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The organic Rankine cycle (ORC) is an established thermodynamic process that converts waste heat to electric energy. Due to the wide range of organic working fluids available the fluid selection adds an additional degree of freedom to the early design phase of an ORC process. Despite thermodynamic aspects such as the temperature level of the heat source, other technical, economic and safety aspects have to be considered. For the fluid selection process in this paper, 22 criteria were identified in six main categories while distinguishing between elimination and tolerance criteria. For an ORC design, the suggested method follows a practical engineering approach and can be used as a structured way to limit the number of interesting working fluids before starting a detailed performance analysis of the most promising candidates. For the first time the selection process is applied to a two-stage reference cycle which uses the waste heat of a large reciprocating engine for cogeneration power plants. It consists of a high temperature and a low temperature cycle in which the condensation heat of the high temperature (HT) cycle provides the heat input of the low temperature (LT) cycle. After the fluid selection process the detailed thermodynamic cycle design is carried out with a thermodynamic design tool that also includes a database for organic working fluids. The investigated ORC cycle shows a net thermal efficiency of about 17,4% in the high temperature cycle with Toluene as the working fluid and 6,2% in low temperature cycle with iso-Butane as the working fluid. The electric efficiency of the cogeneration plant increases from 40,4% to 46,97% with the both stages of the two-stage ORC in operation.
A 3-stage model of a low pressure steam turbine has been equipped with extensive instrumentation to assess aerodynamic performance and for validation of numerical methods. Emphasis was placed on detailed measurements at the inlet and exit of the last stage guide vane. Two configurations were examined – the first used a guide vane with lean in the last stage and a the second used a guide vane combining both lean and sweep. The experimental results from the two configurations have been compared with data from various design methods, ranging from through-flow to 3D multistage viscous simulations with mixing planes. Despite the challenges in modelling complex rotating blades in a wet steam environment, good agreement between the numerical and experimental results was obtained, and the new stator vane combining lean and sweep achieved the desired increase in reaction at the hub section.
Striving for smaller losses in turbomachinery has led to many advancements in the design of seals. Modern sealing concepts such as brush seals hold a great potential to increase the efficiency of both flight engines and stationary turbines. At the same time, in order to maintain stable operating conditions of the rotor, swirl-induced forces must be kept at a minimum in the sealing channels. Therefore, the influence of the permeable and flexible bristle pack of brush seals on the flow around the rotor surface must be known. In this paper the swirl flow in the cavities of two different seal geometries is studied experimentally and numerically. A conventional three-tooth labyrinth serves as a reference. A second seal arrangement with a bristle pack upstream of two teeth is compared with the reference labyrinth. The swirl is evaluated experimentally from total and static pressure measurements in various axial and circumferential positions. Additionally, the axial swirl distribution is calculated using computational fluid dynamics (CFD). Here, the numerical model of the brush seal is based on the porous medium approach and is calibrated using the experimental values of the leakage and the bristle clearance by adjusting the thickness of the bristle pack. The calibrated CFD model is then used to study the impact of the brush seal on the swirl component of the sealing flow. The observed significant decrease of the swirl by the brush seal shows good agreement with the experimental data. The impact of changes in bristle pack clearance on the swirl is also investigated and compared with experimental evidence. The aim is to show that the brush seals have a natural tendency to interrupt seal swirl. They can therefore be used for swirl control in order to create a beneficial impact on the dynamic stability of turbomachines.