imperial turbocharger group introduction (sept 2015)

The Turbocharger Group at Imperial College London Introduction to people, facilities, and technologies Prof Ricardo F Martinez-Botas Professor in Turbomachinery Imperial College London Department of Mechanical Engineering September 2015

Dr Aaron Costall Research Fellow Imperial College London Department of Mechanical Engineering

Contents • Location • Academic reputation • Publication record and patents • Clients & research partners • Sources of funding • People • Facilities • Competence summary • Imperial-UTM connection • Past work • Selected technologies • Current PhD projects • Contact details

The Turbocharger Group at Imperial College London Introduction to people, facilities, and technologies

Location

The Turbocharger Group at Imperial College London Introduction to people, facilities, and technologies

Where are we? • Imperial College London

is located at the heart of London’s museum district (“Albertopolis”) in South Kensington

• The Turbocharger Group is part of the Dept of Mechanical Engineering; the Turbo Lab is located on Level 1 of the City & Guilds Building

Location: ‘Albertopolis’

Royal College of Art Royal Albert Hall

Royal College of Music

Hyde Park

Imperial College London Victoria & Albert Museum

Natural History Museum

Science Museum

Department of Mechanical Engineering

Academic Reputation – UK Rankings 2014 Research Excellence Framework (REF): Aeronautical, Mechanical, Chemical and Manufacturing Engineering

Funding bodies:

Guardian University League Table 2015 • 1st in Mechanical Engineering • 5th overall

The Complete University Guide 2015 • 2nd in Mechanical Engineering • 6th overall

Rank order Institution name Cat A

FTE

Overall quality profile (percentage of research activity at each quality level)

4* 3* 2* 1*

1 University of Cambridge 32 47% 45% 7% 1%

2 Imperial College London 173 46% 43% 10% 1%

3= University of Manchester 34 30% 60% 10% 0%

3= University of Leeds 32 30% 54% 16% 0%

5= University of Birmingham 33 27% 60% 13% 0%

5= University of Manchester 34 27% 57% 16% 0%

7= Cranfield University 157 26% 58% 16% 0%

7= Loughborough University 127 26% 57% 16% 1%

9 University of Strathclyde 67 24% 56% 19% 1%

10 University College London 54 23% 67% 9% 1%

11 University of Sheffield 45 22% 67% 11% 0%

12 Newcastle University 43 21% 60% 19% 0%

13 University of Bath 61 19% 70% 11% 0%

14 University of Sheffield 30 18% 71% 10% 1%

15 University of Greenwich 9 17% 57% 26% 0%

16 University of Birmingham 21 14% 71% 15% 0%

17 Queen's University Belfast 50 11% 77% 12% 0%

18 University of Bradford 17 9% 54% 35% 1%

19 University of Brighton 9 7% 60% 26% 7%

20 Brunel University London 63 6% 63% 28% 3%

Academic Reputation – European & Global Rankings

QS World University Rankings 2014/15 • 1st equal in Europe overall • 2nd equal in world overall • Source: http://www.topuniversities.com/qs-world-university-rankings

Times Higher Education Supplement 2015 • 3rd in Europe, 6th in world for engineering and technology • 14th in world overall • Source: http://www.timeshighereducation.co.uk/world-

university-rankings/

Times & Sunday Times Good University Guide 2014 • 9th in world in Mechanical Engineering • 10th in world overall • Source: http://www.thetimes.co.uk/tto/public/gug/

http://www.topuniversities.com/qs-world-university-rankings

http://www.timeshighereducation.co.uk/world-university-rankings/

http://www.timeshighereducation.co.uk/world-university-rankings/

http://www.thetimes.co.uk/tto/public/gug/

Publication Record Scopus record • Number of publications by

affiliation • Search term: “turbocharger” • Source:

http://www.scopus.com

Last 5 years (2010–2015 inc.)

All years

http://www.scopus.com/

Publication Record

Witty’s Review (APC Spoke bid) – Automotive Publications

Publication Record • Prof Ricardo Martinez-Botas • Publications involving

turbochargers and turbocharging Chen, H., Hakeem, I., and Martinez-Botas, R.F., “Modeling of a Turbocharger Turbine under Pulsating Inlet Conditions”, Proc. Instn. Mech. Engrs., J. Power and Energy, 210, (1996), 397-408. Arcoumanis, C., Martinez-Botas, R.F., Nouri, J.M. and Su, C.C., “Performance and Exit Flow Characteristics of Mixed Flow Turbines'”, Int. J. of Rotating Machinery, 3, (1997), 277-293. Karamanis, N.K., Martinez-Botas, R.F. and Su, C.C., “Mixed Flow Turbines: Inlet and Exit Flow under Steady and Pulsating Conditions”, Trans. ASME, J. Turbomachinery, 123, (2001), 359-371. Panting, J., Pullen, K.R, and Martinez-Botas, R.F., “Turbocharger Motor-Generator for Improvement of Transient Performance in an Internal Combustion Engine”, Proc. Instn. Mech. Engrs., J. Auto. Eng., 215, (2001), 369-383. Karamanis, N. and Martinez-Botas, R.F., “Mixed-flow Turbines: Steady and Unsteady Performance”, Proc. Inst. Mech. Engrs., Int. J. Eng. Res., 3, (2002), pp. 127-138. Palfreyman, D and Martinez-Botas, R.F., “The Pulsating Flow Field in a Mixed Flow Turbocharger Turbine: An Experimental and Computational Study”: ASME J. Turbo., 127, (2005), 144-155. Pesiridis, A. and Martinez-Botas, R.F., “Experimental Evaluation of Active Flow Control Mixed-Flow Turbine for Automotive Turbocharger Application”, ASME J. Turbo., 129, (2007), 44-52. Szymko, S., Pullen, K.R., Martinez-Botas, R.F. and McGlashan, N.R., “The Development of a Dynamometer for Torque Measurement of Automotive Turbocharger Turbines”, Proc. Instn. Mech. Engrs., Journal of Automotive Engineering, 221, (2007), 225-239. Hakeem, I., Su, C.C., Costall, A. and Martinez-Botas, R.F., “Effect of Volute Geometry on the Steady and Unsteady Performance of Mixed-flow Turbines”, Proc. Instn. Mech. Engrs., Journal of Power and Energy, 221, (2007), 535-550. Rajoo, S. and Martinez-Botas, R.F., “Review of Mixed-Flow Turbines: a Review”, Transactions of ASME, Journal of Turbomachinery, 130, (2008), 044001-1-12. Rajoo, S. and Martinez-Botas. R.F., “Variable Geometry Mixed Flow Turbine for Turbochargers: An Experimental Study”, International Journal of Fluid Machinery and Systems, 1, (2008), 155-168. Rajoo, S and Martinez-Botas, R.F., "Unsteady Effects in a Nozzled Turbocharger Turbine", Transactions of ASME, Journal of Turbomachinery, 132, (2010), 031001-1-9. Copeland, C., Seiler, M., and Martinez-Botas, R.F., “Comparison between Steady and Unsteady Double-Entry Turbine Performance Using the Quasi-Steady Assumption”, ASME, J. Turbomachinery, 133, (2011), 031001-1-10. Costall, A.W., Martinez-Botas, R.F., Baines, N.C., and McDavid, R.M., “Pulse Performance Modeling of a Twin Entry Turbocharger Turbine Under Full and Unequal Admission”, Transactions of ASME, Journal of Turbomachinery, 133, (2011), 021005-1-9. Martinez-Botas, R.F., Pesiridis, A. & Yang, M.. “Overview of boosting options for future downsized engines”, Sci China Tech Sci, Series D, 54, (2011), 1-6. Romagnoli, A., Martinez-Botas, R.F. & Rajoo, S., “Steady state performance evaluation of variable geometry twin-entry turbine”, International Journal of Heat and Fluid Flow, 32, (2011), 477-489. Romagnoli, A. & Martinez-Botas, R.F., “Performance Prediction Of A Nozzled & Nozzleless Mixed-Flow Turbine in Steady Conditions”, Int. Journal of Mechanical Sciences, 53, (2011), 557-574. Romagnoli, A., Copeland, C., Martinez-Botas, R.F., Rajoo, S., Seiler, M. & Costall, A., “Comparison Between The Steady Performance Of Double-Entry And Twin-Entry Turbocharger Turbines”, Transactions of ASME, J. Turbomachinery, 133, (2011), 031001-10. Copeland, C., Newton, P., Martinez-Botas, R.F. and Seiler, M., “The Effect of Unequal Admission on the Performance and Loss Generation in a Double-Entry Tubocharger Turbine”, Transactions of ASME, Journal of Turbomachinery, 134(2), (2012), 021004-1-11. Copeland, C., Martinez-Botas, R.F. and Seiler, M., “Unsteady performance of a twin entry turbocharger turbine with a comparison to steady flow conditions”, Transactions of ASME, Journal of Turbomachinery, 134(2), (2012), 021022-1-11. Chiong, M.S., Rajoo, Martinez-Botas, R.F. and Costall, A.W., “Engine turbocharger performance prediction: one-dimensional modeling of a twin entry turbine geometry”, accepted in Journal of Energy Conversion and Management, 57, (2012), 68-78. Newton, P., Copeland, C., Martinez-Botas, R.F. and Seiler, M., “An Audit of Aerodynamic Loss in a Double Entry Turbine under Full and Partial Admission”, accepted for publication in the International Journal of Heat and Fluid flow, 33(1), (2012), 70-80. Romagnoli, A. and Martinez-Botas, R.F., “Heat transfer analysis in a turbocharger turbine: an experimental and computational evaluation”, Journal of Applied Thermal Energy, 38, (2012), 58-77. Mamat, A, Romagnoli, A. and Martinez-Botas, R.F., “Design and development of a low pressure turbine for turbo compounding applications”, Int. J. Gas Turbine, Prop. & Pow. Sys., 4, (2012), 1-8.

Publication Record • Prof Ricardo Martinez-Botas • Publications involving

turbochargers and turbocharging Chiong, M.S., Rajoo, S., Romagnoli, A. and Martinez-Botas, R.F., “Single Entry Mixed Flow Turbine Performance Prediction with 1-D Gas Dynamic Code Coupled with Mean Line Model”, Int. J. Gas Turbine, Propulsion and Power Systems, 4, (2012), 8-16. Rajoo, S., Pesiridis, A. and Martinez-Botas, R.F., “Novel Method to Improve Engine Exhaust Energy Extraction with Active Control Turbocharger (ACT)”, International Journal of Engine Research, 3, (2013), 127-138. Pesiridis, A. and Martinez-Botas, R.F., “Experimental Testing of an Active Control Turbocharger Turbine Inlet equipped with a Sliding Sleeve Nozzle”, Proc. Instn. Mech. Engrs., Journal of Automotive Engineering, 227, (2013), 800-811. Newton, P., Romagnoli, A., Martinez-Botas, R.F., Copeland, C. and Seiler, M., “A Method of Map Extrapolation for Unequal and Partial Admission in a Double Entry Turbine”, Journal of Turbomachinery, 136(7), (2013), 0 Teng, C., Xu, L., Yang, M. and Martinez-Botas, R.F., “Radial Turbine Rotor Response to Pulsating Inlet Flow”, Journal of Turbomachinery, 136(7), (2013), 071003. Pesiridis, A., Vassil, B., Padzillah, P. And Martinez-Botas, R.F., “A Comparison of flow control devices for variable geometry turbocharger application”, International Journal of Automotive Engineering and Technologies 3 (1), 1-21, (2014). Mamat, A., Romagnoli, A. and Martinez-Botas, R.F., “Characterization Of A Low Pressure Turbine For Turbocompounding Applications In A Heavily Downsized Mild-Hybrid Gasoline Engine”, Energy, 64(1), (2014), 3-16. Romagnoli, A, Martinez-Botas, R.F. and Rajoo, S., “Unsteady performance analysis of a twin-entry variable geometry turbocharger turbine”, Energy, 38(1), (2014), 176-189. Terdich, N., Martinez-Botas, R.F., Romagnoli, A. et al., “Mild Hybridisation via Electrification of the Air System: Electrically Assisted and Variable Geometry Turbocharging Impact on an Off-road Diesel Engine”, ASME J. Eng. Gas Turb. & Pow. 136 (2014). Padzillah, M.H., Rajoo, S. and Martinez-Botas, R.F., “Influence of Speed and Frequency Towards the Automotive Turbocharger Turbine Performance under Pulsating Flow Conditions”, Energy Conversion and Management, 80, (2014), 416-428. Chiong, M.S., Rajoo, S., Romagnoli, A., Costall, A.W. and Martinez-Botas, R.F., “Integration of Meanline and One-Dimensional Methods for Prediction of Pulsating Performance of a Turbocharger Turbine", Energy Conversion & Management, 81, (2014), 270-281. Chebli E., Casey M., Martinez-Botas R.F., et al. “The Variable Outlet Turbine Concept for Turbochargers”, Journal of Turbomachinery, 136, (2014), 121001-121014. Newton, P., Martinez-Botas, R.F. and Seiler, M., “A 3-Dimensional Computational Study Of Pulsating Flow Inside A Double Entry Turbine”, in-press, Journal of Turbomachinery, (2014), doi:10.1115/1.4028217. Turner J.W.G., Popplewell A., Patel R., Martinez-Botas, R.F. et al., 2014, Ultra Boost for Economy: Extending the Limits of Extreme Engine Downsizing, SAE International Journal of Engines, 7, (2014), 387-417. Kant, M., Romagnoli, A., Mamat, A.M. and Martinez-Botas, R.F., “Heavy-duty engine electric turbocompounding”, in-press, Proc IMechE Part D: J Automobile Engineering, (2014), doi: 10.1177/0954407014547237. Chiong, M.S., Rajoo, S., Romagnoli, A. and Martinez-Botas, R.F., “Non-adiabatic pressure loss boundary condition for modelling turbocharger turbine pulsating flow”, Energy Conversion and Management, (2015), DOI: 10.1016/j.enconman.2014.12.058 Padzillah, M.H., Rajoo, S., Yang, M. and Martinez-Botas, R.F. “Influence of pulsating flow frequencies towards the flow angle distributions of an automotive turbocharger mixed-flow turbine”’ Energy Conversion and Management, (2015), Paper No. ECM-D-14-03231R1. Hey, J., Malloy, A., Lamperth, M. and Martinez-Botas, R.F., “Conjugate heat transfer analysis of an energy conversion device with an updated numerical model obtained through inverse identification”, Energy Conversion and Management, 94:198-209. DOI:10.1016/j.enconman.2015.01.065 Mingyang, Y, Martinez-Botas, R.F., Zhang, Y. and Zheng, X., “Influence of Self- Recirculation-Casing-Treatment on High Pressure Ratio Centrifugal Compressor", Journal of Propulsion and Power, (2015), Ref. No.: 2014-05-B35438.R2. Costall, A., Gonzalez Hernandez, A., Newton, P. and Martinez-Botas, R,F, “Design methodology for radial turbo expanders in mobile organic Rankine cycle applications”, Applied Energy, (2015), http://dx.doi.org/10.1016/j.apenergy.2015.02.072.

Publication Record

Journal publications 2010–2015

BY TOPIC BY JOURNAL PUBLISHER Turbine 19 Journal of Turbomachinery ASME 10 Turbocompounding 5 Energy Conversion & Management Elsevier 7 1D modelling 4 Energy Elsevier 3 Compressor 2 Journal of Automobile Engineering IMechE 2 Supercharging 2 International Journal of Engines SAE 2 Electric systems 2 Journal of Engine Research IMechE 2 Organic Rankine cycle 1 International Journal of Heat and Fluid Flow Elsevier 2 Other 2 Applied Energy Elsevier 1

Journal of Engineering for Gas Turbines and Power ASME 1 Journal of Propulsion and Power AIAA 1 Other 6

TOTAL 37 TOTAL 37

Patents

Application Type Innovations Case Ref. Innovations Title Country Status Application Number Filing Date PRV - Provisional 2453 Improved Turbo Charger United Kingdom Abandoned 426733.20 06 December 2004 PCT - Patent Cooperation Treaty 2453 International Patent Application Published PCT/GB05/004663 06 December 2004 NTL - National 2453 United States of America Granted 11/720953 06 December 2004 NTL - National 2453 Japan Granted 2007-543928 06 December 2005 EPO - European Patent Office 2453 European Patent Application Pending 5814004.70 06 December 2005 DIV - Divisional 2453 Japan Abandoned 2011-258302 06 December 2005 PRV - Provisional (1st Priority) 4123 Passive Control Turbocharger United Kingdom Abandoned 707501.30 18 April 2007 PCT - Patent Cooperation Treaty 4123 International Patent Application Expired PCT/GB2008/001377 18 April 2008 NTL - National 4123 United States of America Pending 12/596233 16 October 2009 NTL - National 4123 Japan Granted 2010-503593 18 April 2008 EPO - Designated State 4123 United Kingdom Granted 8737036.70 18 April 2008 EPO - Designated State 4123 Switzerland Granted 8737036.70 18 April 2008 EPO - Designated State 4123 Spain Granted 8737036.70 18 April 2008 EPO - Designated State 4123 Netherlands Granted 8737036.70 18 April 2008 DIV - Divisional 4123 Japan Abandoned 2013-108358 22 May 2013 EPO - Designated State 4123 Italy Granted 8737036.70 18 April 2008 EPO - Designated State 4123 Germany Granted 8737036.70 18 April 2008 EPO - Designated State 4123 France Granted 8737036.70 18 April 2008 EPO - European Patent Office 4123 European Patent Application Granted 8737036.70 18 April 2008 PRV - Provisional (1st Priority) 5541 Low Pressure Turbine United Kingdom Abandoned 1103222.40 24 February 2011 PCT - Patent Cooperation Treaty 5541 International Patent Application Published PCT/GB2012/000110 02 February 2012 NTL - National 5541 United States of America Pending 14/001230 23 August 2013 NTL - National 5541 Russian Federation Abandoned 2013139996.00 29 August 2013 NTL - National 5541 Republic of Korea Pending 10-2013-7024809 17 September 2013 NTL - National 5541 Mexico Pending MX/a/2013/009701 22 August 2013 NTL - National 5541 Malaysia Pending PI 2013003099 21 August 2013 NTL - National 5541 Japan Published 554934.00 07 August 2013 NTL - National 5541 India Abandoned 7163/DELNP/2013 12 August 2013 EPO - European Patent Office 5541 European Patent Application Published 12705149.80 15 August 2013 NTL - National 5541 China Published 201280010380.60 07 August 2013 NTL - National 5541 Canada Pending 2827972.00 21 August 2013 NTL - National 5541 Brazil Abandoned BR 11 2013 021330 2 21 August 2013 PRV - Provisional (1st Priority) 6132 A Symmetric Turbine United States Pending 61/790,799 15 March 2013 PCT - Patent Cooperation Treaty 6132 International Patent Application Published PCT/GB2014/050771 14 March 2014 PRV - Provisional (1st Priority) 6381 Rotating Vane Turbocharger United Kingdom Abandoned 1308680.60 14 May 2013 PCT - Patent Cooperation Treaty 6381 International Patent Application Published PCT/GB2014/051466 13 May 2014 PRV - Provisional (1st Priority) 6467 Inlet Duct Treatment United Kingdom Abandoned 1308381.10 09 May 2013 PCT - Patent Cooperation Treaty 6467 International Patent Application Published PCT/GB2014/051416 09 May 2014 PRV - Provisional (1st Priority) 6833 New Concept of Turbocharge

Volute Japan Pending JP2013-271673 27 December 2013

PCT - Patent Cooperation Treaty 6833 International Patent Application Pending PCT/JP2015/50050 05 January 2015

Publication Record and Patents – Summary Publications and Patents on Turbocharging, 2010–2015 • 37 journal papers • 40+ conference papers • 3 “Best Paper” awards (2 ASME, 1 IMechE) • 8 PhD theses • 7 patents • 1133 citations

126 132

253 222

318

82

Citations 2010-2015

2010 2011 2012 2013 2014 2015 (so far)

Clients & Research Partners

Turbocharger suppliers • MHI, Ltd. • ABB • BorgWarner • Honeywell/Garrett • IHI • Cummins Turbo (Holset)

OEMs & others • Ford • Caterpillar Inc. • JLR • Lotus • Honda R&D • Daimler AG • Ricardo

Sources of Funding

Diversity of funding (since 2009):

SOURCE £ k INDUSTRIAL 2,605 TSB 1,082 EPSRC 1,534 APC 800 EU 500 ETI 480 Other 600 TOTAL 7,601

SOURCE £ k SPLIT INDUSTRIAL 3,685 48% PUBLIC 3,916 52% TOTAL 7,601

Ability to attract co-funding from both public and industrial sources (near equal split):

FUNDING SOURCE

INDUSTRIALTSBEPSRCAPCEUETIOther

FUNDING SPLIT

INDUSTRIAL

PUBLIC

Latest News APC (competition 3) award! • Winners announced 27 March 2015 • Perkins, Denso, CMCL, Loughborough, Imperial • £25.1M total project costs • Imperial: optimize air system to obtain 2% CO2 benefit

People A growing and diverse team… • 5 staff, 9 PhD students o 26 PhDs graduated (as of July 2015)

• Multiple nationalities represented o British, Chinese, German, Italian, Malaysian, Singaporean, Spanish + Algerian, Canadian, Greek, Korean, Pakistani, Taiwanese, Thai (past students)

Staff • Prof. Ricardo Martinez-Botas (Head of Thermofluids Division) • Dr Aaron Costall (Research Fellow) • Dr Peter Newton (Postdoc) • Mr Harminder Flora (Research Officer) • Mr Radoslav Ivanov (Research Associate)

Academic Visitors • Dr Srithar Rajoo (UTM Centre for Low Carbon Transport) • Dr Apostolos Pesiridis (Brunel University)

Test Facilities – Overview

Turbo Lab (Room 123H) 1. Pulse flow turbine test rig 2. Compressor test rig 3. Electric Turbo Assist (ETA) test rig 4. Oil conditioning 5. Turbocharger balancing

PULSE FLOW

ETA COMPRESSOR

BALANCING

CONTROL DESK

APPROXIMATE LAYOUT

Other facilities (not shown) • Supercharger • Battery testing cell • ORC expander (in preparation)

1

3 2

OIL

4

5

Test Facilities – Turbo Lab (Room 123H)

1. Pulse Flow Turbine Test Rig • Turbo lab (“180”) established by the late Prof. Neil Watson • Turbocharging courses held since 1973 (jointly with M. S. Janota) • Turbocharger research led by Ricardo Martinez-Botas since 1994

Key features and capabilities: • Cold flow • Single or two entries (twin/double) • Steady or pulsating flow • Instantaneous pressure and mass

flow measurements • Dynamometer direct torque

measurement • Turbine exit flow field

measurement (5 hole probe)

Test Facilities – Turbo Lab (Room 123)

1. Pulse Flow Turbine Test Rig • Departmental compressors can supply

compressed air up to ~1.2kg/s • Incoming air heated to avoid

condensation following expansion • Heater capability ~72kW • Typical temperatures up to 70C

(~100C max.) • Flow splits into two

after heater

FILTERED COMPRESSED AIR FROM CENTRALIZED COMPRESSORS

72kW HEATER

2 SUPPLY LIMBS


1. Pulse Flow Turbine Test Rig • V-Cone steady mass flow

measurement • Pulse generator (rotating

discs with cut-outs)

V-CONES x 2 (1 PER LIMB) – STEADY MASS FLOW RATE

PULSE GENERATOR


1. Pulse Flow Turbine Test Rig • Inlet measuring plane o Hot-wire traverse (36-point array) o Instantaneous pressure (both limbs) o Pulse-average temperature (both limbs)

• Exit measuring plane o 5-hole probe traverse, fully articulated (r, q)


1. Pulse Flow Turbine Test Rig • Eddy current dynamometer o Optical speed sensor o Load cell direct torque measurement o ~60k rpm max speed (equiv. ~100k rpm “hot”) o ~60 kW max power absorption

EDDY CURRENT DYNO TURBINE

ROTOR

STATOR PLATE 2

STATOR PLATE 1

MAGNETIC ROTOR

Test Facilities – Turbo Lab (Room 123) 1. Pulse Flow Turbine Test Rig – Summary

Benefits • Wide steady flow capacity and efficiency measurements o 3–4x wider than typical gas stand map o Dyno loading map width not limited by compressor

• Pure aerodynamic efficiency o Measure turbine housing reaction torque no bearing losses in

efficiency measurement o Cold flow negligible heat transfer effects

• Pulse flow turbine performance characterization

Limitations • Max power absorption and max speed o Best suited to “truck” engine sized turbochargers (rather than pass

car) – but accommodations can be made… o Larger – can scale down (e.g., ABB 60% scale version) o Smaller – region of interest is low power, low speed (high U/Cis) in

any case


2. Compressor Test Rig

Key features and capabilities: • 100 kW • ~20:1 reduction drive • ~80k rpm max compressor speed

Current research project: • “Aerodynamic impact of fouling in

centrifugal compressors” o PhD research of Miss Maria

Esperanza Barrera-Medrano o Sponsor: Energy SmartOps FP7

European Community program (Marie Curie Actions)


3. Electric Turbo Assist (ETA) Test Rig

OIL OUTLET

SPEED SENSOR

THERMOCOUPLES

COOLING OIL INLET

LUBRICATING OIL INLET

E-M CONNECTOR

LOAD CELL

COMPRESSED AIR INLET

GIMBAL BEARINGS

• Developed for the TSB VERITAS project (Cat were lead partner)

Key features and capabilities: • Cold, steady flow • Electrical machine motoring

or regeneration (rectifier connected to UK grid)

• Direct e-m torque measurement (blank compressor)

• Bearing and cooling oil conditioning (flow rate and temperature)

BLANK COMPRESSOR FOR E-M CHARACTERIZATION


4. Oil conditioning (“Oil Cart”)

Key features and capabilities: • Originally specified for the

TSB VERITAS project on Electric Turbo Assist

• Provides bearing and cooling oil conditioning (flow rate and temperature) to the ETA machine

Competence Summary

Areas of research • Turbochargers and turbocharging o Turbine performance measurement under steady and pulsating flow Steady flow map measurement (aerodynamic map + enhanced width) Pulsating flow experiments

o Turbine modelling Turbine map extrapolation and meanline methods (0D) Pulse flow and twin-entry characterization (1D) Characterization of performance in pulsating flow (3D)

o Design for unsteady flow Turbine and volute design and optimization (mixed flow, variable geometry, active control)

o Compressor testing Compressor fouling (energy smartOps – FP7 Marie Curie)

• Supercharging o Eaton supercharger map measurement (TSB Ultraboost)

• Downsizing – TSB HyBoost and Ultraboost projects

Competence Summary

Areas of research (cont’d) • Energy recovery & storage o Electrical machines Electric turbocharging – Electric Turbo Assist (TSB VERITAS) Exhaust turbogenerators – Low Pressure Turbine (TSB HyBoost) Thermal modelling & temperature control of e-m’s

o Battery research Optimum battery capacity for electric vehicles Battery modelling for degradation prediction Vehicle-level battery thermal management

o Bottoming cycles Organic Rankine cycle; thermo-chemical recuperation

• (IC engine) system level modelling o ONDAS (ONe Dimensional wave Action Simulation) o GT-SUITE licenses available o Experience with Caterpillar Dynasty (development and apps)

Competence Summary

Other departmental areas of expertise

Thermofluids • DNS (laminar-turbulent transition, heat transfer in two-phase flows); LES of

combusting and multi-phase flows; optical instrumentation for combustion and two-phase flows; unsteady fluid mechanics

Mechanics of Materials • Adhesion and adhesives; deformation and fracture; metal forming and materials

modelling; nanomaterials; soft solids; structural integrity

Applied Mechanics • Design engineering; dynamics; mechatronic systems; medical engineering; non-

destructive evaluation; nuclear engineering; railways; tribology • Rolls-Royce Vibration UTC (since 1990); Rolls-Royce Nuclear UTC (since 2010); SKF

UTC in Advanced Modelling and Measurements in Tribology (since 2010); Headquarters of the UK Research Centre in Non Destructive Evaluation

Imperial–UTM connection

Imperial–UTM – background • Dr Srithar Rajoo carried out PhD research at Imperial College (2003–07)

under Prof Ricardo Martinez-Botas (first Malaysian student)

• Sri’s PhD was funded by the Malaysian government – attached to the Universiti Teknologi Malaysia (UTM)

• Since returning to UTM in 2007, Sri has been Senior Lecturer, Head of Automotive Laboratory and has been a visiting academic at Imperial College throughout that time

• This long standing collaboration culminated in creation of the UTM Centre for Low Carbon Transport, launched by the Malaysian Deputy Prime Minister at Imperial in January 2014

Imperial–UTM connection

UTM Centre for Low Carbon Transport • Prof Ricardo Martinez-Botas and Dr Srithar Rajoo are directors of the center, on

behalf of Imperial and UTM respectively

• The centre enables o UTM PhD students and Postdocs to carry out research at Imperial College (not just in the

Turbocharger Group) o Directly UTM-funded research at Imperial o UTM-funded Research Fellow at Imperial (Dr Peter Newton) o Set-up of a transient engine test facility at UTM

• Targets for first five-year contract period: o 10 PhDs enrolled (college-wide) o 10 Postdocs engaged (college-wide)

• First PhD students to begin Autumn 2014

Past work

Technology Strategy Board (TSB) projects HyBoost (Imperial, Ford, Ricardo, CPT/Valeo) • Downsized gasoline engine development (2.0L – 1.0L) EcoBoost (Focus/Fiesta) • Imperial College developed a high performance Low Pressure Turbine (LPT) for (electric)

turbocompounding/EWHR (downstream of turbocharger turbine) • LPT wheel design provides >70% efficiency for very low expansion ratios (1.02–1.2)

Ultraboost (Imperial, Bath, Leeds, JLR, Lotus, Shell, GE, CD-adapco) • Extreme downsized gasoline engine development (5.0L 2.0L, 60%) • Ultraboost seeks to develop a highly pressure-charged, downsized, spark ignition engine that is

capable of a 35% reduction in CO2 emissions over a naturally aspirated 5.0L V8 while maintaining performance, emissions and transient response.

VERITAS (Imperial, Caterpillar, BorgWarner, Loughborough University) • Vehicle Energy Recovery through Intelligent Turbo Assist System • Imperial characterized VTG turbine and electrical machine • Iteration 2 ETA currently installed on test rig

Selected technologies

Low Pressure Turbine

• Low Pressure Turbine as installed in the Imperial College test facility

• Rapid prototyping technique for volute and duct manufacturing

• Peak efficiency occurs in a region of very low expansion ratio (main design objective)

• Total-to-static efficiency at design point >70%

0.60

0.70

0.80

0.90

1.00

1.10

1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35N

orm

aliz

ed to

tal-t

o-st

atic

effi

cien

cy, η

t-s

Expansion ratio

80% 90% 100% 110% 120%

Experimental results

50000 60000 70000 40000 30000

>70% peak efficiency

Speed (RPM):

Very low pressure ratio

Selected technologies

Electric Turbo Assist (ETA) Test Rig (TSB VERITAS project)

OIL OUTLET

SPEED SENSOR

THERMOCOUPLES

COOLING OIL INLET

LUBRICATING OIL INLET

E-M CONNECTOR

LOAD CELL

COMPRESSED AIR INLET

GIMBAL BEARINGS

Key features and capabilities: • Cold flow • Steady flow • Electrical machine motoring

or regeneration (connected to UK grid)

• Direct torque measurement • Bearing and cooling oil

conditioning (flow rate and temperature)

Harminder Flora Research Officer / Design Tutor

• Joined Turbocharger research group 1986

• Key responsibilities include: • Provide technical support to PhD students

and staff • Design of experimental test procedures and

apparatus • Sourcing and specifying instrumentation,

equipment and materials. • Developing 3D CAD models and

manufacturing specifications and plans. • Providing input to research proposals, and

publications • Co Author on several research

publications • Co Inventor on several patents

Turbocharger Group

Current PhD Projects

Balamurugan A. Gurunathan, “Bala” Variable Geometry Nozzle to Optimise Pulsating Exhaust Energy Recovery in an Internal Combustion Engine • Started/expected finish:

• 10/2012–03/2016 • Sponsor:

• Malaysian Ministry of Education, and National Defence University of Malaysia

• Research field: • 1D/3D CFD analysis and experiments

• Objectives: • Investigate experimentally the steady and

unsteady performance improvement of variable geometry mixed flow turbine with a new optimized nozzle vane geometry

• Results so far: • Preliminary CFD calculations of a mixed flow

turbine with lean nozzle vanes shows good agreement with experimental measurements for both efficiency and mass flow parameter

• Started/expected finish: • 02/2013–10/2016

• Research field: • Dynamics; Control; Unsteady fluid mechanics

• Sponsor: • China Scholarship Council

• Objectives: • Improve turbochargers’ performance under

unsteady exhaust flow • Results so far:

• Designed a pulse-optimized flow control mechanism, which is proven by CFD tools to be able to increase the turbine efficiency by more than 10% at bottom mass flow point in an exhaust pulse

• Patent applied in mid-2014

Kun Cao, “Allen”

Active Flow Control Turbocharger

All operating points pushed back to optimal design point

Design point

Maria Esperanza Barrera-Medrano Aerodynamic impact of fouling in centrifugal compressors • Started/expected finish:

• 04/2013–06/2016 • Sponsor:

• Energy SmartOps FP7 European Community program (Marie Curie Actions)

• Research field: • Compressor fouling – modelling and

experiments • Objectives:

• Analysis and assessment of compressor status, through evaluation of performance parameters, for overall energy reduction

• Detection and evaluation of fouling and its effects on compressor performance, defining when the compressor should be cleaned

Performance Parameters

Fouling Degree

“MAXIMUM PERMISSIBLE DETERIORATION”

Mohd Ibthisham Ardani, “Sham” Thermal characteristics of lithium-ion battery pack: Numerical and experimental investigation

Model domain Lumped thermal model vs unsteady heat conduction model


• Sponsor: • Universiti Teknologi Malayasia

• Research field: • Electrochemistry, heat transfer

• Objectives: • Explore capacity fade at different electrical loadings

and thermal conditions; cooling of HEV battery packs to identify possibilities for enhancement

• Develop experiments both at cell and battery pack level in order to validate numerical models

• Explore novel reduced order modelling methods to simulate battery pack behaviour

• Results so far: • Latest electrochemistry-thermal model matches well

with published data

Uswah Khairuddin Aerodynamic Optimisation of Turbocharger Turbine Geometry under Steady and Unsteady Conditions


• Sponsor: • Ministry of Education Malaysia &

Universiti Teknologi Malaysia • Research field:

• Turbocharger optimization • Objectives:

• To develop a novel methodology that integrates evolutionary algorithms with CFD simulation to execute aerodynamic optimisation of turbocharger turbine geometry

• Results so far: • Up to 2.3 percentage points efficiency

increase after optimisation

Muhammad Bin Ismail, “Izzal” Preserving Exhaust Pulse Energy and Reducing Residual Concentration by Pulse Separation for a Downsized Turbocharged Gasoline Engine


• Sponsor: • Majlis Amanah Rakyat (MARA)

• Research field: • Turbocharging

• Objectives: • To develop a turbocharger matching method that

includes more predictive, physics-based twin scroll turbine modelling, and which takes into account pulse separation for turbocharged engines.

• Results so far: • A combination of appropriate turbine sizing and

pulse divided exhaust manifold design highlights the potential for improved engine scavenging, the reduction of trapped residual gas and improved specific fuel consumption.

GT-POWER engine modelling

Exhaust manifold design

Turbine re-sizing

Jose Francisco Cortell Impact on turbine efficiency due to the inlet flow area and inlet conditions for enhanced exhaust energy extraction


• Sponsor: • UTM Centre for Low Carbon Transport

• Research field: • Variable geometry turbocharging

• Objectives: • Improving the inlet and outlet conditions for

enhanced energy extraction in turbocharger turbines

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VANE ANGLE

Miles Robertson Aerodynamic design of turboexpanders for Organic Rankine Cycle (ORC) systems


• Sponsor: • Imperial College PhD Scholarship

• Research field: • Organic Rankine Cycle

• Objectives: • Collaborate with TSB (Innovate UK) consortium to

specify and deliver a working ORC test rig. • Optimise ORC turboexpander design using a

combination of simulation and experimental methods • Results so far:

• A high-level cycle simulation has been constructed to predict performance and required component sizing, across a range of organic working fluids

Torsten Palenschat Optimisation of the efficiency of an asymmetric volute turbine while maintaining the mass flow constant

Small Scroll Large Scroll

• Started/expected finish: 03/2015–09/2018 • Sponsor: Daimler AG • Research field: Turbocharger optimisation • Contact: [email protected] • Objectives:

• Understanding the characteristic of an asymmetric twin scroll turbine using a thorough numerical loss analysis and steady as well as unsteady experiments

• Optimising the efficiency of the asymmetric turbine under pulsating conditions using mean-line and 3D CFD simulations

• Validation of numerical results as well as evaluation of optimised designs through Imperial College’s own testing facility

Turbocharger Group

Completed PhD Projects

Wan S-I Wan Salim, “Owan” Study of Steady and Unsteady Turbine Performance for Turbocharger Matching and Engine Performance Simulations


• Sponsor: • Universiti Tun Hussein Onn Malaysia (UTHM,

Johor) • Research field:

• Turbochargers • Objectives:

• Study effects of experimental turbine map width on current map extrapolation methods and engine performance prediction used by 1D gas dynamics engine simulation codes

• Study turbine performance under unsteady inlet conditions at various turbine loads and wastegate openings

• Effects of map width in extrapolation methods, unsteady turbine performance at different loads and pulse frequencies

Experimental test results showing unsteady mass flow at different pressure ratios and pulse frequencies

Rongchao Zhao Study of a two-stage turbine characteristic under pulsating conditions


• Sponsor: • Joint research with Tsinghua University

• Research field: • Turbocompounding

• Objectives: • Understand the characteristic of a two-stage

turbines under pulsating conditions • Explore methods to improve two-stage turbine

efficiency under pulsating conditions • Results so far:

• Pulsating flows lead to lower averaged expansion ratio in HPT

• The efficiency of LPT rotor is more sensitive to inlet pulsating flow, compared with HPT rotor

Contact Details

Prof Ricardo F Martinez-Botas Dr Aaron Costall

Professor in Turbomachinery Research Fellow

611 City & Guilds Building 610A City & Guilds Building

Turbocharger Group

Imperial College London Department of Mechanical Engineering South Kensington Campus London SW7 2AZ

Tel.: +44 207 594 7241 Tel.: +44 207 594 7186 Mob.: +44 7812 152 563 Mob.: +44 7869 108 460

Email: [email protected] [email protected]

Web: www.imperial.ac.uk/turbochargers

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mailto:[email protected]

mailto:[email protected]

http://www.imperial.ac.uk/turbochargers

imperial turbocharger group introduction (sept 2015)

Documents