Exergy, EnginSoft, and LuxProvide will collaborate to design and optimise two different sealing systems to enhance the performance of Exergy’s proprietary technology—the multistage radial outflow turbine (ROT) for Organic Rankine Cycle (ORC) plants. This efficiency boost will help Exergy become more competitive in the Waste Heat Recovery (WHR) market, where the ROT faces unfavourable operating conditions.
The project focuses on optimising a standard labyrinth sealing system for different operating scenarios and validating a new, innovative brush sealing system both experimentally and numerically. Validation will be carried out using a dedicated test bench and advanced CFD models, made possible through access to high-performance computing (HPC) infrastructure and specialised engineering tools.
In this regard, EnginSoft has committed to supplying expertise in fluid dynamics analysis and CFD modelling, while LuxProvide will supply the hardware and support required to conduct CPU-intensive parallel computations.
The project aims to minimise leakage losses, potentially improving turbine performance by up to 3%. By applying high-fidelity CFD simulations and real-world testing, the team will assess both sealing systems under operational conditions, delivering an optimised solution for greater energy efficiency.
The core innovation lies in the application of brush seal technology to ORC radial outflow turbines—an industry first—which enables significantly reduced leakage due to tighter clearances, unlike traditional labyrinth seals. This advanced approach combines supercomputing power with engineering innovation to address efficiency challenges in WHR applications. The outcome will be the development of next-generation sealing solutions for radial turbines, helping Exergy reduce power losses, increase efficiency, and expand its market share in sectors like geothermal and waste heat recovery.
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