DIMA – Sez. Macchine (Ing-Ind-08) · Turbomachinery - 1 DIMA – Sez. Macchine (Ing-Ind-08) i....

DIMA – Sez. Macchine (Ing-Ind-08)[Fluid Machinery for Energy Conversion Systems]

Research Team Members:

Roberto Capata Ph.D., Assist. Prof. [RTD]Roberta Masci, Doctoral CandidateRoberto Melli, Adjoint Professor (Ric. in pensione)Pier Francesco Palazzo, Doctoral Candidate Lorenzo Tocci, Doctoral Candidate Raffaele Ruscitti, ProfessorEnrico Sciubba Ph.D., ProfessorClaudia Toro Ph.D., Junior Researcher [Assegnista]Federico Zullo Ph.D., Junior Adjoint Researcher

Total of 40 Journal publications from 2011 to 2016

DIMA – Sez. Macchine (Ing-Ind-08)

Research Fields:

a)Turbomachinery:Theory,Thermo-Fluiddynamic analysis,Applications

b)Theoretical &Applied Thermodynamics

DIMA – Sez. Macchine (Ing-Ind-08)Turbomachinery - 1

i. Theoretical & applied study of the feasibility of a standalone microturbogas (UMGT, Ultra-Micro Gas Turbine). Ideally, onthe basis of dimensional analysis, the power density of a Turbogas increases inversely to its main dimensions(external rotor diameter). We have integrated zero- and one-dimensional studies with 3D CFD simulations (fluid- &thermal fields) and 3D structural calculations to identify the most convenient operational ranges for a back-to-back radialconfiguration in the range of Drotor=0.01-0.03 m. The result was a novel correlation which can be directly applied to theBalje maps to estimate the actual efficiency for the Reynolds numbers relevant to these dimensions (~104). Aprototype was built and tested which did not reach self-sustaining power generation. A second prototype, based on themodification of an existing commercial UMGT, is in the works.The first part of the study was funded by an external Agency.

Participants: R.Capata, E.Sciubba


ii. The concept of the UMGT designed under Phase(i) above was applied to a Hybrid UAV: thetechnological advances in brushless electricmotors make a fully electric propulsion (via asuitable propeller) interesting. In the schemedeveloped here, we envision a UAV propelled byan electric motor powered by a small battery:when the battery SOC falls below a preset limit,the turbogas is switched on, recharging thebattery. This peculiar mode of operation allows fora fully «thermal» propulsion in the operationalranges in which noise is not an issue, and fora very low-dB propulsion in specific parts ofthe mission.The study was funded by an external Agency.

Participants: R.Capata, L.Marino, E.Sciubba


iii. As a logical spinoff of Phases (i) and (ii) a mini-turbogasconcept was developed for a Hybrid Vehicle. One or twoelectric motors (depending on whether the traction is onone- or on both axles) power the vehicle. The electric poweris provided by a battery pack. When the SOC of thebatteries falls below a certain preset limit, a small turbogasis switched on, recharging the batteries. This configuration iscalled «series hybrid powertrain» (we nicknamed it LowEmission Turbo-Hybrid Engine - LETHE), and has severaladvantages: consumption per mission is lower; the fuel canbe CH4 or GPL; the weight of the electrical engine plus theGT is much lower than that of an equivalent ICE; the vehiclecan be run in an all-electric mode in city centres and berepowered on the highway. Two sets of simulations wereperformed, for an urban sedan and for a bus: the resultsshow that the concept is feasible, environment friendly andtechnologically advantageous. Funding is being provided byan external sponsor.

Participants: R.Capata, E.Sciubba, L.Tocci

DIMA – Sez. Macchine (Ing-Ind-08)Turbomachinery – 4 & 5

iv. As an alternative to the LETHE concept, a system is being studied to recover the exhaust thermal power of a Dieselengine via an Organic Rankine Cycle installed on board, directly downstream of the engine and upstream of theexhaust plenum. Since the temperature of the exhaust gas varies between 300 (turbocharged diesels) and 600 (airbreathing diesel), and both values are quite well standardized, two configurations were considered. The first is based ona synthetic fluid operating in a Rankine cycle (whence the name ORC) that is boiled by the 300°C gas in a HRSG,expanded in a turbine, condensed in an additional radiator and compressed by a pump before being reinjected into theboiler. The second cycle is similar, but uses water as a working medium, because of the higher boiling temperatures.Both cycles have a relatively low efficiency (7-10% the low-T version and about 25% the high-T one), but the net gain inpower output justifies their implementation. At present, three possible applications are being studied: one for a Britishdiesel train (nominal output 1000 kW, recovered power about 150 kW); a second one for a turbochargedcommercial truck (nominal power 500 kW, recovered power about 35 kW), and one for a city taxi (nominal power100 kW, recovered average power about 10 kW). For all configurations, a feasibility study has been performed, and aprototype system for the train is being built by the sponsor (Entropea Lab, London) in their facilities in Baltimore.UDR1 has participated by designing the turbine.The study is being funded by an external sponsor.

v. Another related study is underway: the application of an ORC to a standalone microturbogas (nominal power 100 kW,recovered power about 25 kW). This system -in a variant that comprises an additional absorption heat pump- has beenproposed to the Sapienza University for installation on the roof of the Aula Magna. The design is being carried outcompletely by our group.This study is being sponsored -via the spinoff CAESAR- by an external Company.Participants: R.Capata, R.Masci, E.Sciubba, L.Tocci, C.Toro, other external co-authors

OptimizationusingNeuralNetworks

Plantlayout

Thermodynamicmodelling

SmallscaleORCoptimization

• OptimizationoftheORCthermodynamiccycle• DesignandmanufacturingoftheORCcomponents

inthesmallscalerange(20– 100kWe)• Testingfacilitiesandlabsforexperimental

validation

FluidMachineryforORC

DIMA – Sez. Macchine (Ing-Ind-08)Turbomachinery – 6 & 7

vi. CFD of turbomachinery components: viscous adiabatic turbulent flows inrotoric & statoric channels, both axial & radial. Accurate RANS ans LESsimulations allow for a better identification the flow phenomenology: bladecooling, porous coating, entropy generation as a design decision parameter,heat recovered combustion chamber, modular super-compact heatexchangers for gas and organic fluid microturbines.

vi. Design and construction of an axial rotoric turbine blade in TiAl: conception,3D simulation, structural analysis, advanced manufacturing, centrifugalmelting of two generations of prototypes.

Participants: R.Capata, R.Masci, E.Sciubba, other external co-authors


PERISTALTIC PUMPS IN DIALYSIS (R.Capata)

1. Allowable shear on blood cells vs. pumping head: parametric evaluation

2. Blood flow limiting capability, fluid behaviour evaluation3. Rotary and/or reciprocating geometry analysis

“Constructal” heat exchangers: theoretical analysis, validation of design concept & testing of 3 prototypes.R.Capata, E.Sciubba & other external co-authors


Turbomachinery – 8

viii.Conceptual definition, implementation and prototyping of an Expert System for theautomatic preliminary design of turbomachinery (incompressible & compressible,axial and radial, single and multi-stage). A first-order design (type and structure,velocity triangles for each stage, specific work, efficiency and cost) is performed byan «intelligent expert system» consisting of a knowledge base of qualitative andquantitative design rules and of a multi-level inference engine that includes fuzzydecision rules.


Theoretical & Applied Thermodynamics 1

- Exergy-based analysis of energy conversion systems- Thermo-Economic evaluations of the feasibility of different system configurations

Aconcept study:solardriven gasturbine

• GTCChybridization withasolartower power plant

• Thermodynamic andthermo-economic analysis ofdifferentplant configurations (Base-load/peaker designed power plant)

• Plant simulations at different operating conditions (linkedtosunlight daily andshort-term variations incloudy days)

• Qualitativeandquantitativeassessment offuel savings,CO2emission reductions

Solartowerinstallationcostsbreakdown

Participants: R.Masci, C.Toro, FBK Trento

Thermo-Economic analysis of High-T Concentrated Solar process using air as heat transfer fluid

CMP

CSP CC HRSG

ST

COND

65

10

151489

20 25 7

22

1

2

24

19

Flue gases to stack

Heat released to the Environment

Net electric energy output

Air inlet

Solar energy input

Natural gas input

1415

137

4815

415

3382

635

4815

1611

0

1000

2000

3000

4000

5000

6000

HRSG CMP CSP ST

Exer

gy -

Exer

gy C

ost [

kW]

J-CSP

1034

12

4286

312 263

4417

62

4286

1333

262

0

1000

2000

3000

4000

5000

6000

HRSG CMP CSP ST CC

Exer

gy -

Exer

gy C

ost [

kW]

H-CSP

117 177

1006

72 187272 373

1464

163367

0

1000

2000

3000

4000

5000

6000

CMP GT CC ST HRSG

Exer

gy -

Exer

gy C

ost [

kW]

CCPP

Ex_D

C_ex,D

0.0

0.5

1.0

1.5

2.0

2.5

0

50

100

150

200

250

HRSG CMP CSP ST

Rela

tive

cost

diff

eren

ce -

r_ec

o [-

]

Econ

omic

cos

t [U

SD/h

]

J-CSP

0.0

0.5

1.0

1.5

2.0

2.5

0

50

100

150

200

250

HRSG CMP CSP ST CC

Rela

tive

cost

diff

eren

ce -

r_ec

o [-

]

Econ

omic

cos

t [U

SD/h

]

H-CSP

0.0

0.5

1.0

1.5

2.0

2.5

0

50

100

150

200

250

CMP GT CC ST HRSG

Rela

tive

cost

diff

eren

ce -

r_ec

o [-

]

Econ

omic

cos

t [U

SD/h

]

CCPP

C_eco,D

Z_inv

r_eco

0

10

20

30

40

50

60

70

80

90

100

J-CSP H-CSP CCPP

Exer

gy [%

]

Product

HRSG

CMP

ST

COND

CC

GT

CSP

0

1.000

2.000

3.000

4.000

5.000

6.000

7.000

8.000

9.000

10.000

J-CSP H-CSP CCPP

Exer

gy [k

W]

TheJulich (J-CSP)CSPplantwiththermalenergystoragehasbeencomparedwithaHybridplant(H-CSP)usingairasworkingfluid

• ExergyAnalysis

• ExergyCostAnalysis

• EconomicCost

CSP HRSG

ST

CMP

TES

COND

1

24

2 45

9

8

10

19

11

12

20

1716

3

Net electricenergy output

Solar energy input

Heat released to the Environment

“Sabatier” CO2 methanation

Evaluationofthepotentialofthetechnology

- Optimizationoftheplantdesign

(pinchanalysis)-CAMEL-ProTM code

Steady-statesimulations

Designconditions

Thermodynamic,Exergy,Thermo-economic,

Economicandsensitivityanalysis

Off-designconditions

Thermodynamic,Exergy,Thermo-economicandEconomicanalysis

Transientsimulations

Sabatierreactortransientresponse

Planttransientresponse

Heat recovery

SabatierbasedcycleforCO2 methanation

-200%

-100%

0%

100%

200%

300%

400%

500%

0 10 20 30 40 50 60 70

cel[€/MWh]

CH4

O2

El

Productcostsvariationwithelectricitycost

1% 2%

97%

O2 Electricity CH4

Shareofproductcosts

Products CostCH4 cost [€/smc] 0,47O2 cost [€/smc] 0,003Electricity cost [€/MWh] 50,44

1% 1%

5%

39% 54%

ThermalEnergy O&M CO2 CI Electricity

CostassumptionsElectricity cost[€/MWh] 20CO2 sequestration[€/tCO2] 25CO2 emissiontrades[€/tCO2] 9Thermalenergy[€/MWh] 31Operation hours[h/year] 7008

ParticipantsR.Masci, E.Sciubba, C.Toro

CAMEL-ProTM GTPower Plant

Air-cooledgasturbinecycles:simulationoffirst-stagecoolingeffectsongasturbinecycleperformance

Thermodynamicanalysis

Alumped thermodynamic modelofblade cooling

First-stagecooling

requirements

AtagivenPR,amaximum inthermalefficiency islikelytobereachedbelowstoichiometric

conditions,imposedbythelargeamountsofcoolingairrequired

ParticipantsR.Masci, E.Sciubba

Analysisandcomparisonofsolar-heatdrivenStirling,BraytonandRankinecyclesforspacepowergeneration

55%

57%

59%

61%

63%

65%

67%

69%

71%

73%

75%

4 9 14 19

ηI

π

R-B

R-I-B

R-R-B

R-R-I-B

Comparison of thermal efficiency of Brayton cycles with different configurations

Stirling cycle thermal efficiency comparison for different working fluids (TH=1500K, TL=200K,εr =0.85)

ParticipantsC.Toro, other external co-authors

R-B R-R R-R-R R-R-B R-I-B R-R-I-B

CycleparameterH2 N2 50%volN2 50%volH2 Ar N2 N2 Ar N2 N2 N2

pL [bar]

TL [K]

π/

TIT

1

200

10

1

200

10

1

200

10

0.75

84

200

0.15

64

1000

0.75

65

1000

0.15

85

200

1

200

10

1

200

10

1

200

10

1500 1500 1500 1500 1500 1500 1500 1500 1500 1500

ηI [%]

ε [%]

ψ [kW/m2]

61.7 62.2 67 77.87 84.25 88.9 84.28 66.6 68.1 71.8

61.8

0.8344

62.36

0.847

70.5

1.062

78.3

0.01413

84.63

0.00797

89.34

0.0117

84.8

0.02115

70.11

1.037

71.68

0.479

75.65

0.575

Rankine and Brayton cycles results(R-B Regenerative Bryton; R-R Regenerative Rankine; R-R-R Regenerative-Reheated-Rankine; R-R-B Regenerative-Reheated-Brayton; R-I-B Regenerative-Intercooled-Brayton; R-R-I-B Regenerative-Reheated-Intercooled-Brayton)

Cycleworkingfluid H2 N2

Stirlingworkingfluid H2 N2 He H2 N2 He

pL [bar]

TL [K]

rv

TH

1

200

2.15

1

200

2.3

1

200

1.55

1

200

2.15

1

200

2.3

1

200

1.55

1500 1500 1500 1500 1500 1500

mwf,hs [kg/s] 0.060 0.060 0.060 0.78 0.78 0.78

mwf,cs [kg/s] 0.011 0.011 0.011 0.16 0.16 0.16

ηStirling [%] 62.2 62.2 62.2 62.2 62.2 62.2

ηI [%]

ε [%]

ψ [kW/m2]

52.8 52.8 52.8 52.8 52.8 52.8

64.8

0.483

64,8

0.483

63.3

0.483

64.8

0.483

64,8

0.483

63.3

0.483

Stirling cycles results



Extended Exergy Analysis: a rigorously thermodynamic-based method for theidentification of the exergy footprint of a society.

E.Sciubba



Analisiexergetiche deisistemidiconversionedell'energiaeapprofondimentiditermoeconomia perlavalutazionedifattibilitàdidiversisistemi,ancheafontirinnovabili.

•Modelli di dinamica delle popolazioni e sostenibilità che includono principi termodinamici

•Studio di processi termodinamici di non-equilibrio

•Studio di funzioni automorfe e lororappresentazioni e studio delle funzionidi Painlevé, in particolare per le loroapplicazioni in:üFisica del plasma, onde non lineari(resonant oscillations in shallow water,convective flows with viscousdissipation, Görtler vortices in boundarylayers, Hele-shaw problems).üProblemi di conduzione del segnale infibre ottiche con risposta non-lineare.

•Discretizzazione di sistemi integrabili(con applicazioni in analisi numerica)tramite trasformazioni di Backlund



DiagnosticaePrognosticadiImpiantiSviluppodiprogrammiperlaclassificazioneeprevisionedicatenediguastoperimpiantiperlaproduzionedienergiaconl'utilizzodimetodologieintelligentiopensource

Sviluppodicodiciperl'ottimizzazionediretidiscambiatoridicaloreapplicataaimpiantidiliquefazionegas,impiantiindustriali

Progettazionediimpiantididissalazione

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