Effect of CO2
Effect of CO2
Effect of CO2-based binary mixtures on the performance of radial-inflow turbines for the
supercritical CO2 cycles
Yang, Yueming; Wang, Xurong; Hooman, Kamel; Han, Kuihua; Xu, Jinliang; He, Suoying; Qi, Jianhui
DOI
10.1016/j.energy.2022.126429
Publication date
2023
Document Version
Final published version
Published in
Energy
Citation (APA)
Yang, Y., Wang, X., Hooman, K., Han, K., Xu, J., He, S., & Qi, J. (2023). Effect of CO -based binary
mixtures on the performance of radial-inflow turbines for the supercritical CO cycles. 2Energy, 266, Article
2
126429. https://doi.org/10.1016/j.energy.2022.126429
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Keywords: Recently, the supercritical carbon dioxide (SCO2 ) power cycle has become a hotspot in the field of energy-
Supercritical carbon dioxide efficient utilization. The utilization of additives in the power cycle has been proven to be an effective way
Radial-inflow turbine to improve the SCO2 power cycle efficiency. As one of the core components of the system, the influence of
CO2 -based binary mixture
CO2 -based mixtures on turbine performance needs to be further explored. In this study, the preliminary design
Numerical simulation
and three-dimensional numerical simulation of a 500 kW radial-inflow turbine (RIT) for small-scale SCO2 power
Turbine stage losses
systems were carried out. Furthermore, the design and off-design performance of high Reynolds number and
small size turbine under the change of the CO2 -based binary mixture compositions and mixing ratios were
studied. Increasing the amount of nitrogen, oxygen, or helium into CO2 has a negative effect on the RIT
performance, and the appropriate amount of xenon or krypton can improve the turbine efficiency. Moreover,
mixtures with higher krypton additions adapt to higher heat source conditions. The loss of the turbine stage
passage shows that a large amount of helium greatly reduces the working fluid density, and the high amount
of xenon has a great influence on the dynamic viscosity, which all makes the RIT operation deviate from
the steady state. Therefore, the CFD model simulation fails indicating that RIT designed based on pure CO2
may not run smoothly and continuously. The losses in the stage with pure CO2 and CO2 –Kr mixture were
investigated. The results indicate that the losses originated from the stator cannot be ignored and that the
improvement of efficiency is mainly owed to the reduction in clearance losses. There is no doubt that the
viewpoints proposed in this paper have significant reference value for the practical application of the SCO2
power cycle using mixtures.
∗ Corresponding author at: School of Energy and Power Engineering, Shandong University, Jinan 250061, China.
E-mail address: j.qi@sdu.edu.cn (J. Qi).
https://doi.org/10.1016/j.energy.2022.126429
Received 2 July 2022; Received in revised form 9 November 2022; Accepted 12 December 2022
Available online 19 December 2022
0360-5442/© 2022 Elsevier Ltd. All rights reserved.
Y. Yang et al. Energy 266 (2023) 126429
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Table 1
The initial conditions of the calculation.
Parameter Value
Power, 𝑊 [kW] 500.00
Rotational speed, 𝑁 [kRPM] 100.0
Inlet total temperature, 𝑇01 [K] 833.15
Inlet total pressure, 𝑃01 [MPa] 20.00
Mass flow rate, 𝑚̇ [kg/s] 5.30
Pressure ratio (Total-Static), 𝑃 𝑅 [–] 2.22
Flow coefficient, 𝜑 [–] 0.38
Head coefficient, 𝜓 [–] 0.86
illustrated in Fig. 2. The rotor design part takes into account the well- The construction of the cycle system consumes vast labor power
established loss model to estimate the total losses. For the stator design and financial resources, and the assembly of the test-rig is very costly.
process, TOPGEN does not consider the loss and assumes it as an Hence, it is impractical to build a corresponding test-rig to adapt to the
isentropic expansion process [27]. However, in the research process, cycle system of different mixtures. Considering the above situation, the
it is observed that the loss caused by the stator is obvious, so the existing turbine model designed for pure CO2 is selected to simulate
optimized stator structure [28] is selected in this paper. Through the the situations using different CO2 -based binary mixtures. In this study,
efficiency iteration process shown in Fig. 2, the point where the overall the 3D steady and unsteady simulations are conducted by the ANSYS
efficiency matches the geometric losses is obtained. The final detailed platform. ANSYS-BladeGen is used to build the 3D turbine model,
geometric module provides the necessary information for the three- and the structured mesh used in CFD simulation is generated through
dimensional (3D) blade optimization stage. Moreover, the feasibility TurboGrid. Fig. 4 presents the mesh of the computation domain, which
of each design scheme is addressed based on the selection criteria includes two nozzle passages and a single rotor passage. Since the
that comprise not only optimal operating ranges of the aerodynamic existence of 0.1 mm tip clearance has a noticeable impact on the turbine
design, but also manufacturability and structural/vibration constraints. flow performance, the grid at this position is refined.
To obtain the real gas properties, TOPGEN is coupled to the REFPROP ANSYS-CFX is employed to perform the numerical simulation. The
database by the National Institute of Standards and Technology (NIST). boundary conditions of the designed RIT are the same as the design
For SCO2 , TOPGEN gives access to the Span and Wagner equations of conditions, as shown in Table 1. The total pressure, the total tempera-
state (SW EoS) [29]. ture, and the absolute velocity direction are imposed as the stator inlet
The design conditions for the input of the calculation model are boundary conditions, whereas the static pressure is set as the rotor
listed in Table 1. After filtering the feasible data, a set of turbine outlet boundary condition. The Mixing-Plane method between stator
parameter data is obtained as shown in Table 2. According to the and rotor interfaces is set in the steady-state simulation for information
geometric parameters after optimizing the design, the ANSYS-BladeGen exchange. Since using simplified passage model, the interfaces between
module is adopted to construct the 3D model of the turbine stage part. passages are defined as periodic boundaries. The characteristics of
The final calculation 3D model applied in the following simulation can turbine internal flow are complex, as separated flows and vortex mix
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Table 2
Design parameters for turbine.
Rotor parameter Value Stator parameters Value
Inlet radius, 𝑟4 [mm] 31.63 Inlet radius, 𝑟1 [mm] 41.91
Inlet blade height, 𝑏4 [mm] 2.25 Blade height, 𝑏1 [mm] 2.35
Inlet absolute flow angle, 𝛼4 [°] 66.16 Outlet radius, 𝑟3 [mm] 33.21
Inlet relative flow angle, 𝛽4 [°] −20.22 Stator installation angle, 𝛼1 [°] 56.00
Tip clearance, 𝜀𝑡 [mm] 0.10 Stator blade length, 𝑟3 [mm] 15.00
Outlet hub radius, 𝑟6ℎ [mm] 9.49 Outlet absolute flow angle, 𝛼3 [°] 65.08
Outlet shroud radius, 𝑟6𝑠 [mm] 18.53 Outlet relative flow angle, 𝛽3 [°] 67.56
Outlet hub angle, 𝛽6ℎ [°] −38.29 Trailing edge thickness, 𝑡3 [mm] 0.90
Outlet tip angle, 𝛽6𝑡 [°] −57.03 Stator blade number, 𝑍𝑠 [–] 20
Blade thickness, 𝑡𝑟 [mm] 1.00
Rotor blade number, 𝑍𝑟 [–] 13
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Fig. 5. The isobaric heat capacity, 𝐶𝑝 , of CO2 –Xe binary mixtures as a function of
temperatures, 𝑇 , calculated by this study and MD at 15 MPa.
Fig. 6. Variation of mixtures isentropic exponent vs. the mole fraction of additives.
Table 3
Mesh independency study.
Mesh Rotor cell Stator cell 𝑚/[kg/s]
̇ 𝜂𝑡−𝑠 /% 𝑀(all (enhance the turbine efficiency) is selected to compare the turbine per-
number/×104 number/×104 blade)/[N m] formance under off-design conditions and explore the change of turbine
1 34.0 11.6 5.34 78.95 47.85 operation range. Moreover, to further study the underlying reasons
2 49.4 15.5 5.33 78.62 47.57 for the mixture’s effects through simulations, the entropy change of
3 74.3 19.3 5.30 79.07 47.50 the turbine stage passage is analyzed. Finally, the variation of turbine
4 111.2 30.2 5.29 79.14 47.48
efficiency is calibrated by a transport characteristic, and the source of
losses is revealed by loss breakdown, which provides a reference for
Table 4 optimizing the turbine to adapt to the specific cycle.
Comparison of 1D design and simulation values of SCO2 RIT.
Case 𝑊 /kW 𝜂𝑡−𝑠 /% 𝑚/[kg/s]
̇ 3.1. SCO2 RIT with SCO2 -based binary mixtures at design point
1D TOPGEN results 500.00 79.02 5.30
3D CFD results with CO2 RK 496.78 79.07 5.30 CO2 -based binary mixtures with different components and mixing
3D CFD results with RGP table 498.25 79.05 5.29
ratios are used to explore the influence of additives on the turbine per-
formance. The selected mole fractions, 𝑥, of various additives are 0.5%,
1%, 5%, 10%, 20%, 30%, 40%, and 50%. Then the steady-state simu-
and Mesh 4 for these parameters are 0.18%, 0.08% and 0.04%. These lation is carried out under the design condition. The constant boundary
relative errors are quite limited, indicating that Mesh 3 has sufficient condition at the stator inlet is set to 833.15 K and 20 MPa. At the rotor
resolution for carrying out the following simulations. For the single outlet, the static pressure maintains 9.009 MPa. The additive changes
passage model, the cell number of the stator is 193,000, and the cell the thermodynamic and transport characteristics of the working fluid
number of the rotor is 743,000. in the supercritical region, so it is necessary to use a parameter to
The data in the RGP tables are derived by setting the mole fraction calibrate the working fluid characteristics. Roberts et al. [39] suggested
𝐶
of CO2 to 1 and the mole fraction of the additive to 0 in the mixture that the isentropic exponent, 𝛾 = 𝐶𝑝 , is an important criterion of
𝑣
composition. To study the independence of the RGP table to the res- similarity in the performance of turbomachinery. Their study showed
olution, 5 different RGP tables with different resolutions, 100 × 100, that the choking 𝑚, ̇ the pressure ratio, and the isentropic efficiency
200 × 200, 300 × 300, 400 × 400 and 500 × 500 are generated and of the compressors are all significantly affected by the changes in 𝛾.
applied in simulation. Considering the independence, stability, conver- Under the inspiration of Roberts’s work, this study attempts to use 𝛾 as
gence, and accuracy of the simulation, RGP tables with a resolution of the parameter to calibrate the mixture characteristics for the following
400 × 400 are finally adopted in the following simulations. exploration of their influence on the RIT.
Table 4 shows the comparison between the 3D numerical simulation Through the comparison of 𝛾 of the CO2 -based mixtures for multiple
results and the 1D results. The CFD simulation data are consistent state points, limited change can be found within the operating tempera-
ture range of RIT. So it can be considered that the specific mixture has a
with the TOPGEN design results, which manifests that the simulation
relatively stable 𝛾 in this interval. However, for different additives, the
process and the design process are mutually verified and explains
changes of the mixture 𝛾 are different with the increasing amount of the
the rationality of the RIT model. Furthermore, the simulation results
additives, as shown in Fig. 6. The introduction of xenon has the greatest
based on RGP tables are close to those based on the Aungier-Redlich-
effect on the thermal properties of CO2 , while nitrogen and oxygen have
Kwong cubic equation [37,38], demonstrating the accuracy of the RGP 𝜕𝛾
the smallest impact. In addition, the CO2 –He mixture 𝛾 growth rate, 𝜕𝑥 ,
table resolution and the process of obtaining the mixture’s physical
increases with an increased 𝑥 of helium. This phenomenon indicates
properties.
that with the increase of 𝑥, the effect of adding helium tends to be
more significant to the change of the CO2 properties. Furthermore, the
3. Results and analysis 𝛾 of the CO2 –Kr mixture increases almost linearly with the increase of
𝑥.
A 500 kW SCO2 RIT is designed and discussed. Firstly, the tur- The variations of the RIT isentropic efficiency with different com-
bine operated with various mixtures under a designed condition to ponents and mixing ratios of the mixtures are shown in Fig. 7. As
explore its performance change. Then the mixture with a positive effect the variation of 𝛾 implies, the introduction of xenon has the largest
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3.2. SCO2 RIT with SCO2 -based binary mixtures under off-design condition
The above analysis shows that under the premise that the inlet and
outlet boundary conditions of the turbine are constant, the influence
of different additives on the turbine is obviously different, and the
turbine performance also changes significantly with the amount of
additives. The influence of mixtures on turbine performance under off-
design conditions is further analyzed. In this section, only CO2 –Kr
binary mixture is analyzed as it is the only helpful additive to improve
turbine efficiency. Fig. 10 shows the efficiency curve of the off-design
Fig. 7. Variation of RIT isentropic efficiency vs. the mole fraction of additives.
conditions when the turbine outlet pressure is constant and the inlet
pressure is changed. When the additive’s 𝑥 is 1%, the mixtures have
little effect on the variable operating conditions of the turbine, and
impact on turbine efficiency. With the increase of xenon amount, the the turbine highest efficiency point almost coincides with the oper-
efficiency shows a trend of first increase and then decrease, and the ation using pure CO2 . However, with the increase in the amount of
highest efficiency point appears at 𝑥 about 10%. When 𝑥 of xenon is krypton, the deviation of the turbine performance curve under off-
higher than 20%, the turbine efficiency decreases rapidly. Contrary design conditions becomes larger. With an increased 𝑥 of krypton,
to adding xenon, the addition of krypton will increase the turbine the highest point of turbine efficiency moves to the right, which is
efficiency. Nitrogen and oxygen are often considered to be inevitable the direction of increasing inlet pressure. Moreover, the mixtures with
impurity gases, but the effect on turbine efficiency is little when mixed higher amount of krypton show detrimental effects under the lower
in a small amount. Helium has been widely used in the applications of turbine inlet pressure. The above results indicate that the operational
power conversion systems, such as the Gas Cooling High-Temperature range of the turbine becomes narrow.
Reactor. When helium is used as an additive, it has a negative effect Fig. 11 shows the influence of different ratios of CO2 –Kr mixture
on turbine efficiency. With the increase of 𝑥, the decline rate of turbine on the turbine shaft power and 𝑚̇ under variable working conditions.
efficiency accelerates. In all, mixing an appropriate amount of krypton For the turbine shaft power in Fig. 11, the distribution is almost linear
or a small amount of xenon into the working fluid can improve the with respect to the inlet pressure when the mixing ratios change. The
turbine performance, while the other three additives negatively affect 𝑚̇ demand increases with the increase of inlet total pressure, and the
turbine operation. binary mixture with higher krypton 𝑥 brings a greater growth rate in 𝑚. ̇
To further analyze the influence of working fluid properties on On the one hand, with an increasing Kr amount and operating pressure,
turbine performance, the following research is carried out. Fig. 8 il- the working fluid 𝜌 increases, resulting in a rise in 𝑚.
̇ On the other hand,
lustrates the variation curves of mixture 𝜌 and turbine 𝑚̇ as the mole for a fixed turbine geometry, 𝑚̇ depends mainly on pressure. A larger
fraction of additive changes under the design condition. The turbine pressure drop accelerates the overall flow speed in the turbine so that
𝑚̇ is closely related to the mixtures 𝜌 when the CFD simulations are 𝑚̇ increases.
carried out with fixed geometry and inlet velocity. When a higher 𝜌
of the mixture is used in the turbine, the operating 𝑚̇ will decrease. 3.3. Turbine stage losses analysis
On the contrary, a lower 𝜌 of the mixture causes a higher 𝑚. ̇ The 𝜌 of
the CO2 –Xe mixture deviates most from pure CO2 with an increased To understand the influence of mixtures on turbine performance
𝑥 of xenon. Therefore, the change of 𝑚̇ is the largest, resulting in the more clearly, the overall loss of the turbine stage is studied. Fig. 12 de-
instability of turbine operation, which is manifested in the significant picts the entropy rise in the passage at different percentages of the blade
reduction of efficiency, as shown in Fig. 7. As a bioinert gas with low spans when the RIT uses pure CO2 . The entropy growth rate fluctuates
molecular weight, helium has low 𝜌 and high kinematic viscosity, 𝜇. It greatly in the middle and downstream part of the rotor passage, which
significantly reduces the working fluid 𝜌, making the 𝑚̇ of the turbine is caused by the vortex generated through the tip clearance leakage
decrease linearly. The shaft power of RIT depends on the 𝑚̇ and the flow. More separated flow and secondary flow in the channel lead to
enthalpy levels of working fluid at the inlet and the outlet, shown in an increase in flow losses. Further, Fig. 13 shows the changes in the
Eq. (4): average entropy in the turbine stage passage under the different mixing
ratios of nitrogen, xenon, helium, and krypton. The losses in the stator
𝑊𝑡𝑢𝑟 = 𝑚𝑔 (ℎ1 − ℎ6 ) = 𝑚𝑔 𝜂𝑡𝑢𝑟 (ℎ1 − ℎ6𝑠 ) . (4) passage gradually decrease with the increase of the xenon 𝑥. However,
Turbine total to static isentropic efficiency can be calculated through: the losses decrease at first and then increase in the rotor passage.
When the 𝑥 of xenon exceeds 20%, the stage losses increase sharply,
ℎ1 − ℎ6
𝜂𝑡𝑢𝑟 = 𝜂𝑡−𝑠 = . (5) indicating that the influence of mixtures on the turbine performance
ℎ1 − ℎ6𝑠 is intensified, and even affects its operation stability. According to the
Then the total enthalpy difference between the inlet and outlet previous analysis, nitrogen and oxygen have similar effects on turbine
of the turbine is calculated. The variations of enthalpy difference performance, so this section only analyzes the influence of nitrogen
and output power with the increased mole fractions of additives are on stage losses. Overall, nitrogen has a negative effect on the rotor
shown in Fig. 9. The power output can be predicted by the enthalpy turbine stage losses. The effect of the CO2 –Kr mixture is opposite to
difference, while the 𝑚̇ has a relatively small effect on the trend of that of the CO2 –N2 mixture, and the losses gradually decrease with
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Fig. 8. Variation of mixture density and RIT mass flow rate vs. the mole fraction of additives.
Fig. 9. Variation of mixture enthalpy at stator inlet and shaft power vs. the mole fraction of additives.
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Fig. 11. Variation of the shaft power and mass flow rate vs. the turbine inlet pressure.
Fig. 12. Static entropy contours at different spans with pure CO2 .
a high helium amount, the steady-state simulation can hardly reach 3.4. Breakdown of losses
convergence. It is concluded that the unsteady characteristics of the
turbine are strong, and the steady-state simulation cannot predict tur- From the perspective of transport characteristics of the working
bomachinery performance well. Then the transient simulation of the fluids, the influence of the dynamic viscosity, 𝜇, on the turbine stage
turbine under this working fluid is analyzed. Comparing the entropy losses are investigated in this section. Through the transport model
increase between the steady-state and transient simulations in Fig. 15, calculation based on the thermophysical properties from REFPROP
the two performance predictions are significantly different. It is mainly database, it can be found that different additives have variant levels
of increase effect on the 𝜇. The dynamic viscosity of the mixture obeys
reflected in the loss prediction produced by the interaction effect
a states principle shown in Eq. (6) [40]:
between the stator and rotor. Under the real situation (transient simu-
lation), the entropy rise is obvious from the stator outlet to the rotor ̄ = 𝜇 ∗ (𝑇 , 𝑥)
𝜇(𝑇 , 𝜌, 𝑥) ̄ = 𝜇 ∗ (𝑇 , 𝑥)
̄ + 𝛥𝜇(𝑇 , 𝜌, 𝑥) ̄ + 𝛥𝜇0 (𝑇0 , 𝜌0 )𝐹𝜇 (𝑇 , 𝜌) , (6)
leading edge. However, the stage averaging between static and dynamic ∗
where the superscript denotes a dilute gas value, and the subscript 0
passages only accounts for the time average interaction effects. Even
denotes a reference fluid value. 𝐹𝜇 is a mixture’s factor that contains
though the stage averaging assumes a sufficiently large physical mixing
the use of mixing rules.
generated by the relative motion, the neglected transient interaction When nitrogen and oxygen are introduced as impurity gases with
still plays an important role. This is because the 𝜌 of the mixture has a slight amount, the change of 𝜇 is little, and the influence on the
been greatly reduced at high helium amount, which is significant for turbine performance can be ignored. The amount of helium also has
small size and high-speed RITs. Then the turbine operation tends to a limited effect on the 𝜇 of the mixture, only reducing the 𝜌 to a
be more unstable as the transient interaction between the stators and great extent. Therefore, the turbine efficiency deviates from the nor-
rotors intensified. Therefore, the turbine designed with pure CO2 is no mal working condition after the 𝑚̇ changes, which will cause larger
longer suitable for high mixing ratio CO2 –He mixtures. losses. The addition of krypton and xenon has a great influence on
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Y. Yang et al. Energy 266 (2023) 126429
Fig. 13. Variation of the passage entropy change vs. the streamwise location.
the transport characteristics of CO2 , and the influence from xenon slip-wall on the blade walls). Endwall and secondary flow losses are
is more intense. The simulation results show that the working fluid determined as the entropy rise over each component caused by viscous
pressure and temperature levels are in the range of 8 MPa to 20 MPa endwall effects and induced secondary flows (i.e., by setting a slip-wall
and 700 K to 835 K during turbine operation. As shown in Fig. 16, the on the shroud and hub surfaces, which also prevents in large part the
𝜇 of the mixtures under different mixing ratios are analyzed in com- development of secondary flows). Tip clearance loss is calculated as
bination with the turbine operation efficiency. For the binary mixtures the proportional entropy rise on the rotor due to the existence of tip
of CO2 –Kr and CO2 –Xe, there is a reasonable 𝜇 range that makes the clearance. Mixing loss is determined from the entropy rise across the
turbine efficiency higher than that by adopting pure CO2 . However,
mixing-plane in the steady CFD predictions. All these procedures can
when the 𝜇 exceeds the reasonable range, it will have a negative effect
be done by adjusting the CFD simulations.
on the turbine operation and reduce the turbine efficiency. The reason
for this phenomenon is analyzed from the level of the turbine flow Fig. 18 shows a breakdown of the different contributions to losses
field. The Mach number contours of the 50% blade span under the from the turbine stage passage. Tip leakage loss decreases with the
different amounts of krypton are obtained, as shown in Fig. 17. The increase of krypton amount. It can be explained that the dynamic
local low Mach number region begins to appear at the blade inlet viscosity 𝜇 of the mixtures increases with the increase of the krypton
pressure side, which is unfavorable to the normal condition, seriously 𝑥. In the meantime, smaller tip clearance is more sensitive to the
hindering the output work of the turbine. Therefore, when substances change of transport characteristics of the working fluid. As a result,
similar to krypton and xenon are added, the appropriate amount can the tip clearance leakage decreases, and losses accordingly decrease.
ensure the 𝜇 of the mixture in a reasonable range so that conducive to The loss reduction caused by the rotor section is obvious, which is
improving the turbine performance. assumed to be related to the decrease of the flow Re. An increase
The cause of turbine loss has been preliminarily analyzed, but the in the 𝜇 of the mixtures reduces the overall Re of the fluid flow.
exploration of the loss mechanism of the CO2 -based mixture turbine Therefore, the decrease in turbulence intensity will mitigate the flow
is not detailed enough. Therefore, to assess the performance of the separation. Moreover, the losses caused by the stator passage cannot
turbine stage when CO2 -based mixture is applied, a loss breakdown
be ignored compared with the rotor passage. Most of the loss models
study is performed. The purpose of this loss breakdown is twofold:
in the 1D preliminary design now focus on the rotor losses of the
firstly, to clarify the difference in the loss mechanism of SCO2 RITs
turbine, such as incidence loss, passage loss, tip clearance loss, and
between using pure CO2 and mixtures; secondly, to seek high loss
regions to inform future preliminary design methods for the design exit energy loss. However, limited attentions are focused on modeling
of efficient turbomachinery. In this section, the CO2 –Kr mixture is of the stator losses. With the increase of the krypton 𝑥, the endwall
used as an example. To study loss mechanism, the way to distinguish and secondary flow losses in the stator are reduced, but the stator
different losses are presented. Entropy loss is determined following the profile and trailing edge losses are gradually increased. Therefore, the
method of Wheeler and Ong [41,42]. Profile and trailing edge losses efficiency improvement of the CO2 –Kr mixture is mainly due to the
are determined as the entropy rise over each component resulting from reduction of the tip clearance loss and the endwall and secondary flow
the blade boundary layer and trailing edge losses (i.e., by setting a losses of the passage.
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4. Conclusion
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Fig. 17. Mach number contours of the turbine with different krypton mole fraction.
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13