Numerical Investigation of Multi-Stage Radial Turbine Performance Under Variable Waste Heat Conditions for ORC Systems

This study investigates the performance of a centrifugal radial turbine within an Organic Rankine Cycle (ORC) system, focusing on operation beyond the design point due to variable waste heat sources. With the goal of integrating the turbine into optimal ORC operating conditions, its performance was analyzed using R245fa as the working fluid over three stages with varying numbers of blades. A detailed computational analysis was performed using Ansys CFX software (Version 2020 R2) with the k-ω SST turbulence model using thermodynamic data from the NIST Refprop database. The results showed significant discrepancies when operating beyond the design point. At an inlet pressure of 780 kPa, the turbine internal power was calculated to be 120 kW—double the manufacturer’s maximum of 60 kW—and the mass flow rate exceeded 6 kg/s compared to the design value of 2.72 kg/s. These results highlight the challenges of adapting the turbine to fluctuating waste heat conditions, as factors such as tip clearance, blade geometry, and high outlet pressure have a significant impact on efficiency and system performance.