Post by AENS Consulting

⚡ Hydrogen fuel cell vehicles need a smarter way to manage air. The answer lies in a radial turbine expander — and designing one from scratch is exactly what this work is about. The Challenge Fuel Cell Electric Vehicles (FCEVs) run on compressed air fed into the fuel cell stack. That air needs to be delivered at the right pressure, flow rate, and temperature — continuously. Conventional electric-only compressors work, but they waste energy. The fuel cell exhaust carries recoverable enthalpy that, if captured efficiently, can assist the compressor and reduce parasitic power consumption. The engineering solution: a radial turbine expander with inlet guide vanes — designed to extract maximum energy from low-temperature exhaust gas and drive the compressor shaft as an auxiliary power source. The Design Process This project followed a full turbomachinery design workflow: → Literature review + CFD analysis of prototype rotor geometry → 2D meanline design using an in-house developed code → Parametric study across 6 rotor geometry variables → Response Surface Methodology (RSM) + Multi-Objective Genetic Algorithm (MOGA) optimisation → 3D CFD validation (RANS, SST turbulence model) on the optimised geometry → Nozzle guide vane (NGV) and volute casing design → Full system integration and compressor matching Why This Matters Every percentage point of turbine efficiency recovered at this scale translates directly into extended vehicle range, reduced motor load, and better system-level performance. The design of rotating turbomachinery for clean energy applications demands a precision that only integrated CFD and optimisation workflows can deliver. This is the intersection of clean energy, turbomachinery, and simulation-driven engineering that AENS Consulting works in every day. → Radial turbine and compressor design → Turbomachinery CFD and optimisation → Hydrogen + FCEV system simulation → Full design workflows from 1D meanline to 3D CFD 📩 Working on clean energy systems, rotating machinery, or propulsion challenges? Let's build the solution. 🌐 www.aensconsulting.com | 📧 [email protected] #FCEV #HydrogenEnergy #TurbineExpander #Turbomachinery #CFD #RadialTurbine #CleanEnergy #FuelCellVehicle #EngineeringSimulation #AENSConsulting #TurbochargerDesign #DesignOptimisation #MOGA #ComputationalFluidDynamics #AerospaceEngineering #AutomotiveEngineering #ZeroEmissions #RenewableEnergy #AENS