DEVELOPMENT OF TURBOEXPANDER BASED

NITROGEN LIQUEFIER
By

P f Ranjit
Prof.
R jit Kumar
K
S h
Sahoo
Prof. Sunil Kumar Sarangi
DIRECTOR, NIT ROURKELA

Department of Mechanical Engineering

NIT Rourkela
R
k l

CONTENTS
11. Liquefaction
Liq efaction S
Systems
stems
2. Process Design
3. Major Components of Liquefier
3
4. Design of Heat Exchanger
5. Design of Turboexpander
5
6. Design of JT Valve
7. Design of Phase Separator
8. Assembly of the Liquefier
9. References
9

1. Liquefaction
i
f
i
Systems
S

Linde Cycle
In 1895, Carl Von Linde made this air liquefaction system

Compressor

Heat Exchanger

3
Joule
Thomson
Valve

1
g

Tempera
ature, T

3
Phase
separator

Liquid

f
f

Entropy,s

Fig. 1

Fig. 2

T=const
1

Claude System
In 1902, Georges Claude made an air liquefaction system with an
expansion engine.
engine
2

Temperatture, T

H
Heat
E
Exchangers
h

Compressor

T=const

JT
Valve
g

5
8

Expander
e

Phase
separator

q
Liquid

Entropy,s

Fig. 3

Fig. 4

Kapitza System

In 1939,
1939 Claude cycle is modified by eliminating the third or low
temperature heat exchanger.

Compressor
1

Heat Exchangers
3

7
JT
Valve

3
6

Expander
e

Fig. 5

Phase
Ph
separator

Liquid

Heylandt
y
System
y
In 1949, Davies modified the Claude cycle by eliminating the first heat
exchanger
exchanger.

Heat Exchangers

Compressor
1

3
9

8 7

JT
Valve
6

Expander
e

Fig. 6

Phase
separator

Liquid

2. Process
P
D
Design
i

CASE -1 (Claude Cycle)

CASE -2 (Modified Claude Cycle Eliminating

Last Heat Exchanger)

CASE -3 (Modified Claude Cycle Eliminating

First Heat Exchanger)

CASE -1
Pressure
10
20
30
0 93
0.93
0 89
0.89
0 86
0.86

Pinch1
3
3
3
Pinch2
2
2
2
Pinch3
1
1
1
50%
50%
50%
t

m
1
1
1
mf
0.05534 0.07933 0.09567

50
0 83
0.83
3
2
1
50%
1
0.1155

80
0 73
0.73
3
2
1
50%
1
0.142

100
07
0.7
3
2
1
50%
1
0.1521

130
0 67
0.67
3
2
1
50%
1
0.1644

150
0 66
0.66
3
2
1
50%
1
0.171

CASE -2
Pressure
10
20
30
50
80
100
130
0.93 0.89
0.85
0.82
0.71
0.68
0.65

Pinch1
3
3
3
3
3
3
3
Pinch2
1
1
1
1
1
1
1
50% 50%
50%
50%
50%
50%
50%
t
m
1
1
1
1
1
1
1
mf
0.05581 0.0797 0.09579 0.1161 0.1412 0.1517 0.1636
CASE -3
Pressure
10
20
0.14
0.14

Pinch1
3
3
Pinch2
1
1
50%
50%
t
m
1
1
mf
0.003936 0.01319

30
50
80
100
0.15
0.2
0.3
0.35
3
3
3
3
1
1
1
1
50%
50%
50%
50%
1
1
1
1
0.0237 0.04673 0.07726 0.09425

130
0.38
3
1
50%
1
0.1147

150
0.4
3
1
50%
1
0.126

150
0.62
3
1
50%
1
0.17

Fig. 7 Variation of Yield with compression pressure

Claude cycle (Case-1)

(At 10 bar)
103.93 K
x=0.3230

127.12 K

300 K

297 K

186 kW
Kapitza cycle (Case-2)

105.34 K

90.45 K

14 kW

103.93 K
x=0.2372

102.93 K

1.4kW

(At 10 bar)
127.09 K

103.93 K
x=0.2355
0 355

300 K

297 K

78.44 K

105.35 K

88 97
88.97

Animated Process Flow Diagram

HX-2b

HX-1

HX-2a

Compressor

JT
Valve

Turboexpander

Phase separator

Fig. 8

7 95 bar
7.95

C
1
Make
Up
Fluid

9
Mixer-1

1.1 bar

3
HX-1

7.9 bar
100 2 K
100.2

8
1.15 bar

7.9 bar
100 2 K
100.2

4g
HX-2b

8 bar
310 K

HX-2a

1.1 bar
300 K

4
7

JT
Valve

Mixer-2

1.2 bar
1.2 bar 5g
78.8 K
1.3 bar
1.2 bar
78.8 K

1.15 bar

6
Turboexpander

1.2 bar
78.8 K
Liquid
5f
Phase separator

Fig. 9 Process Diagram of Nitrogen Liquefier

Fig. 10 T-S Diagram of Nitrogen Liquefier

Parameters and Variables

Parameters

Effectiveness
Eff ti
off heat
h t exchanger
h
1,1
1 1
Pinch point for heat exchanger 2, p
Efficiency of turbo expander,
Mass flow ratio diverted through Turbo expander,
Initial Values

Yield, y
Enthalpy of cold fluid at outlet of HX1,h9
Unknown Variables:

hp,h3, h4, h5, h6, h6s, h7, h8, h9, x5, y

i. Pinch point specification of Heat exchanger-2

Splitting the HX2 into two parts, First heat exchanger being the one where the hot
nitrogen gas is cooled up to the saturation temperature of 100.13 K & the second part
being the condensing part. The minimum temperature difference occurs at the point
where the condensation begins and is called as pinch point.
For the specified pinch value p, for HX2, we
have

We can get enthalpy hp, at that pinch

temperature and pressure

4g
g
Pinch, p

8
Temperature

Tp = T4 g p

4g

Distance

Fig. 11

ii. HX1 and HX2a

Assume

Q h 9 = 1h 2 '+ h 8 (1 1 )

h9 = 1h2 '

From HX1 and HX2a Energy balance

1
1.

h8 =

[h 9 (1 y)(1 ) h 2 (1 ) + h 4g (1 ) h p (1 y)]
[( )(1 y)]
[h 4g (1 ) + (1 y)(h 8 h p )]

2.

h3 =

3.

h 9 = 1h 2 '+ (1 1 )h 8

(1 )

Fig. 12

iii. Turbo-expander
From the figure,
From Allprops, find s3, at h3 and p3.
3 6s is the isentropic expansion
3-6s
3-6 is the actual expansion

The enthalpy at the end of expansion is found out

as

s 6s = s 3

h6 can b
h6s
be gett ffrom p6s
6 and
d s6s.
6

(h 3 h 6 )

( h 3 h 6s )

Temperatture, T

s6 > s6sg, the hot gas is not wet at the end of

expansion

h 6 = h 3 ( h 3 h 6s )
Entropy,s

Fig. 13

iv. Mixer-2
Applying energy balance equation for the mixer, enthalpy at outlet of mixer is

h7 =

[h 6 + (1 y)h 5g ]
(1 y)

1.3 bar

1.2 bar

1.2 bar
78.8 K

v .Heat Exchanger 2

Fig. 14

Enthalpy at outlet of hot fluid is found out by energy balance between

hot and cold fluids as

h4 =

[h 3 (1 ) (1 y)(h 8 h 7 )]
(1 )

Fig. 15

5g

vi. JT valve
Throttling is an isenthalpic expansion process. Equating the enthalpies
before and after throttling
4

7.9 bar
100.13 K

1.2 bar
78.8 K

h5 = h 4
x5 =

( h 5 h 5f )
( h 5g h 5f )

Fig. 16

vii. Yield

The liliquid
Th
id yield
i ld obtained
bt i d per kkg off gas passing
i th
through
h th
the th
throttling
ttli valve
l
Is (1-x5),
Here (1-) kg of gas passing through the throttling valve is

y = (1 )(1 x 5 )

Fig. 17 Snapshot of the process design Program

3:Inlet to turboexpander and HX-2

3-6: Expansion in turbine
3-4: High pr. Stream in HX-2
2

4-5: Expansion in JT valve

7(5g+6) -8: Low pr. Stream in HX-2

P: Pinch point temp. (100.13-99.13)

3
4

4g

6
7

T-S
T
S Diagram

5g

Fig. 18

Parametric Study

Yield increases with increase in

mass fraction through the
turboexpander.

After a maximum mass fraction

through the turboexpander, yield
starts decreasing.
g

The maximum mass fraction

decreases with increase in the
pressure of compression.
compression
Fig. 19 Effect of Variation of
mass fraction through
Turboexpander

Parametric Study

Yield increases with increase in

the effectiveness of the HX-1.

A minimum
i i
effectiveness
ff ti
i
is
present after which the yield
becomes zero.

Requirement
of
high
effectiveness increases with
increase
in
compression
pressure
Fig. 20 Effect of Variation of
effectiveness 1 of HX-1

Parametric Study

Yield decreases with increase

in the pinch point of the HX-2.

The rate of decrease in yield is

less with p
pinch p
point of HX-2

yield increases with increase in

compression pressure

Fig. 21 Effect of Variation of pinch

point of second heat exchanger

Parametric Study

Yield increases with increase in

the
efficiency
of
the
turboexpander.

y
yield
increases with increase in
compression pressure.

Fig. 22 Effect of Variation of

turbo expander efficiency

3. M
Major
j C
Components
t off Li
Liquefier
fi

Major Components Of The Liquefier

i.

Compressor

ii. Cold Box

iii. Heat Exchangers
iv. Turboexpander
v. JT Valve
vi Liquid nitrogen Separator along with
vi.
transfer line

i. Compressor

Screw oil flooded,

compressor : 340
nm3/hr,
/h
11
b
bar
(Kaeser make)

This
compressor
is
available
in
our
laboratory with oil filter,
pressure controller and
p
pipe layout.

ii Cold Box
ii.

It is a double walled 750

mm dia
di
x 1800 mm
height cylinder.

4. Design Plate Fin Heat Exchanger

Basic Components of a Plate Fin Heat Exchanger

Parts of plate fin heat exchanger

Cross Flow and Counter Flow

Types of flow in a Heat exchanger

FIN TYPES

Fig. 25 Different types of fin

Advantages of Offset Strip Fins Plate Fin Heat Exchanger

Large heat transfer area per unit volume
Flow area goodness factor: Ratio of the Colburn factor to
friction factor for the given surface is higher for the OSF as
compared to other fins.
High effectiveness: very close temperature approaches
between streams.
Significant reductions in size, weight.

Thermal input data for HX-1

Thermal data of process stream Nitrogen
Hot Fluid
Inlet temperature
310 K
Outlet temperature

120 45 K
120.45

Mass flow rate

82.22 g/sec

Pressure at inlet

8 bar

Allowable pressure drop

0 05 bar
0.05

Cold Fluid
Inlet temperature
100.74 K
Outlet temperature
305 8 K
305.8
Mass flow rate
78.68 g/sec
Pressure at inlet
Allowable pressure drop

1.15 bar
0.05 bar

All properties like density , enthalpy, specific heat, viscosity, prandtl

number are determined at mean temperature and pressure.
Effectiveness , UA , heat load are also calculated from the above inlet
and exit conditions.

INPUT :
1 Fin frequency,
1.
frequency f
2. Fin thickness, t
3. Fin length, lf
4. Fin height,
g h
5. Plate thickness, p

Basic dimensions of fin used in the heat exchanger

HX-1 Fin Specification Hot and Cold Side
Fin frequency
Fin metal thickness
Fin length
Fin height
Separating plate thickness

714 fins/m
0.2 mm
1.5 mm
6.3 mm
0 8 mm
0.8

CALCULATION :
1. Fin spacing, s =

(1 ft )
f

2. Plate spacing, b=h+t

b h t
3. Free flow area per fin, aff = (s t )h
4 Frontal
4.
F t l area per fin,
fi afr = (s + t )(h + t )
5. Heat transfer area, as = 2hl + 2ht + 2sl

Fi Parameters
Fin
P
t
S- fin spacing
H- fin height
T- fin thickness
ll- strip length
Geometry of a typical offset strip fin surface

6. Fin area, af = 2hl + 2ht

4 total free flow area length 2(s t )hl
=
total heat transfer area
hl + ht + sl
a
8. Ratio of fin area with total surface area, = f
as
a
9. Frontal area ratio, = ff
afr
7. Equivalent diameter, De =

10. Dimensionless parameters for the fin

h
s
l
=
s
t
=
s

Assume width of heat exchanger, W and No. of layers in hot and cold side, nh and nc.
11. Total area between plates, Afr = b n W
12. Total free flow area, Aff = Afrf
m
13. Core mass velocity, G =
Aff
14. Reynolds number, Re = GDe

15. Critical Reynolds number Re j * = 1568 .58( ) 0.217 ( ) 1.433 ( ) 0.217

Ref * = 648.23( ) 0.06 ( )0.1 ( ) 0.196

Maiti Correlations for offset serrated fins

y

For Re>Re*,
j = 0.18(Re)
(R ) 0.42 ( ) 0.288 ( ) 0.184 ( ) 0.005
f = 0.32(Re) 0.286 ( )0.221 ( ) 0.185 ( ) 0.023

F R
For
Re<Re*,
R *
j = 0.36(Re) 0.51 ( ) 0.275 ( ) 0.27 ( ) 0.063
f = 4.67(Re) 0.70 ( )0.196 ( ) 0.181 ( ) 0.104

Where

h
s
l
=
s
t
=
s

Manglik and Bergles Correlations for OSF fins

j = 0.6522 Re 0.5403 0.1541 0.1499 0.0678

[1 + 5.269 10

Re1.340 0.504 0.546 1.055

f = 9.6243 Re 0.7422 0.1856 0.3053 0.2659

[1 + 7.669 10

Where

s
h
t
=
l

De =

t
s

2shl
2(hl + ht + sl ) + ts

Re 4.429 0.920 3.767 0.236

0.1

0.1

Joshi and Webb Correlations for OSF fins

For Re <Re
<Re* (Laminar Flow)

For Re <Re*+1000 (turbulent Flow)

17. Convective heat transfer coefficient, h =

18. Fin parameter,M =

( 2 * hc )
(K f * t )

19. Fin effectiveness,

f =

(G j c )
(Pr)0.667

tanh( Ml )
( Ml )

A
20. Surface effectiveness, o = 1 ( f A ) (1 f )
o

21 Overall
21.
O
ll h
heatt ttransfer
f coefficient,
ffi i t

1
1
pAo
(A /A )
=
+
+ oc ohh
U o oh hh KW AW
oc hc

22. The ratio of total heat transfer surface area

to the separating surface area (wall area) , Ao / Aw = 1 Nf * t

1 ( Af / Ao )
UoAo
23. Heat transfer area may now be calculated as Ao =
Uo

24. The required length of the heat exchanger

is calculated from the equivalent diameter definition, as L =
fLG 2
25. The pressure drop p =
2Deb

De * Ao
4 * Aff

Effect of longitudinal heat conduction

1. Frontal area of fin, Afrt = W * H
2. Free flow area for hot fluid Affh
3. Free flow area for cold fluid, Affc
4. Wall conduction area, Aw = Afrt Afrh Afrc
5 Conductivity of fin
5.
fin, Kw
6. N.T.U required = N.T .U =

1
1 CR .
ln
(1 CR ) 1

7. Assuming a Factor of safety = F.S

8. N.T.U (considering longitudinal heat conduction), (N.T .U )lc = (N.T .U ) F .S
9. UA considering longitudinal conduction (UA)lc = (N.T .U )lc * Cmin

10. Area considering longitudinal conduction, A =

(UA)lc
U

11. Length of the heat exchanger (considering longitudinal heat conduction) L = De Ao

4 Aff
K Aw
12. Wall conduction parameter, = w
LCmin
13. Dimensionless parameters, y = * N .T .U * Cr
14. -

(1 Cr )
(1 Cr )(1 + y )
(1 + )y

1 (1 + )y

15. -

= ( y /(1 + y )1 / 2

16. -

(1 + )
(1 )

(1 Cr ) * N.T .U
1 + NTU Cr
(1 Cr )
18. Ineffectiveness (1 ) =
exp(( r1 ) Cr
17 17.

19. Effectiveness = [1 (1 )]

r1 =

Dimensions of the HX-1

D
Deepak
k

M
Manglik
lik

Joshi
J
hi &
Webb

Core length

2002

1888

2277

Core width

180

180

180

Core Height

165

165

165

Number of layers in hot side

10

10

10

Number of layers in cold side

2D Drawing views & Photograph of HX-1

Thermal input data for HX-2

Hot fluid
Inlet temperature
120.45 K
Outlet temperature
100.2 K,
x= 0.064
M
Mass
fl
flow
rate
4.9 g/sec
/
Pressure at inlet
7.95 bar
Allowable pressure drop 0.05 bar

Cold fluid
Inlet temperature
Outlet temperature
Mass flow rate
Pressure at inlet
Allowable pressure drop

HX-2 fin specification

Fin Density
714 & 500 Fins/m
Plate spacing
6.5 mm
Fin length
10 mm
Separating
plate 0.8 mm
thickness
Fin metal thickness
0.2 mm

91.38 K
100.81K
78 68 g/sec
78.68
1.2 bar
0.05 bar

2D Drawing views & Photograph of HX-2

5. Design Turboexpander

1. A turboexpander, is a centrifugal or axial flow turbine through

which a high pressure gas is expanded to produce work that is
often used to drive a brake compressor.
2 To
2.
T design
d i
the
h turboexpander
b
d a fixed
fi d state off process stream
parameters or design point is required. So the design point is
fixed as per the process design,
design done previously.
previously
The design points are as follows
Working Fluid

Nitrogen

Turbine inlet temperature, Tin

124 K

Turbine inlet pressure, Pin

7.97 bar

Discharge pressure, Pex

1.2 bar

Mass flow rate, m

76.46 g/s

NIT ROURKELA

Major Parts Of Turboexpander

Turbine Wheel
Brake Compressor
Shaft
Aerostatic Thrust Bearing
Tilting Pad Bearing
Nozzle
Diffuser
NIT ROURKELA

Brake compressor

Shaft

Turbine Wheel

Shaft with brake compressor and Turbine wheel

Turboexpander Assembly

Brake
Brake nozzle compressor

shaft
Nozzle

Tilting Pad
Bearing
Aerostatic
thrust Bearing
g

NIT ROURKELA

Turbine wheel
Diffuser

Turboexpander Assembly Animation

Design Of Turbine Wheel

NIT ROURKELA

ds

ns ds diagram show the maximum obtainable efficiency and the

optimum
p
design
g ggeometryy as function of diameter and speed
p
of the
turbine.

ns

ns ds diagram for radial inflow turbines

NIT ROURKELA

Specific speed and specific diameter of the turbine wheel are calculated
by
Q3
s =
(1)
3/ 4
(hin3s )
D2 ( hin 3 s )1 / 4
ds =
Q3

Where

Q3 = k1 * Qex

(h)in3s = k2 (h0in hexs )

(2)
(3)
(4)

To achieve the maximum possible efficiency, within the subsonic

zone, the value of specific speed and specific diameter selected
from the ns ds diagram of Balje.
Balje
ns= 0.5471
and ds = 3.4728
NIT ROURKELA

Ratio of eye tip diameter to turbine inlet diameter,

Dtip
=
= 0.6
D2

(5)

Ratio of eye hub to eye tip diameter ,

D hub
=
= 0.425
Dtip

(6)

Power produced,
produced

P = m (h0in hex ) = 2.8523 kW

(7)

Number of blades=10
Thickness of blades= 0.6 mm
Blade height at inlet,
b

( D

m tr
Z tr t tr ) 2C

((8))
m 2

Dimensions of the Turbine wheel

O t diameter
Outer
di
t off the
th turbine
t bi
: 29.6
29 6 mm
Speed of the turbine

: 1,38,778 rpm

Eye tip diameter

: 17.8 mm

Eye hub diameter

8.9 mm

Number of blades

10

Thickness of blades

: 0.6 mm

Height of blade at turbine inlet : 0.7 mm

NIT ROURKELA

Velocity Triangle

Inlet to Turbine (m/s)

Exit to Turbine (m/s)

C2

187.38

C3

110.31

W2

94 48
94.48

W3

152 97
152.97

U2

215.11

U3

96.8

60.38o

45.92o

26o

95o

NIT ROURKELA

Determination Of Blade Profile

y The blade profile determined by Haselgrubber
Haselgrubbers
s method assuming

pressure balanced flow path.

y This technique gives three dimensional contours of the blades and

simultaneously determine the velocity, pressure and temperature

profile
fil in
i the
th turbine
t bi wheel.
h l

Design of Brake compressor

Input parameters:
Process gas

Air/Nitrogen

Power to be dissipated : 2.85 kW

Angular speed

: 14534.67 rad/s (1, 38,777 rpm)

pressure
Inlet total p

: 4.1 bar

Inlet total temperature

: 300 K

Expected efficiency

: 60%

NIT ROURKELA

Specific
p
speed
p
and Specific
p
diameter are g
given by
y
s =

Q1
hs

(9)

3/ 4

D h
ds = 2 s
Q1

1/ 4

(10)

to achieve the subsonic operation within the constraints

of available power and rotational speed,
s =1.95 and ds = 2.9

(11)

P = sf mbU 2 = ( sf 1Q1 2 D2 ) / 4 = 2852

2

= power input
i
t ffactor
t
=1
1.02
02
sf = Slip factor = 0.9

NIT ROURKELA

(12)

Dimensions of Brake Compressor

Di
Diameter
t att inlet
i l t

15 mm

Diameter at outlet

33.7 mm

Blade height at inlet

3 mm

Number of blades

12

Thickness of blades

0.75 mm

Power to be dissipated : 2.85 KW

Angular speed

NIT ROURKELA

: 14534 rad/sec

Dimensions of Nozzle
Wt = Throat width
Dt = Throat diameter
Dn = Nozzle diameter
D2 = Turbine inlet diameter
Cn = Chord length

m tr
= 1 . 84 mm
Width at throat
throat, w t =
Z n bt t C t

((13)
3)

Cmt
0

tan
=
29
.
06
=
Throat angle,
g , t
C
t

(14)

Blade pitch length, pn = Dt Zn = 3.79 mm

(15)

Inner diameter of nozzle ring,

Din =

Dt + wt 2 wt Dt Cos t = 29 .8 mm
2

(16)

Chord length of the nozzle is given by

Ch n =

2 u S

u
z 1 + cot +
sin s

NIT ROURKELA
2

2

= 4 .4

mm

(17)

Design of Diffuser
1 Kinetic energy at the rotor outlet should be recovered using a
1.
diffuser.
2. The best suited diffusing
g angle
g
which minimizes the loss in
pressure recovery is 5o-6o
Aex =

Qex 0.0148
=
= 0.00087
0 00087 m 2
17
C ex

The exit diameter is found out to be 33.3 mm

Assuming radial clearance 0.1 mm
The inlet diameter is 29.8mm
The length of the diffuser is 87.4 mm
NIT ROURKELA

(18)

Design Of Shaft
We have chosen the diameter of the shaft and checked for maximum
stress and critical speed .
Di
Diameter
t off the
th shaft
h ft = 16 mm
The length of the shaft and dimension of the collar depends upon the
dimensions of the bearings.
Length of the shaft

= 108.1
108 1 mm

Diameter of the collar = 44 mm

NIT ROURKELA

Check for maximum stress:

P i h l speed
Peripheral
d att th
the ti
tip off th
the collar
ll

(14534.67 0.036)
= 116.27 m/s
2
1
2

=
Vsurf
= 225 < 230 MPa
Stress at the root of the collar,

Vsurf = d 2 =

(19)
(20)

The permissible stress for the shaft.

Check for critical speed:
Bending critical speed for uniform shaft is given by

f = 0 .9 d l

= 0.9 0.016 / 0.1

1.80 1011
= 6650.09 Hz
8440

=3,99,005 rpm
Which is below the operating speed of 1,38,778 rpm

NIT ROURKELA

(21)

Gas Lubricated Bearings

Advantages of gas bearings
1. Clean operation
2. Lower viscosity provides low friction,resulting in lower heat
generation.
3. Gases are chemically stable over a much wider range of
t
temperatures
t

Disadvantages of gas bearings

1. Lower load carrying capacity.
2. Suffer from problem of instability.
3 Demand high mechanical precision.
3.
precision
NIT ROURKELA

Gas Lubricated Bearings

Two types of bearings used for the turboexpander
rotor
t
A. Thrust Bearings
i
i.

Aerostatic Thrust Bearing

ii.

Aerodynamic thrust bearing

iii.

Thrust
ust Foil
o Bearing
ea g

B. Journal Bearings

NIT ROURKELA

i.

Rubber stabilized Aerostatic Journal Bearing

ii.

Pivot less Tilting Pad Journal Bearing

iii.

Aerodynamic Journal bearing

iv.

Journal Air Foil Bearing

Aerostatic Thrust Bearings

A double or combined thrust
bearing consists of a pair of thrust
plates, with the shaft collar in
between, forming the bearing
surfaces.
Load on

Neutral
Upper Thrust Plate

Thrust Collar

Shaft
Lower Thrust Plate
W

NIT ROURKELA

Aerodynamic Thrust Bearings

It has shallow angled grooves

cut in one of the bearing
surfaces.

NIT ROURKELA

Thrust Foil Bearings

Bump foil Gas bearings consist of three
parts:
a. top foil
b. bump foil structure
c. the bearing housing

Bump Foil

Advantages:

Bearing
Housing

1 Self-acting.
1.
Self-acting
2. Rotor dynamically stable.
3. Accommodate thermal growth.
4. Accommodate Misalignment.
5. High ability to damp.
6. Better wear resistant.

T FFoilil
Top

Rubber Stabilized Aerostatic Journal Bearings

Rubber Stabilised Aerostatic Journal Bearings consists of a plain aerostatic

bearing mounted on a pair of rubber O-rings. The O-rings convert the rigid
aerostatic bearing to a flexible one, so that enough damping is provided to
pass over the limiting speed of half speed whirl.
NIT ROURKELA

Pivot less Tilting Pad Journal Bearings

It consists of three pads floating
around the journal, within the pad
housing, surrounded by gas films
on all sides.

Pad made of high density metal impregnated graphite

Aerodynamic Journal Bearings

In a herringbone grooved journal

bearing, the grooves are cut in the
form of two opposing helices

Herringbone grooved bearing

Journal Air Foil Bearings

As the shaft rotates a Top Foil

aerodynamic pressure is
generated between the
rotating shaft and the
Bump
p Foil
smooth top foil due to
Gas Film
wedging.

Aerodynamic
A
d
i
pressure
determines
the
load
carrying capacity of shaft
and it deforms the top foil
and bump foil to prevent
contact between rotor and
bearing, which results zero
wear of the bearings.

Bearing Block

Modification in Turboexpander

Present Model

Modified Model

Supporting structures

The major supporting structure of the turboexpander are

A. Cold end casing
B. Bearing
g housing
g
C. Warm end housing

NIT ROURKELA

Supporting structures
A Cold
A.
C ld end
d casing
i
1. The cold end housing is the lower
mostt partt which
hi h is
i capable
bl to
t hold
h ld the
th
Teflon insulation rings so that the heat
could not enter into itit.
2. It contains nozzle diffuser centrally.
3 It takes the process gas inside and
3.
cooled gas comes out centrally from
the diffuser.
NIT ROURKELA

Supporting structures

B. Bearing block
The bearing housing is the central
component providing support to the
t
two
j
journal
l bearings
b i
and
d the
th two
t
thrust bearings.

NIT ROURKELA

Supporting structures
C Warm end housing
C.
1. The warm end housing has a nozzle to
p
which is fitted
the brake compressor
above brake compressor by shrink fit
operation.
2. There is an inlet and exit tube through
which air is sucked in and compressed
air goes out.
out

NIT ROURKELA

Fabricated of Turboexpander Parts

Turbine wheel

Brake compressor

Shaft
NIT ROURKELA

Tilting pad journal bearing

Lock Nut (Compressor Side)

NIT ROURKELA

Aerostatic thrust bearing

Lock Nut (Turbine Side)

Nozzle Diffuser

N
Nozzle
l cover

Exhaust gas plate

Spacer

Compressor end
NIT ROURKELA

B i bl
Bearing
block
k

C
Cold
end housing

Photograph of Turboexpander test setup

H.P. Pressure Vessel

Bearing supply gas

Turbine inlet gas

NIT ROURKELA

Turbine exit gas

v. J
JT Valve
a e

A Swagelok make fine needle valve is converted to act as a expansion

JT valve.

It is connected with a long pipe,

pipe so that it will be easier to operate the
valve from the top of the cold box flange, while it will be quite below
inside the cold box.

vi. Phase Separator

A 25 liter capacity phase separator has been designed and

fabricated.

3D model of Liquefier
Liq. Nitrogen exit
Turboexpander
Exit to the Compressor
Inlet to the HX1

HX2
Cold Box
HX1
Phase separator

NIT ROURKELA