Experimental Research of Thermal-Flow and Vibration Characteristics of a 1 Kw ORC Microturbine
More details
Hide details
1
Institute of Fluid-Flow Machinery, Polish Academy of Sciences, Department of Turbine Dynamics and Diagnostics,
Fiszera 14, 80-231 Gdansk, Poland
Publication date: 2026-03-11
Acta Mechanica et Automatica 2026;20(1)
KEYWORDS
ABSTRACT
This paper discusses the experimental research findings on a high-speed microturbine in an ORC system using the low-boiling fluid HFE-7100. The microturbine prototype features a hermetic design and was developed using oil-free technology, incorporating gas bearings powered by a low-boiling fluid. One of the main objectives of the study was to determine the thermodynamic parameter ranges within which the microturbogenerator could operate correctly. Tests of the microturbine were conducted within a rotational speed range of 10,000 rpm to approximately 75,000 rpm, with receiver loads ranging from 200 We to 2,000 We. The power of the heat source and the flow rate of the HFE-7100 working fluid ranged from 12 to 20 kWt and 30 to 60 g/s, respectively. The chosen range of heat source power was deliberate and simulated the actual operating conditions of domestic boilers. In addition to meas-urements of thermal, flow, and energy parameters, vibration measurements of the turbogenerator were carried out to assess the dynamic state of the machine. The study found that for each power level of the heat source, the optimum generator load was de-termined at which the electrical output of the system reached its maximum. The work includes the electrical and dynamic character-istics of the high-speed microturbogenerator.
REFERENCES (35)
1.
Zhang Y, Tsai YCh, Ren X, Tuo Z, Wang W, Gong L, Hung TCh. Experimental study of the external load characteristics on a micro-scale organic Rankine cycle system. Energy. 2024:306;132453.
https://doi.org/10.1016/j.ener....
2.
Zhang H-H, Zhang Y-F, Feng Y-Q, Chang J-Ch, Chang Ch-W, Xi H, Gong L, Hung T-Ch, Li M-J. The parametric analysis on the system behaviors with scroll expanders employed in the ORC system: An experimental comparison. Energy. 2023:268;126713.
https://doi.org/10.1016/j.ener....
3.
Wei J, Hua Q, Yuan L, Li G, Wang J, Wang J. A review of the research status of scroll expander. Proceedings of the Institution of Mechanical Engineers, Part A: Journal of Power and Energy. 2023:237(1);176-197.
https://doi:10.1177/0957650922....
4.
Kaczmarczyk TZ, Żywica G. Experimental research of a micropower volumetric expander for domestic applications at constant electrical load. Sustainable Energy Technologies and Assessments. 2022:49;101755.
https://doi.org/10.1016/j.seta....
5.
Montazerinejad H, Eicker U. Recent development of heat and power generation using renewable fuels: A comprehensive review. Renewable and Sustainable Energy Reviews. 2022:165;112578.
https://doi.org/10.1016/j.rser....
6.
Huo E, Xin L, Wang S. Thermal stability and pyrolysis mechanism of working fluids for organic Rankine cycle: A review. International Journal of Energy Research. 2022;46:19341–19356.
https://doi.org/10.1002/er.851....
8.
Alshammari F, Alshammari AS, Alzamil A. Advanced energy conversion strategies using multistage radial turbines in Organic Rankine Cycles for low-grade heat recovery. Case Studies in Thermal Engineering. 2025:69;106034.
https://doi.org/10.1016/j.csit...
9.
Ahmed AM. Thermal efficiency investigation for organic Rankine cycle and trilateral flash cycle using hydrofluoroether working fluids. Results in Engineering. 2024:21;101648.
https://doi.org/10.1016/j.rine....
10.
Witanowski Ł. Multi-Objective Optimization of a Small-Scale ORC-VCC System Using Low-GWP Refrigerants. Energies. 2024:17(21);5381.
https://doi.org/10.3390/en1721....
11.
Hasan A, Mugdadi B, Al-Nimr MA, Tashtoush B. Direct and indirect utilization of thermal energy for cooling generation: A comparative analysis. Energy. 2022:238(Part C);122046.
https://doi.org/10.1016/j.ener....
12.
Kaczmarczyk TZ. Experimental research of a pumping engine in a micro-ORC system with a low-boiling medium. Archives of Thermodynamics. 2024:45(4);125‒140.
https://doi.org/10.24425/ather....
13.
Zuo Q, Liu P, Meng W, Zeng X, Li H, Wang X, Tian H, Shu G. Bayesian optimized LSTM-based Sensor Fault Diagnosis of Organic Rankine Cycle System. Energy and AI. 2025;100519.
https://doi.org/10.1016/j.egya....
14.
Li J, Gurgenci H, Guan Z, Li J, Li L, Xue Y. Multi-objective optimization of a small scale SCO2 turbine rotor system with a shaft cooler. Mechanics & Industry. 2022:23;21.
https://doi.org/10.1051/meca/2....
15.
Hossain MS, Sultan I, Phung T, Kumar A. An Optimum Design for a Fast-Response Solenoid Valve: Application to a Limaçon Gas Expander. Dynamics, 2024:4(2);457-474.
https://doi.org/10.3390/dynami....
16.
Zaniewski D, Klimaszewski P, Klonowicz P, Witanowski Ł, Lampart P, Jędrzejewski Ł, Suchocki T. Organic Rankine cycle turbogenerator cooling – Optimization of the generator water jacket heat exchange surface. Applied Thermal Engineering. 2023:223;120041.
https://doi.org/10.1016/j.appl....
17.
Kaczmarczyk TZ, Ihantowicz E, Żywica G, Kaniecki M. Experimental study of the prototype of a Roto-Jet pump for the domestic ORC power plant. Archives of Thermodynamics. 2019:40(3);83-108.
https://doi.org/10.24425/ather....
18.
Sanaye S, Ghaffari A. Transient modeling and thermal analysis of an innovative dual‑loop Rankine–organic Rankine heat recovery system integrated with a gas engine. Journal of Thermal Analysis and Calorimetry. 2023:148(20);10951-10971.
https://doi.org/10.1007/s10973....
19.
Murthy AA, Norris S, Subiantoro A. Performance of a four-intersecting-vane expander in a R134a refrigeration cycle. Applied Thermal Engineering. 2022:209;118244.
https://doi.org/10.1016/j.appl....
20.
Peng N, Wang E, Wang W, Lu J, Li M. Aerodynamic analysis of a 1.5 kW two-stage counter-rotating partial-admission impulse turbine for small-scale power system with a high expansion pressure ratio. Case Studies in Thermal Engineering. 2024:53;103824.
https://doi.org/10.1016/j.csit....
21.
Gunawan G, Permana DI, Soetikno P. Design and numerical simulation of radial inflow turbine of the regenerative Brayton cycle using supercritical carbon dioxide. Results in Engineering. 2023:17;100931.
https://doi.org/10.1016/j.rine....
22.
Zhang Y, Zhang S, Peng H, Tian Z, Gao W, Yang K. Thermodynamic analysis of Tesla turbine in Organic Rankine Cycle under two-phase flow conditions. Energy Conversion and Management. 2023:276;116477.
https://doi.org/10.1016/j.enco....
23.
Wang E, Peng N. A Review on the Preliminary Design of Axial and Radial Turbines for Small-Scale Organic Rankine Cycle. Energies. 2023:16(8);3423.
https://doi.org/10.3390/en1608....
24.
He S, Tong Z, Tong S, Chen K, Cao XE. Collaborative optimization of turbo-expander impellers and guide vanes to mitigate flow-induced vibrations. Physics of Fluids. 2025;37(3);035178.
https://doi.org/10.1063/5.0257....
25.
Ahmed AM. Assessment of the thermal efficiency of subcritical power generation cycles using environmentally friendly fluids at various heat source temperatures. Energy Sci. Eng. 2022:10;4768-4781.
https://doi.org/10.1002/ese3.1...
26.
Peng N, Wang E, Wang W. Design and analysis of a 1.5 kW single-stage partial-admission impulse turbine for low-grade energy utilization. Energy. 2023:268;126631.
https://doi.org/10.1016/j.ener....
27.
Witanowski Ł, Klonowicz P, Lampart P, Ziółkowski P. Multi-objective optimization of the ORC axial turbine for a waste heat recovery system working in two modes: cogeneration and condensation. Energy. 2023:264;126187.
https://doi.org/10.1016/j.ener....
28.
Kottapallia A, Konijeti R. Numerical and experimental investigation of nonlubricated air scroll expander derived from a refrigerant scroll compressor. Front Heat Mass Transfer. 2022:19(1);1-11.
https://doi.org/10.5098/hmt.19...
29.
Daniarta S, Kolasiński P, Imre A.R, Sowa D. Artificial intelligence-driven performance mapping: A deep learning-based investigation of a multi-vane expander in retrofitted organic Rankine cycle. Energy Conversion and Management. 2024:315;118763.
https://doi.org/10.1016/j.enco....
30.
Colak AB, Arslan O. Numerical analysis-based performance assessment of the small-scale organic Rankine cycle turbine design for residential applications. Thermal Science and Engineering Progress. 2024:51;102626.
https://doi.org/10.1016/j.tsep....
31.
Abdalhamid AMK, Eltaweel A. Design and analysis of a single-stage supersonic turbine with partial admission. Energy. 2024:309;133100.
https://doi.org/10.1016/j.ener....
32.
Abbas WKA, Baumhögger E, Vrabec J. Experimental investigation of organic Rankine cycle performance using alkanes or hexamethyldisiloxane as a working fluid. Energy Conversion and Management: X. 2022:15;100244.
https://doi.org/10.1016/j.ecmx....
33.
Sun H, Gao P, Wu X. Performance investigation of a two-stage partial admission axial impulse turbine used for low temperature organic rankine cycle. Renewable Energy. 2025;249:123276.
https://doi.org/10.1016/j.rene....
34.
Kaczmarczyk TZ, Żywica G. Experimental study of the effect of load and rotational speed on the electrical power of a high-speed ORC microturbogenerator. Applied Thermal Engineering.2024:238;122012.
https://doi.org/10.1016/j.appl....
35.
Sun H, Li H, Gao P, Hou F, Hung TCh, Chang YH, Lin ChW, Qin J. Numerical simulation and low speed experiment of a low partially admitted rate axial turbine for small scale organic Rankine cycle. Applied Thermal Engineering. 2024:238;122002.
https://doi.org/10.1016/j.appl....