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Design and Characteristics of a Micro-

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 Proceedings of the 2015 International Mechanical Engineering Congress & Exposition
IMECE15
November 13-19, 2015, Houston, Texas

IMECE2015-51030
FINAL

DESIGN AND CHARACTERISTICS OF A MICRO-HYDROKINETIC TURBINE SYSTEM

a a,b a a a,c
Jacob Riglin , Cosan Daskiran , Nick Oblas , W. Chris Schleicher , Alparslan Oztekin
a
P.C. Rossin College of Engineering and Applied Science, Lehigh University, Bethlehem, PA 18015
b
Turkish Military Academy, Department of Mechanical Engineering, Ankara, Turkey
c
Corresponding author (alo2@lehigh.edu)

ABSTRACT
Small, hydrokinetic systems generating between 0.5
and 10 kW of power allow for the potential of portable power
generation. An optimized propeller turbine approximately
0.6826 m in diameter and a diffuser with an area ratio of 1.31
were used to produce a prototype for preliminary testing. The
optimized diffuser augmented hydrokinetic turbine was
investigated numerically to predict power and thrust curves for
comparison during experimental testing. A gear box with a 10:1
gear ratio was selected for converting torque to angular
velocity. A DC permanent magnet generator was selected for
mechanical-electrical power conversion. At the ideal generator
operating conditions consisting of a shaft rotation rate of 1150
RPM, a voltage of 48 V, and current of approximately 8 A, 375
W of power may be generated at a river flow speed of 1.5 m/s.
Numerical predictions coupled with component efficiencies
yield a system efficiency of approximately 0.61 before DC/DC
conversion and 0.52 after DC/DC conversion.
INTRODUCTION
Renewable energy is necessary to reduce dependency
upon fossil fuels. Hydrokinetic resources remain one of the
untapped energy sources estimated to be comprised of
approximately 120 TWh/yr [1]. Producing power from river
and tidal applications may provide a substantial improvement
in renewable energy production and assist with reducing
harmful emissions into the atmosphere. One application of
river-based turbine design is portability which allows for the
transport the turbine system from one location to another based
on the user power demands, limit the overall environmental
impact of the device, and eliminates the need for a continuous
supply of fossil fuels to meet the desired energy demand. For
river applications, power production is generally limited to a
range of 0.5 to 10 kW. Turbine operation in rivers is restricted
by the Betz limit, dictating that the maximum power conversion
from the free flowing fluid to the turbine is 0.593. The
efficiency cap is due to the requirement that mass is conserved
and cannot be destroyed during the energy conversion process.
Gilbert and Foreman [2, 3, 4, 5], developed the
concept of augmenting a wind turbine with a diffuser, in
annular fashion, negating the Betz limit and increasing the
power production of the turbine. Gilbert et al. developed
experimental plots of loading coefficient for each component as
a function of the tip speed ratio [4]. Diffuser augmentation was
applied to hydrokinetic turbines (DAHkT) to improve
performance with rotor disk sized that were approximately two
orders of magnitude smaller than typical large-scale wind
turbines. Mehmood et al. investigated numerous diffuser
designs for tidal turbine application based on NACA hydrofoils
(NACA 0010, NACA 0016, and NACA 0018) [6, 7, 8].
Through the use of the investigated hydrofoils, Mehmood et al.
was able to produce a 233% increase in velocity at the throat of
the diffuser. The increase in velocity provides promise for
enhancing turbine power output when a specific geometry is
applied.
Work has been conducted to produce a portable
turbine that can produce 500 W of continuous power [9, 10, 11,
12, 13, 14]. A propeller based turbine design was introduced by
Schleicher et al. and introduced a higher value of solidity of the
turbine blades than used in typical hydrokinetic and tidal
turbine designs. Blades were designed and optimized such that
the coefficient of performance produced by the turbine
exceeded 0.43 and equated to approximately 73 % of the
available power based on the Betz limit [9, 11]. Riglin et al.
[12] optimized a shrouded diffuser design, first proposed by
Matsushima et al. [15] for urban wind application, augmented
onto a preexisting propeller-based turbine design produced
through the design procedure outlined in Schleicher et al. [11].

1 Copyright 2015 by ASME

Diffuser characterization was conducted directly in Riglin et al. t at the tip
[13].
The purpose of this study is to outline the efforts made TURBINE AND DIFFUSER DESIGN
transitioning from turbine-diffuser optimization to a full scale The propeller based turbine design, shown in Figure 1,
prototype for experimental testing. The hydrokinetic turbine was augmented with a simple curved diffuser. The turbine
design component composition is outlined along with design was based off of equations for propellers and designed
descriptions on each selected component. Preliminary using a top down approach. The equations, methodology, and
computational fluid dynamic (CFD) simulations were implementation are highlighted in Schleicher et al. [11]. The
conducted to provide mechanical production predictions. relative blade angle (), relative flow angle (), and wrap angle
Efficiencies of each component are applied to yield the overall () are each characterized. The B-spline shown in Figure 2
system efficiency. The resulting design is to be tested provides curvature to the blade near the leading edge. Due to
experimentally at the circulating water channel located at the the curvature present in the current blade design, the equations
Carderock Division of the Naval Surface Warfare Center [16]. for the blade angles cannot be used and the design was
determined through the use of solidity (), meridional length
NOMENCLATURE (), wrap angle, blade tip diameter (Dt), hub diameter (Dh),
Full Scripts and mean diameter (Dm). The turquoise line in Figure 2 denotes
C coefficient the resulting blade angle along the meanline.
D diameter, m
F blending function
I turbulent intensity, %
L length of diffuser, m
m meridional length, m
P power, W
Re Reynolds number
S mean rate-of-strain tensor, 1/s
T thrust, N or m
U velocity, m/s
Z quantity
Figure 1. Propeller turbine blade (a) front view and (b) top view.
Greek Symbols
relative angle,
change in variable
permutation symbol
wrap angle or diffuser angle,
dynamic viscosity, Pa-s
efficiency
density, kg/m3
solidity
angular velocity, 1/s
Superscript
denotes the blade angle
Subscripts
a absolute
B blades
con converter Figure 2. Blade curvature along the turbine mean line from the
gen generator leading edge (LE) to trailing edge (TE).
gear gear box
H hydraulic The diffuser incorporated in the design consisted of an
I Inlet area ratio (AR) of 1.31 and has a length of approximately 0.381
h at the hub m. The diffuser angle () is 24. The equation for area ratio is
m at the mean value provided as:
D 2
O outlet AR = ( O ) (1)
DI
r relative
T turbulent / thrust

2 Copyright 2015 by ASME

Where DO is the outlet diameter of the diffuser and DI is the
inlet diameter of the diffuser. The list of turbine and diffuser
design parameters is provided in Table 1. The selected area
ratio was determined through central composite design
optimizations conducted by Schleicher & Riglin [12, 17] and
analysis on diffuser design performed by Riglin et al. [13].
Table 1. Geometric Parameters for Blade Curvature and Diffuser
Variable Value Variable Value
Dt 0.6826 m DI 0.6985 m
Dh 0.1651 m DO 0.8001 m
90.0 L 0.381 m
m 0.1524 m ZB 3 intensity and hydraulic diameters were applied to both the inlet
0.83 24.0
AR 1.31
The prototype design, including the hub, nacelle,
elliptical supports, turbine blade, and diffuser are included in
Figure 3. In Figure 3a, the front view of the overall system can
be observed. The leading cone, along with the staggered
elliptical supports, allow for streamlined inflow to minimize
perturbation before interaction with the blades. The nacelle has
a slightly larger diameter and allows for the back end elliptical
supports to be fixed perpendicular to the diffuser.
Figure 3. Prototype design (a) front view and (b) side view with
diffuser implemented from Schleicher et al. [17].
NUMERICAL AND MATHEMATICAL MODELING
The computational domain used to model the fluid
domain was a semi-cylindrical channel identical to that used in
previous studies conducted by Schleicher et al. [9, 11] and
Riglin et al. [12, 13]. The domain width was 6.096 m with
3.048 m from the center of the system to the channel surface.
The outlet of the domain was placed approximately 20Dt
downstream. The boundary conditions of the domain consisted
of a plane of symmetry, a velocity inlet, a pressure outlet, and
no-slip walls. The plane of symmetry along the top of the
channel models the free surface of the river. No slip walls were
used on the cylindrical bottom. A constant velocity inlet was
used and a zero-gauge pressure with zero-gradient velocity was
applied at the outlet. A frozen rotor method is applied to the
turbine region with Coriolis and centrifugal forces being
applied to convert the unsteady velocity field in the absolute
reference frame to a steady velocity field in the relative
reference frame.
Turbulence modeling was accomplished using Menters
k- SST [18, 19] two-equation eddy-viscosity model. This
model offers improved prediction of adverse pressure gradients
in the near wall region as compared to the standard k- and k-
models by incorporating Bradshaws observation that turbulent
shear stress is proportional to the turbulent kinetic energy in the
wake region of the boundary layer [18]. The formulation of the
model and the blending functions used are provided in full
detail by Wilcox [20].
A velocity of 1.5 m/s is applied at the inlet. Turbulence
and outlet. The hydraulic diameter of the domain is 3.7248 m.
The turbulence intensity is calculated by using the following:
UDH
Re = (5)
I = 0.16(Re)18 100% (6)
Here Re is the Reynolds number, is the dynamic viscosity, DH
is the hydraulic diameter, and I is the turbulence intensity. The
turbine blade wall and hub wall are set to a no-slip condition
relative to the rotation rate of the turbine blade ().
The computational domain volume was discretize into
9.6 million structured, hexahedral cells. Cell size was
emphasized around the turbine blades in order to capture flow
separation and pressure distribution more accurately and
effectively. Comprehensive Grid Convergence Index studies
incorporating Richardson extrapolation standards promoted by
Roach et al. [21, 22, 23] and Celik et al. [24] were conducted
for the proposed blade and diffuser designs in previous work
[11, 13]. The current mesh size is acceptable for producing
accurate power and thrust results for the blade incorporated into
the final prototype design.
COMPONENT ANALYSIS AND SELECTION
The prototype consists of components fabricated from
both 316 stainless steel and 6061* aluminum. The supports
shown have an elliptical cross section with major and minor
axes of 1 and 2 respectively, to minimize influence on flow
and production of structural forces. The force produced in the
current geometry can be estimated using worst-case
assumptions i.e. || is calculated using the tip speed of the
blade. = 0.4 from the Moody Diagram for an elliptical pipe:
2
|| = 2 + ( ) (7)
2
1
= ||2 (8)
2
Using equations (7) and (8), the distributed load on
each support is estimated to be = 67.88 N. This is negligible
when considering the structural integrity of the supports. The
velocity magnitude used far exceeds the flow that will be
3 Copyright 2015 by ASME
experienced by the supports and acts as factor of safety due to
the drag force having a proportionally square relationship with Amperes at 12V DC Amperes at 24V DC
velocity. The analysis provides an estimate of thrust that would Amperes at 48V DC Amperes at 90V DC
be generated by the ellipsoid supports and ensures that the Watts at 12V DC Watts at 24V DC
tubing will be able to withstand the anticipated dynamic
loading and remain structurally sound. Watts at 48V DC Watts at 90V DC
Based off of the optimization work done by Primary Operation
Schleicher, the prototype was known to produce approximately 30 1500

DC OUTPUT POWER IN WATTS

431.4 W of mechanical power at a free stream velocity of 1.5
m/s. From this expected power, a 20 Ampere, continuous DC

DC AMPERES OUTPUT
1250
permanent magnet generator was selected for mechanical-to-
electrical power conversion. The generator output specs along
with the anticipated primary operating point are included in 20 1000
Figure 4. The prototype, under the designed conditions, would
result in the operate at 48 V DC output with a current of 750
approximately 8 A. The selected generator may only operate
continuously at currents less than 10 A. Therefore, a majority of 10 500
future testing will be conducted primarily at flow rates of
approximately 1.5 m/s and less. At the design point indicated, 250
the turbine system would be able to operate continuously
without any time limitations. 0 0
The rotation rate of the optimized turbine blade under 0 500 1000 1500 2000 2500
ideal loading is 115 RPM. The generator shaft rotation rate SHAFT RPM
under the preselected operator conditions of the generator is Figure 4. Shaft RPM vs DC output for chosen generator.
approximately 1150-1200 RPM. Therefore, an in-line gearbox
with a 10:1 ratio was selected to couple the turbine shaft and The prototype was designed such that it can interface
the generator shaft. Torque produced by the turbine was with the Ground Renewable Expeditionary Energy System
determined to be 35.83 Nm. After the 10:1 step-down in torque, (GREENS). The input voltage range of GREENS is 18 to 32 V
the resulting torque still exceeds the required 0.153 Nm of DC at a maximum power of 1.0 kW. Due to the input voltage
startup torque for the generator. The current design will be limitations of the system, a DC/DC converter was selected to
capable of operating at flow rates as low as 1.0 m/s, convert the 48 V during generator operation to a 24 V input.
approximately. The gear box has a male input and a female The converter will be used only for initial experimentation.
output. A male-male elastomer coupling was selected to Efficiencies of each component are contained in Table 2.
dampen possible shaft vibration and any slight misalignment
between the turbine runner shaft and the gear box. Table 2. Prototype Component Efficiencies

Gear DC/DC
Efficiency Generator
Box Converter
0.96 >0.85 0.94

NUMERICAL RESULTS AND DISCUSSION

The results from characterizing the performance of
these geometries are presented in Figure 5 and Figure 6. The
power coefficient is presented in Figure 5 and thrust coefficient
in Figure 6 as a function of tip-speed ratio. These non-
dimensional parameters are defined in equations below:
(9)
=
2

= (10)
3 2
8

4 Copyright 2015 by ASME


= (11)
2 2
8
Here, is the angular velocity of the turbine, is the thrust
force, is the tip-speed ratio, is the power coefficient, and
is the thrust coefficient. The final overall system efficiency
is generated through augmenting equation 10 with the
efficiencies listed in Table 2, as follows:
, = (12) output are predicted as function of the geometric turbine size
Where is the efficiency of the DC/DC converter, is
the efficiency of the generator, and is the efficiency of
the gear box.
From Figure 5, the best efficiency point of the
prototype yields a power coefficient of approximately 0.70 at a
tip speed ratio of 2.75. Preliminary results of Schleichers
benchmark design are included along with the results of the
same design operating with a diffuser that has an area ratio of
1.36. The results are obtained at a flow speed of 2.25 m/s. For
the benchmark turbine without any diffuser augmentation, a
maximum power coefficient of 0.43 is obtained at a tip speed
ratio of 1.86. When the diffuser is applied to that design, the
performance increases from 0.43 to 0.59, representing a 37.2%
increase in power. The current prototype displays a 62.8%
increase from the initial benchmark.
After applying equation (12) with and without the
efficiency of the DC/DC converter, curves for the system
and flow conditions and properties. When including the DC/DC
conversion losses, the overall system is still generating 52.2%
of the maximum power acting on the swept area of the turbine
blades. Figure 6 indicates that the thrust of the current
prototype is less than that predicted by Riglin et al. [13] despite
a larger overall system. This suggests that the overall device
will be easier to moor as it will experience less axial loading.

0.7

Mechanical Power- Prototype

0.6
Scheicher et al. [10]
0.5
Riglin et al. [12]- AR=1.36, U=2.25
m/s
0.4 Overall System with DC/DC
CP

Conversion
0.3 Overall System without DC/DC
Conversion
Poly. (Mechanical Power- Prototype)
0.2
Poly. (Scheicher et al. [10])
0.1

0
0.00 1.00 2.00 3.00 4.00 5.00

Figure 5. Power coefficient as a function of tip speed ratio.

5 Copyright 2015 by ASME

 2

1.75

1.5
Thrust- Prototype
1.25 Scheicher et al. [10]
CT

1 Riglin et al. [12]- AR=1.36,

U=2.25 m/s
0.75 Poly. (Thrust- Prototype)

0.5

0.25

0
0.00 1.00 2.00 3.00 4.00 5.00

Figure 6. Coefficient of thrust as a function of tip speed ratio.

From the resulting power output shown above, future speed. A gear box with a constant ratio of 10:1 and an
plans include acquiring experimental data to compare against efficiency of 0.94 was selected for transferring the loading
the numerical prediction of system operation. Efficiencies listed between the turbine blade and the generator. A DC generator
in Table 2, given 10:1 constant gear ratio, and the mechanical was selected with an efficiency of 0.96 for mechanical-
power predicted in Figure 5 allow for the development of key electrical power conversion. An elastomer coupling was
testing points and power output predictions at each individual selected to reduce vibration occurring in the shaft between the
configuration. Table 3 highlights three separate configurations turbine and the gear box. Finally, a DC/DC converter was
and the experimental power output expected. selected with a minimum efficiency of 0.85 to allow for
GREENS interfacing.
Table 3 Prediction of experimental results for varying velocity. Under optimum loading conditions, the maximum
mechanical power coefficient produced from the prototype
TEST system was approximately 0.68. Overall system analysis
CONFIGURATION yielded a maximum efficiency of 0.52 when the DC/DC
1 2 3 converter was applied and 0.61 when it was neglected. Test
configurations and power predictions were then formulated in
Depth (m) 2Dt 2Dt 2Dt preparation for testing at the Carderock Division of the Naval
Flow (m/s) 1.286 1.543 1.800 Surface Warfare Center circulating water channel.
Torque (Nm) 19.67 39.39 54.83
ACKNOWLEDGEMENTS
Generator Shaft
The authors would like to gratefully acknowledge funding from
Ang. Vel. (RPM) 1150 1150 1150 the Office of Naval Research for this work under Award
Power Generation N00014-12-M-0050.
(W) 183.6 350.2 511.9

CONCLUSION
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6 Copyright 2015 by ASME

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