Design of Hydrogen Turboexpanders for Cryogenic

Liquefaction Cycles using Meanline design and

Scaling Methodologies and Flow Field Analysis using CFD

ZEROTH REVIEW

PROJECT TEAM
GUIDE:
SANIL MATHEW B211088ME
Dr.VIJAYARAJ
SUHAIR P B210992ME
VISAL S B211072ME
VIDHYA NAIR B211170ME
INTRODUCTION

Hydrogen liquefaction is an important part of the storage and transport of hydrogen, requiring
efficient processes for large-scale applications.
One of the cycle used for hydrogen liquefaction is the Claude cycle.
The key components of the Claude cycle are compressors, heat exchanger, turboexpander,
liquefaction chamber, separator, recycle line, etc. Hence improving the system efficiency
depends on the performance of these components.

Fig.1 : Claude cycle.

INTRODUCTION

Fig.2: Turbine main parts from z-axis view (left),

leading and trailing edges of rotor blades (right).

Turboexpanders cool and liquefy gases in the Claude cycle by expanding high-pressure gas.
The key components of turboexpanders are inlet guide vanes, rotors, nozzles, bearings, shafts,
and casings.
Our focus is on hydrogen turboexpander design and it's performance analysis under design
and off design conditions.
PROJECT OBJECTIVE

1) To design radial inflow turbine with hydrogen as the working fluid for hydrogen liquefaction
cycle using Meanline design methodology.

2) The potential of adapting a well-established turboexpander with known experimental

characteristics for the development of a hydrogen turboexpander remains unexplored.so the
scaling of an existing air-based radial inflow turbine for hydrogen applications is also Explored

3) To model the turboexpanders and carry out CFD analysis using Ansys.

4) To compare the CFD results with the meanline design data and non-dimensional characteristics
curves of the existing turbine chosen.

5) To conduct flow field analysis to identify the losses which are affecting the hydrogen
turboexpander performance.
METHODOLOGY

Two different methodologies will be employed for the design: Meanline design and Scaling
methodology from an existing design.
Meanline design analysis is done for Radial Inflow Expansion Turbine. Here we have to
develop a turbine from scratch by proposing a design methodology and by applying loss
models to assess the efficiency.
The following steps are performed for this :
- Design code using Matlab.
- Modelling of the turbine components using Ansys Baldegen and Solidworks.
- Meshing using Ansys Turbogrid and Ansys Mesh.
- CFD analysis using Ansys CFX.
METHODOLOGY

In scaling approach, we are trying to adapt/scale a well established air turbine (NASA 1730
Turbine designed with air as the fluid with 15 cm impeller diameter and having experimental
performance curves) to develop a hydrogen turbine.
 REVIEW OF LITERATURE

AUTHOR/YEAR
JOURNEL METHODOLOG RELEVAN
ARTICLE TITLE OF OBJECTIVES MAJOR FINDINGS
NAME Y ADOPTED CE
PUBLICATION

hydrogen turbo-
Kaimiao Zhou,
expander exhibits
Comparative Liang Chen, Comparative Design &
1.88% higher passage
analysis of energy Shanfeng Li, Applied analysis of energy simulation
Mean-line efficiency than the
losses in hydrogen Kang Zhao, Ze Thermal losses in hydrogen of turbo
method helium expander due
and helium turbo- Zhang, Engineering and helium turbo- expanders
CFD simulations to hydrogen’s lower
expanders for Shuangtao Chen, expanders .
viscosity, resulting in
hydrogen liquefiers Yu Hou
increased tip leakage
(year-2023)
flow

Effect of impeller investigate the impact of blade profile

blade profile on the Shuangtao Chen , influence of on nucleation, droplet Design
Applied
cryogenic two- Wan Sun , Lu Niu , impeller blade Mathematical growth, exit angle, exit method
Thermal
phase turbo- Liang Chen , Yu profile on and Geometrical kinetic energy, and for
Engineering
expander Hou cryogenic two- Simulation flow losses in a impeller
performance (year-2017) phase turbo- cryogenic two-phase blade
expander. turbo-expander
 AUTHOR/YEAR
JOURNEL METHODOLOGY
ARTICLE TITLE OF OBJECTIVES MAJOR FINDINGS RELEVANCE
NAME ADOPTED
PUBLICATION

Numerical and optimize the

experimental design of a radial Key Flow Issues
Manoj Kumar a, , 1-D Modeling
investigation to inflow turbine for Identified Flow Issues
Suraj K. Behera , AI Techniques
visualize the fluid cryogenic impact of various Identification
Amitesh Kumar , Energy Sobol Sensitivity
flow and thermal applications, design factors on &
Ranjit K. Sahoo Analysis
characteristics of a enhancing efficiency using design
(Year-2019)
cryogenic efficiency and sobol analysis improvement
turboexpander performance

characterize and
Experimental and Identified optimal
assess the
numerical approach turbine design
performance of a 3D simulations
for characterization Manoj Kumar a, variables.
International cryogenic with ANSYS CFX
and performance Suraj K. Behera , Identified High- Design &
Communications turboexpander Sobol method
evaluation of Amitesh Kumar , pressure conditions simulation of
in Heat and under rotating Design using
cryogenic Ranjit K. Sahoo yield the best turbo
Mass Transfer. conditions using Matlab.
turboexpander (Year-2022). temperature drop expanders.
experimental and
under rotating and efficiency.
numerical
condition.
approaches.
 AUTHOR/YEAR
JOURNEL METHODOLOGY
ARTICLE TITLE OF OBJECTIVES MAJOR FINDINGS RELEVANCE
NAME ADOPTED
PUBLICATION

The Ω method Energy losses are

Analysis of vortex
and entropy almost due to
characteristics and
Xiaoming Li , Kai generation The Ω method turbulent
energy losses in a International Performance
Zhang , Junjie Li, method are dissipation,Tip
cryogenic Journal of optimization
Zhengrong implemented to entropy clearance is a main
hydrogen turbo- Hydrogen of CHTB
OuYang , identify vortex generation parameter impacting
expander for a 5 Energy
Tongqiang Shi structures and method the impeller
t/d hydrogen
(Year-2024) calculate energy performance along
liquefier
losses with angle of incident

High-efficiency experimental and

control strategies Kaimiao Zhou, numerical
optimal characteristic
of a hydrogen Kang Zhao, investigations on CFD
ratio method is
turbo-expander for Liang Chen , Ze a hydrogen Performance
proposed to maintain
a 5 t/d hydrogen Zhang , Kunyu Energy turbo-expander Expirimental optimization
the hydrogen turbo-
liquefier Deng , within a 5 t/d Investigation of CHTB
expander at peak
Shuangtao hydrogen
efficiency.
Chen, Yu Hou liquefaction
(Year-2024) system
GAPS IDENTIFIED FROM LITERATURE OF REVIEW

1) The studies reported in literature regarding the design and CFD analysis of cryogenic hydrogen
turboexpanders are very less.

2) Exploring the possibility of adapting a well established turboexpander with experimental

characteristics for the development of hydrogen turboexpander has not been done yet.
 WORK PLAN

S7 MIDSEM S7 ENDSEM S8 MIDSEM S8 ENDSEM

Identification of the hydrogen Modelling and CFD analysis at the Flow field and performance Flow field and performance
liquefaction cycle from literature design point:- analysis at off-design points for analysis at off-design points for
and design of the turboexpanders the first turboexpander:- the scaled turboexpander:-
to arrive at the geometric details.

Meanline design of hydrogen Modelling and CFD simulation of To investigate the performance To investigate the performance
turboexpander based on the the turboexpanders obtained from and carryout the flow field and carryout the flow field
parameters catering to an meanline design and scaling analysis of the turboexpander analysis of the turboexpander
hydrogen liquefaction cycle methodologies at the design point. obtained from meanline design obtained from scaling
identified from literature. methodology at off-design points methodology at off-design points

Scaling an already existing radial

inflow turbine to develop hydrogen
turboexpander based on the above
parameters to arrive at the
geometric details.
REFERENCE

1) Comparative analysis of energy losses in hydrogen and helium turbo-expanders for hydrogen
liquefiers -Zhou, Kaimiao, Chen Liang, Li Shanfeng, Zhao Kang, Zhang, Ze Chen, Shuangtao Hou,
Yu Hou-2023.

2) Effect of impeller blade profile on the cryogenic two-phase turbo-expander performance -

Shuangtao Chen, Wan Sun b, Lu Niu, Liang Chen, Yu Hou-2017.

3) Numerical and experimental investigation to visualize the fluid flow and thermal
characteristics of a cryogenic turboexpander - Manoj Kumar, Suraj K, Behera, Amitesh Kumar
,Ranjit K. Sahoo-2019.

4) Experimental and numerical approach for characterization and performance evaluation of

cryogenic turboexpander under rotating condition - Kumar, Manoj, Biswal, Rasmikanti,
Behera, Suraj Kumar, Sahoo, Ranjit Kumar, Pal, Sandip-2022.
REFERENCE

5) Analysis of vortex characteristics and energy losses in a cryogenic hydrogen turbo-expander

for a 5 t/d hydrogen liquefier-Xiaoming Li, Kai Zhang, Junjie Li, Zhengrong OuYang, Tongqiang
Shi-2024.

6) High-efficiency control strategies of a hydrogen turbo-expander for a 5 t/d hydrogen liquefier

-Kaimiao Zhou, Kang Zhao b, Liang Chen, Ze Zhang, Kunyu Deng, Shuangtao Chen, Yu Hou-2024.