CFD analysis of variable wall thickness scroll expander integrated into small scale ORC systems

The studies of constant wall thickness scroll expander have pointed out that geometries with large built-in volume ratios are necessary to achieve high performances in small-sized organic Rankine cycle (ORC) units. The variable wall thickness expander design offers the opportunity of increasing the geometric expansion ratio with the number of scroll turns remaining unchanged to avoid sealing and lubricating issues. In this paper, unsteady and three-dimensional computational fluid dynamics (CFD) simulations of scroll expander using variable wall thicknesses were therefore carried out to investigate the effects of the geometry on the internal flow behaviour. The scroll expander was integrated into an ORC unit fed by R123. The dynamic mesh technology of ANSYS Fluent was applied to generate the deforming mesh in the expander working chambers. The aerodynamic performance analysis yielded how over-expansion phenomena occurred at low pressure ratio while under-expansion phenomena were existing at high pressure ratio which are consistent with the thermodynamic theory of scroll expander. The higher pressure ratio was also contributing to higher temperature drops during the expansion process. Moreover, the occurrence of flank leakages through the radial clearances and its effects on the flow field were pointed out further proving the thermodynamic theory of scroll expander.