Design of an Axial Turbine and Thermodynamic Analysis and Testing of a ...

Design of an Axial Turbine and Thermodynamic Analysis and Testing of a K03 Turbocharger

by

Yoshio Samaizu Perez Zuniga

Submitted to the Department of Mechanical Engineering in partial fulfillment of the requirements for the degree of

Bachelor of Science in Mechanical Engineering

at the MASSACHUSETTS INSTITUTE OF TECHNOLOGY

ARCHIVES

MASSACHUSEFT1TS NTITUTE OF TECH"OLOGY

OCT 2 0 2011

LIBRARIES

June 2011

? Massachusetts Institute of Technology 2011. All rights reserved.

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Department of Mechanical Engineering

May 18, 2011

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Samuel C. Collins Professor o echanical Engineering

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Design of an Axial Turbine and Thermodynamic Analysis

and Testing of a K03 Turbocharger

by

Yoshio Samaizu Perez Zuniga

Submitted to the Department of Mechanical Engineering on May 18, 2011, in partial fulfillment of the requirements for the degree of Bachelor of Science in Mechanical Engineering

Abstract

A novel humidification dehumidification desalination system was developed at the Rohseneow Kendall Heat Transfer Laboratory. The HDH system runs by having different pressures in the humidifier and dehumidifier. One of the components that will keep the different pressures is an expander. The expander specification is to work with a pressure ratio of 1.2 while having a high efficiency. Two approaches were developed to achieve this result, one was through the design of a turbine and the second was through the selection and testing of a car turbocharger. The design of a turbine is given in detail and follows the process given in "Design of HighEfficiency Turbomachinery and Gas Turbines" by David Wilson. The final design of the turbine blades was sand cast. Due to the sand casting process, cavitation on the blade material was shown and testing of the blades was not pursued for fear of fast fracturing. The second option of selecting a turbocharger is shown and the process which led to its selection is explained. Through such process a K03 turbocharger was selected to be suitable to run at the low pressure ratios with a moderate efficiency. Testing of the K03 was conducted. The static-to-static isentropic efficiency calculated was 53% ? 11% for a pressure ratio of 1.2 while the total-to-total isentropic efficiency 60% ? 14% at a pressure ratio of 1.2. The high error associated with the efficiencies are due to the turbine experiencing small temperature drops in the order of 10'C or less. The K03 turbocharger is meant to run at higher pressure ratios, in the order of 2 with a manufacturer specified efficiency of 70%. Running the K03 at a pressure ratio of 1.2 decreases the efficiency since its not specified to run at those low pressure ratios. If a turbine or a turbocharger is designed for the exact specifications of the desalination system, it can work with low pressure ratios and be highly efficient.

Thesis Supervisor: John H. Lienhard V Title: Samuel C. Collins Professor of Mechanical Engineering

Acknowledgments

Undertaking this project has been very tough and required the assistance of many people, and I can't possibly thank everyone.

In the process of designing the axial turbine I would like to thank David Wilson for giving me suggestions on what to look for in designing the turbine blades. In producing the sand casted blades I thank Cody Daniel and Mike Tarkanian for offering their lab to cast the blades.

In testing the K03 turbocharger I like to thank Zoltn Spakovszky for letting me use the equipment at the MIT Gas Turbine Laboratory (GTL) . Also I appreciate the help of the lab instructor, Jimmy Letendre for sharing his knowledge in setting up the equipment to use the GTL laboratory and giving me ideas on how to collect data.

The Device Research Laboratory (DRL) lead by Professor Evelyn Wang, where I worked for two years I would like to thank the grad students for giving me great advice in the selection process of the turbocharger, giving me ideas on how to design the test setup and letting me use their equipment. Evelyn, I thank you for giving me the opportunity for working for the DRL lab, it truly has been a life changing experience. The DRL to me as been my MIT lab family, I can always count on their support and they have always made me feel welcomed in their lab even after I no longer worked with them. Andrej and Tom, thank you for taking me in as your undergrad UROP, it was through you that I got to know the DRL family and learn many of the skills I have today with experimentation. Arthur Kariya you where an awesome resource and friend to have, you help me so much in finishing this project with your vast knowledge in experimental testing. Moreover thanks for listening to me when I was frustrated on what to do next. DRL family I am in debt with your help.

Lastly I like to thank the Rohsenow Kendall Heat and Mass Transfer Laboratory (RKLab), lead by Professor John Lienhard V for giving me the resources to start and complete this project. Prakash I thank you for believing in me in achieving my goals

and pushing me forward when times where dark. Ronan, I am grateful for helping me doing the thermodynamic analysis, helping me out in designing the test setup and procedure and helping me in testing the K03 turbocharger. Professor Lienhard, thank you for being understanding in my research process and more importantly for accepting me in the RKLab and trusting me with such a tremendous project. Through this project I have become a better engineer both in the design and testing aspects.

I would like to end with a quote by Friedrich Nietzsche, a philosopher whom I love for his wittiness and wisdom, that I find appropriate in describing my decisions in life at MIT and outside "There is always some madness in love. But there is also always some reason in madness."

Contents

1 Introduction 1.1 Motivation for an Efficient Expander 1.2 Pressure Driven Expanders . . . . . . 1.2.1 Screw Expander . . . . . . . . 1.2.2 Scroll Expander . . . . . . . . 1.2.3 Rotary Vane Expander . . . . 1.3 Dynamically Driven Expanders . . . 1.3.1 Axial Turbomachinery . . . . 1.3.2 Off the Shelf Turbocharger . .

2 The Design of an Efficient Axial Turbine 2.1 Overall Process . . . . . . . . . . . . . . . 2.2 Developing Velocity Diagram ... . . .. 2.3 Blade Profile . . . . . . . . . . . . . . . . 2.4 Disc Profile Design . . . . . . . . . . . . . 2.5 Inlet Cone . . . . . . . . . . . . . . . . . . 2.6 Casing, Bearings, Shaft and Rigidity . . .

22 . . . . 22

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26

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3 Thermodynamic Analysis of Turbocharger and Retroffiting for Lab Test 3.1 Defining Isentropic Efficiency. . . . . . . ... 3.2 Selecting and Retrofiting Turbocharger . . . . . 3.2.1 Matching Operating Points in the Compressor and Turbine . . 41

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