The design and research of two-stage series-connected helium turbine expanders for hydrogen liquefaction system

• Published in: Applied thermal engineering 2024-07, Vol.249, p.123396, Article 123396
• Main Authors: Zhu, Zuchao, Lou, Shumin, Zhang, Yiming, An, Lili, Liu, Yang, Li, Xiaojun
• Format: Article
• Language: English
• Subjects: Dynamic design; Helium turbine expander; Hydrogen liquefaction system; Prototype experiment
• ISSN: 1359-4311
• DOI: 10.1016/j.applthermaleng.2024.123396

•The reverse Brayton cycle is utilized for the hydrogen liquefaction system.•A two-stage series-connected helium turbine expanders unit is designed and tested.•The isentropic efficiency of each expander is higher than 75%.•The unit achieves approximately 31 K temperature drop with pressure ratio of 8.32.•Nozzle throat and impeller tip clearance are the main sources of flow losses. The helium turbine expander, is a crucial part of hydrogen liquefaction systems, that determines the overall efficiency of the system. In this paper, a two-stage series-connected helium turbine expanders is designed to achieve a hydrogen liquefaction capacity of 1.7 tonnes per day (TPD). The proposed expander is based on the reverse Brayton cycle and realizes a high pressure ratio of 8.32 to meet the design objective. A dynamic design process in the expansion end is developed and numerically simulated based on the turbine expander design methodology. The off-rated condition performance of the turbine expander is predicted by adjusting the rotational speed and flow rate. The results show that the reasonable rotational speed range of the turbine expander is 46000–54000 RPM, and the reasonable flow coefficient range is 0.6–1.2, which can maintain a high level of efficiency. The internal flow characteristics of the turbine expander are analysed through numerical simulation. The results show that the outlet temperature is suitable for hydrogen liquefaction, and flow loss mainly occurs in the upper-middle part of the impeller and near the tip clearance, followed by the throat of the nozzle. In the prototype tests to verify the rationality of the design of the turbine expanders, the experimental results show that the two turbine expanders can achieve a temperature drop of 31 K, and isentropic efficiencies of 76.8 % and 80.5 %, respectively, which are higher than the design requirements of 75 %. The actual outlet temperature and isentropic efficiency are compared with the numerical simulation results. The errors are less than 4 % and 10 %, respectively, which means that the prototype manufacturing precision meets the system requirements perfectly. Thus, the design of the two-stage series-connected turbine expanders can satisfy the performance design requirements.