Turbocharger gas turbine

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ganuganu
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Turbocharger gas turbine

Post by ganuganu » Fri Jul 17, 2015 2:41 pm

Many have made these kind of projects, but the main purpose for me is to validate my theoretical, numerical and experimental results together.

Hello everyone iam back again with an interesting project "Gas turbine made out of automobile turbocharger" (Holset HX35W). Did not use any online available calculator to design the combustor.

Thermodynamic calculations and combustor sizing was done using excel sheet.
Operating point:
Mass flow: 0.196kg/s
PR: 2.2
Fuel flow: 0.00205kg/s
Combustion air flow: 0.0353kg/s
Remaining air distributed among PZ cooling, Secondary and tertiary zone to match the turbine inlet temperature(873K). This is just theoretical calculation.

CFD analysis were performed using the commercially available tools Starccm+ and Ansys to cross check or validate my theoretical results. Here are some pics of the simulated result.

CC design: Burning velocity model
Eddy break up concept
K-e model
Swirlers are implemented for improving the combustion efficiency.
The mesh count was about 0.35million cells.
Convergence is e-04.
You can see the swirls clearly in the Vector plot.
Next step to fabricate the combustor.
Attachments
completeebu_radial_Vector_Scene_2.jpg
completeebu_radial_Scalar_Scene_1.jpg
completeebu_Mesh_Scene_1.jpg

metiz
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Re: Turbocharger gas turbine

Post by metiz » Sat Jul 18, 2015 4:56 am

Nice! keep posting updates!
Quantify the world.

ganuganu
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Re: Turbocharger gas turbine

Post by ganuganu » Tue Jul 21, 2015 3:43 pm

In previous simulation i specified the mass flow through each hole but still i had some doubts so today i tried the whole CC simulation where i specified the total mass flow at diffuser inlet and it automatically divides itself into respective zones. There were some small misalignment with my calculated values so iam making some little changes in CC and simulate again tomorrow.

These are today's results. This simulation is a fine mesh result (10million mesh)
Attachments
Untitled.png
ebudivideSZ1_Vector Scene 1.png
ebudivideSZ1_Scalar Scene 1.png

ganuganu
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Re: Turbocharger gas turbine

Post by ganuganu » Thu Jul 23, 2015 9:10 am

The final Design Considerations and results after the analysis both in ANSYS and Starccm+. They are as follows:

ANSYS (PDF Table) : Average exit temp - 805K
Average exit velocity - 142m/s

Starccm+ (EBU model): Average Exit temp - 760K
Average Exit velocity - 135m/s

Expected Thrust: 50 to 60N.

Even in ANSYS EDM was analysed and the results were same like EBU in Starccm+
Liner Holes: 2mm (Count 10)
Secondary Holes: 10mm (Count 10)
Dilutions holes Set 1: 10.5mm (Count 10)
Dilution holes set 2: 9.5mm (Count 10)
Mass flow Through LH + SH + DH1 +DH2 = 0.158Kg/s
Mass flow through Swirler: 0.0375Kg/s
Total Length of the CC = 205mm
Total Length with Diffuser = 380mm
Swirler Blade Count: 8
Note: Exit nozzle has been designed at the turbine exit.
Fabrication to be started.

metiz
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Re: Turbocharger gas turbine

Post by metiz » Thu Jul 23, 2015 11:27 am

Good luck! please keep posting updates
Quantify the world.

ganuganu
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Re: Turbocharger gas turbine

Post by ganuganu » Wed Jul 29, 2015 2:50 pm

The previous simulation was steady state RANS analysis now i have done a unsteady LES (Large eddy simulation) analysis. This shows the actual burning of fuel-air in a combustor. Here is the link to the video.

https://www.youtube.com/watch?v=eNHowG28yl4

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