Giulio Contaldi

Energy recovery using sliding vane rotary expanders

Energy recovery from low grade energy sources represents a technological challenge which can significantly contribute to the energy balance between production and consumption. Mechanical and electrical production can be done both from thermal energy usually wasted and low temperature renewable sources. In this sense, the interest is twofold. Many efforts have been made and studies produced, mainly making reference to a well known organic Rankine cycle (ORC) of transformations: in spite of this, the expander technology still represents an open aspect and call for a reliable and low cost development.

Sliding Vane Rotary Compressor Energy Optimization

The reduction of the electrical energy for producing compressed air gives an important contribution to the overall energy saving in the industrial context. Among the different technologies, Sliding Vane Rotary Compressors (SVRC) demonstrate unforeseen potential in terms of energy saving due to some intrinsic features specifically related to this machine.One of the most important contribution is given by cooling the air during compression; this could be achieved by a proper oil injection conceived for this purpose. A mathematical model describing the oil injection process is presented in this paper. It considers the main parameters which describe the spray formation, its penetration inside the cell till to the intersection with metallic surfaces and the resulting air cooling.The influence of the most important design and operating injection parameters have been checked on the model and design rules are outlined in order to produce an oil injection potentially able to reduce mechanical work.© 2012 ASME

Energy saving in sliding vane rotary compressors using pressure swirl oil atomizers

In industrial contexts, electrical energy for compressed air represents an important share of the global electricity consumption: this figure accounts for 4–5% of the total. Among the existing compressor technologies, rotary volumetric machines proved to be more suitable than other types (dynamic, reciprocating, etc.) in terms of pressure and flow rate delivered. Even though not as widespread as screw machines, but thanks to the technological improvements made in the last two decades, sliding vane rotary compressors are characterized by premium specific energy consumptions and demonstrate an unforeseen potential in terms of energy saving due to some intrinsic features specifically related to these machines. The current research focuses on an innovative oil injection technology that is not only able to fulfill the sealing and lubrication requirements but also to cool the air during the compression phase. A comparison between the mathematical model of the new oil injection technology and the experimental p-V diagrams measured through a set of piezoelectric transducers is shown. The compression work reduction, predicted in the model and further measured at the shaft and observed in the indicator diagrams, gives a strong consistency to the injection technology.

Energy Saving in Sliding Vane Rotary Compressors

Electrical energy for producing compressed air in industrial contexts represents an important share of the overall electricity consumption: this figure accounts for 4-5 %.

Grid generation methodology and CFD simulations in sliding vane compressors and expanders

The limiting factor for the employment of advanced 3D CFD tools in the analysis and design of rotary vane machines is the unavailability of methods for generation of computational grids suitable for fast and reliable numerical analysis. The paper addresses this challenge presenting the development of an analytical grid generation for vane machines that is based on the user defined nodal displacement. In particular, mesh boundaries are defined as parametric curves generated using trigonometrical modelling of the axial cross section of the machine while the distribution of computational nodes is performed using algebraic algorithms with transfinite interpolation, post orthogonalisation and smoothing. Algebraic control functions are introduced for distribution of nodes on the rotor and casing boundaries in order to achieve good grid quality in terms of cell size and expansion. In this way, the moving and deforming fluid domain of the sliding vane machine is discretized and the conservation of intrinsic quantities in ensured by maintaining the cell connectivity and structure. For validation of generated grids, a mid-size air compressor and a small-scale expander for Organic Rankine Cycle applications have been investigated in this paper. Remarks on implementation of the mesh motion algorithm, stability and robustness experienced with the ANSYS CFX solver as well as the obtained flow results are presented

An intracooling system for a novel two-stage sliding-vane air compressor

Lube-oil injection is used in positive-displacement compressors and, among them, in sliding-vane machines to guarantee the correct lubrication of the moving parts and as sealing to prevent air leakage. Furthermore, lube-oil injection allows to exploit lubricant also as thermal ballast with a great thermal capacity to minimize the temperature increase during the compression. This study presents the design of a two-stage sliding-vane rotary compressor in which the air cooling is operated by high-pressure cold oil injection into a connection duct between the two stages. The heat exchange between the atomized oil jet and the air results in a decrease of the air temperature before the second stage, improving the overall system efficiency. This cooling system is named here intracooling, as opposed to intercooling. The oil injection is realized via pressure-swirl nozzles, both within the compressors and inside the intracooling duct. The design of the two-stage sliding-vane compressor is accomplished by way of a lumped parameter model. The model predicts an input power reduction as large as 10% for intercooled and intracooled two-stage compressors, the latter being slightly better, with respect to a conventional single-stage compressor for compressed air applications. An experimental campaign is conducted on a first prototype that comprises the low-pressure compressor and the intracooling duct, indicating that a significant temperature reduction is achieved in the duct.

Experimental investigation on materials and lubricants for sliding-vane air compressors

Positive-displacement compressors and, among them, sliding-vane rotary machines are widely used in the compressed air sector. As in many other industrial fields, the efficient utilization of energy has become a major goal also in this sector. The aim of the present activity is the experimental investigation on the influence of two vanes materials (cast iron and aluminium with anodized surface) and of four commercial lubricants (characterized by different formulations and additives concentrations) on the performance of a mid-capacity sliding-vane rotary compressor in a number of operating pressures. The performance is identified by both the volume flow rate and the absorbed mechanical power, evaluated according to the international standard ISO 5167 and ISO 1217. The campaign indicates that the considered lubricants do not affect appreciably the volumetric flow rate. On the other hand, the specific lubricants determine a variation of about 1% of the mechanical power for both materials, while the specific material a variation between 0.9% and 2.6%. The best performance is achieved by aluminium vanes and a synthetic poly-α-olefin lubricant.