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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
DIMA – Sez. Macchine (Ing-Ind-08)
DIMA – Sez. Macchine (Ing-Ind-08)
DIMA – Sez. Macchine (Ing-Ind-08)Turbomachinery - 2
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
DIMA – Sez. Macchine (Ing-Ind-08)Turbomachinery - 3
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)
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
DIMA – Sez. Macchine (Ing-Ind-08)
DIMA – Sez. Macchine (Ing-Ind-08)
DIMA – Sez. Macchine (Ing-Ind-08)
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
DIMA – Sez. Macchine (Ing-Ind-08)
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.
DIMA – Sez. Macchine (Ing-Ind-08)
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
DIMA – Sez. Macchine (Ing-Ind-08)
Theoretical & Applied Thermodynamics 2
Extended Exergy Analysis: a rigorously thermodynamic-based method for theidentification of the exergy footprint of a society.
E.Sciubba
DIMA – Sez. Macchine (Ing-Ind-08)
DIMA – Sez. Macchine (Ing-Ind-08)
Theoretical & Applied Thermodynamics 1
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
DIMA – Sez. Macchine (Ing-Ind-08)
Theoretical & Applied Thermodynamics 1
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Progettazionediimpiantididissalazione
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