests; investigations on blade cascades are foreseen in the future. Due to high stream densities and temperatures, a throat size compatible with probes intrusion made a continuous cycle plant unaffordable, requiring an input thermal power of around 2.5 MW. A reduction to 30 kW has been achieved by adopting a blow-down tunnel: the fluid, slowly vaporized in a high pressure vessel, feeds the nozzle at a lower pressure. The vapour is then collected in a low pressure tank and condensed. The loop is closed by liquid compression through a pump. Such a batch operating system also offers the option to select test/condensation pressures and temperatures, allowing experimentation of a wide variety of working fluids, even though new ORC compounds (e.g. Siloxanes, Fluorocarbons) remain of major interest. Maximum temperature and pressure are 400 °C and 50 bar. Despite the unsteady operational mode, the inlet nozzle pressure can be kept constant by a control valve. Depending on the fluid and test pressure, experiments may last from 20 seconds to several minutes, while their set-up requires a few hours. Fast response pressure transducers, pressure probes and thermocouples have been selected for thermodynamic measurements; Laser Doppler Velocimetry (LDV) and Schlieren techniques allow direct measurements of velocity and flow visualization. The design has been carried out with a lumped parameter approach, using Siloxane MDM and Hydrofluorocarbon R245fa as reference compounds and FluidProp® for properties calculation.

An extensive experimental analysis on the subject of unsteady flow field in high-pressure turbine stages was carried out at the Laboratorio di Fluidodinamica delle Macchine (LFM) of Politecnico di Milano. The research stage represents a typical modern HP gas turbine stage designed by means of three-dimensional (3D) techniques, characterized by a leaned stator and a bowed rotor and operating in high subsonic regime. The first part of the program concerns the analysis of the steady flow field in the stator-rotor axial gap by means of a conventional five-hole probe and a temperature sensor. Measurements were carried out on eight planes located at different axial positions, allowing the complete definition of the three-dimensional flow field both in absolute and relative frame of reference. The evolution of the main flow structures, such as secondary flows and vane wakes, downstream of the stator are here presented and discussed in order to evidence the stator aerodynamic performance and, in particular, the different flow field approaching the rotor blade row for the two axial gaps. This results set will support the discussion of the unsteady stator-rotor effects presented in Part II (Gaetani, P., Persico, G., Dossena, V., and Osnaghi, C., 2007, ASME J. Turbomach., 129(3), pp. 580–590). Furthermore, 3D time-averaged measurements downstream of the rotor were carried out at one axial distance and for two stator-rotor axial gaps. The position of the probe with respect to the stator blades is changed by rotating the stator in circumferential direction, in order to describe possible effects of the nonuniformity of the stator exit flow field downstream of the stage. Both flow fields, measured for the nominal and for a very large stator-rotor axial gap, are discussed, and results show the persistence of some stator flow structures downstream of the rotor, in particular, for the minimum axial gap. Finally, the flow fields are compared to evidence the effect of the stator-rotor axial gap on the stage performance from a time-averaged point of view.

This paper presents the first results of a wide experimental investigation on the aerodynamics of a vertical axis wind turbine. Vertical axis wind turbines have recently received particular attention, as interesting alternative for small and micro generation applications. However, the complex fluid dynamic mechanisms occurring in these machines make the aerodynamic optimization of the rotors still an open issue and detailed experimental analyses are now highly recommended to convert improved flow field comprehensions into novel design techniques. The experiments were performed in the large-scale wind tunnel of the Politecnico di Milano (Italy), where real-scale wind turbines for micro generation can be tested in full similarity conditions. Open and closed wind tunnel configurations are considered in such a way to quantify the influence of model blockage for several operational conditions. Integral torque and thrust measurements, as well as detailed aerodynamic measurements were applied to characterize the 3D flow field downstream of the turbine. The local unsteady flow field and the streamwise turbulent component, both resolved in phase with the rotor position, were derived by hot wire measurements. The paper critically analyses the models and the correlations usually applied to correct the wind tunnel blockage effects. Results evidence that the presently available theoretical correction models does not provide accurate estimates of the blockage effect in the case of vertical axis wind turbines. The tip aerodynamic phenomena, in particular, seem to play a key role for the prediction of the turbine performance; large-scale unsteadiness is observed in that region and a simple flow model is used to explain the different flow features with respect to horizontal axis wind turbines.

The present article proposes a novel methodology to evaluate secondary flows generated by the annulus boundary layers in complex cascades. Unlike two-dimensional (2D) linear cascades, where the reference flow is commonly defined as that measured at midspan, the problem of the reference flow definition for annular or complex 3D linear cascades does not have a general solution up to the present time. The proposed approach supports secondary flow analysis whenever exit streamwise vorticity produced by inlet endwall boundary layers is of interest. The idea is to compute the reference flow by applying slip boundary conditions at the endwalls in a viscous 3D numerical simulation, in which uniform total pressure is prescribed at the inlet. Thus the reference flow keeps the 3D nature of the actual flow except for the contribution of the endwall boundary layer vorticity. The resulting secondary field is then derived by projecting the 3D flow field (obtained from both an experiment and a fully viscous simulation) along the local reference flow direction; this approach can be proficiently applied to any complex geometry. This method allows the representation of secondary velocity vectors with a better estimation of the vortex extension, since it offers the opportunity to visualize also the region of the vortices, which can be approximated as a potential type. Furthermore, a proficient evaluation of the secondary vorticity and deviation angle effectively induced by the annulus boundary layer is possible. The approach was preliminarily verified against experimental data in linear cascades characterized by cylindrical blades, not reported for the sake of brevity, showing a very good agreement with the standard methodology based only on the experimental midspan flow field. This article presents secondary flows obtained by the application of the proposed methodology on two annular cascades with cylindrical and 3D-designed blades, stressing the differences with other definitions. Both numerical and experimental results are considered.

Abstract This paper presents the results of the application of a shape-optimization technique to the design of the stator and the rotor of a centrifugal turbine conceived for Organic Rankine Cycle (ORC) applications. Centrifugal turbines have the potential to compete with axial or radial-inflow turbines in a relevant range of applications, and are now receiving scientific as well as industrial recognition. However, the non-conventional character of the centrifugal turbine layout, combined with the typical effects induced by the use of organic fluids, leads to challenging design difficulties. For this reason, the design of optimal blades for centrifugal ORC turbines demands the application of high-fidelity computational tools. In this work, the optimal aerodynamic design is achieved by applying a non-intrusive, gradient-free, CFD-based method implemented in the in-house software FORMA (Fluid-dynamic OptimizeR for turboMachinery Aerofoils), specifically developed for the shape optimization of turbomachinery profiles. FORMA was applied to optimize the shape of the stator and the rotor of a transonic centrifugal turbine stage, which exhibits a significant radial effect, high aerodynamic loading, and severe non-ideal gas effects. The optimization of the single blade rows allows improving considerably the stage performance, with respect to a baseline geometric configuration constructed with classical aerodynamic methods. Furthermore, time-resolved simulations of the coupled stator-rotor configuration shows that the optimization allows to reduce considerably the unsteady stator-rotor interaction and, thus, the aerodynamic forcing acting on the blades.

This paper presents the results of a wide experimental study on an H-type vertical axis wind turbine (VAWT) carried out at the Politecnico di Milano. The experiments were carried out in a large-scale wind tunnel, where wind turbines for microgeneration can be tested in real-scale conditions. Integral torque and thrust measurements were performed, as well as detailed aerodynamic measurements to characterize the flow field generated by the turbine downstream of the rotor. The machine was tested in both a confined (closed chamber) and unconfined (open chamber) environment, to highlight the effect of wind tunnel blockage on the aerodynamics and performance of the VAWT under investigation. The experimental results, compared with the blockage correlations presently available, suggest that specific correction models should be developed for VAWTs. The experimental thrust and power curves of the turbine, derived from integral measurements, exhibit the expected trends with a peak power coefficient of about 0.28 at tip-speed ratio equal to 2.5. Flow measurements, performed in three conditions for tip speed ratio equal to 1.5, 2.5, and 3.5, show the fully three-dimensional character of the wake, especially in the tip region where a nonsymmetrical wake and tip vortex are found. The unsteady evolution of the velocity and turbulence fields further highlights the effect of aerodynamic loading on the wake unsteadiness, showing the time-dependent nature of the tip vortex and the onset of dynamic stall for tip speed ratio lower than 2.

A novel blow-down wind tunnel is currently being commissioned at the Politecnico di Milano, Italy, to investigate real-gas behavior of organic fluids operating at subsonic-supersonic speed in the proximity of the liquid-vapor critical point and the saturation curve. The working fluid is expanded from a high-pressure reservoir, where it is kept at controlled super-heated or super-critical conditions, into a low-pressure reservoir, where the vapor is condensed and pumped back into the high-pressure reservoir. Expansion to supersonic speeds occurs through a converging-diverging Laval nozzle. Siloxane fluid MDM (octamethyltrisiloxane-C8H24O2Si3) is to be tested during the first experimental trials. A standard method of characteristics is used here to assess the influence of the molecular complexity of the working fluid on the design of the supersonic portion of the nozzle by considering different fluids at the same real-gas operating conditions, including linear and cyclic siloxanes, refrigerant R245fa, toluene, and ammonia. The thermodynamic properties of these fluids are described by state-of-the-art thermodynamic models. The nozzle length and exit area are found to increase with increasing molecular complexity due to the nonideal dependence of the speed of sound on density along isentropic expansion of organic fluids.