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Zulfikre Esa, Juliana Hj Zaini, Murtuza Mehdi, Asif Iqbal & Malik Muhammad
Nauman
To cite this article: Zulfikre Esa, Juliana Hj Zaini, Murtuza Mehdi, Asif Iqbal & Malik
Muhammad Nauman (2023) Design, Fabrication & Analysis of a Gravitational Water
Vortex Based Energy Harvester, International Journal of Green Energy, 20:1, 77-88, DOI:
10.1080/15435075.2021.2023880
Article views: 97
CONTACT Malik Muhammad Nauman malik.nauman@ubd.edu.bn Faculty of Integrated Technologies, Universiti Brunei Darussalam, Bandar Seri Begawan
BE1410, Brunei
© 2022 Taylor & Francis Group, LLC
78 Z. ESA ET AL.
GWVPP system’s main configuration includes the system 2014) used two different turbine blade shapes: flat and curved
inlet configuration and the system basin configuration. blades for harvesting the vortex energy. The turbine with flat
Wanchat et al. (Wanchat and Suntivarakorn 2011; Wanchat blades provided maximum efficiency of 21.63% while that with
et al. 2013) studied multiple GWVPP system inlet-to-basin curved blades was recorded at 22.24%. Sitram et al. (Sritram,
configurations through simulations. Three different GWVPP Treedet, and Suntivarakorn 2015) in their experimental study
system setups were studied: (i) cylindrical tank configuration; analyzed the effect of materials used in fabricating turbine for
(ii) rectangular tank with tangential inlet; and (iii) cylindrical GWVPP systems. The experiments showed that the materials
basin with tangential inlet. Basin configuration is the best with less density and higher specific strength produced more
suited setup for GWVPP system. The most suitable configura torque as it took less time to rotate to achieve maximum
tion was found out to be the basin with inlet guide/tangential velocity. Wichian and Suntivakorn (Wichian and
inlet. The optimal outlet configuration of the GWVPP basin Suntivarakorn 2016) designed turbine blades with baffle plate
was approximately 14–18% of the maximum basin diameter. similar to Pelton turbine concept; the baffles covered 50% of
Dhakal et al. (Dhakal et al. 2015b) and Rahman et al. (2017) did the curved blades and recorded the highest torque of 37.41 N.
analysis studies and reported that the Wt_inlet had to be kept as m. Ullah et al. (Ullah et al. 2020) manufactured a telescopic
small as possible. The study suggested that the optimum inlet multi-stage turbine for GWVPP conical basin system. This
configuration was 1:3 ratio of Wt_inlet to Winlet. Thapa and method was used to fully utilize vortex formation in the
Aakash (Thapa, Mishra, and Sarath 2017) suggested basin. The multi-stage turbine was also found to be comple
a triangular inlet is the most efficient configuration for menting each other by increasing the vortex strength because
GWVPP system as it produced a symmetrical vortex flow of their rigid body rotation.
pattern compared to curved inlet and rectangular inlet. The limited shapes and sizes for GWVPP system motivate
A comparison study of the two basin shapes had been well this study to proposed alternative design specific for GWVPP
documented by Sagar et al. (Dhakal et al. 2014); the study system. The novelty of the presented study will focus on the
investigated the effect of basin height (Hbasin) between the new dome-shaped basin for GWVPP system. The design of the
two basin configurations and the cone angle (Coneangle) toward basin was inspired from the Brachistochrone curve – the fastest
vortex development. The results showed that conical basin descent path (Nishiyama 2013). This design aims to improve
generates higher vortex velocity than cylindrical basin. the vortex velocity formation inside the basin and as an addi
Velocity can be improved by reducing the Coneangle and tional choice for GWVPP system basin configuration. The
increase in the Hbasin. Apart from the basin shapes and inlet study will provide thorough details and analysis of the fabri
configurations, the size of outlet diameter (Doutlet) has signifi cated dome-basin-based GWVPP system through CFD analy
cant roles in vortex air-core formation. Mulligan and Casserly sis and experimentation.
(Mulligan and Hull 2010) determined that by using the cylind
rical basin, outlet diameter to basin diameter ratio (Doutlet
/Dbasin) was at 14% for low head and 18% for high head sites. 2. Methodology
Sreerag et al. (Raveendran et al. 2016) studied the effect of
2.1. Model development and analysis procedure
outlet diameter for a conical basin; it was suggested that the
optimized outlet parameters for the system are around 30% of Within the context of this research study, the design para
basin diameter size (0.3Dbasin). meters are mainly focused on the dome basin shapes and its
Besides the CFD analysis, researchers have conducted parameters. As mentioned above, the model design was
experimentation of the GWVPP system to validate the CFD inspired by the Brachistochrone curve theory that derives
analysis results. These experimental analyses were carried out the fastest path between two elevated points, i.e. curved
to investigate the vortex generation, torque, and angular velo path and straight line path (Nishiyama 2013). CFD analysis
city produced by the GWVPP system. The experimental setup has been done as a preliminary study for developing and
typically consists of a water pump, the GWVPP basin setup, predicting the dome basin model and its performance. It
and turbine runner. In addition, turbine generator (Wanchat was used to determine the optimized configuration of the
et al. 2013), rope brake dynamometer for measuring torque, parameters by understanding and examining the flow pattern
and revolution per minute (RPM) meter for measuring shaft with the developed 3D model of GWVPP system. The opti
speed (Power, McNabola, and Coughlan 2015) were used to mized parameters achieved from the CFD analysis were
analyze the output of the system. Wanchatt et al. (Wanchat selected for fabrication. The dome-basin configuration is
et al. 2013) developed a cylindrical basin experimental setup, modeled with assumption that the air-core vortex is constant
with the maximum efficiency achieved from the setup being and axisymmetric while the flow is incompressible in cylind
30% with 0.2 m outlet configuration and operating head of rical coordinates (Dhakal et al. 2015b, Thapa, Mishra, and
0.3 m to 0.4 m. Sagar et al. (Dhakal et al. 2014) installed Sarath 2017, Dhakal et al. 2014). The CAD drawing of the
a mechanical rope-brake dynamometer to measure the torque dome-basin model and the parameters of interest are shown
of GWVPP system turbine blades and recorded peak efficiency in Figure 1. The selected parameters for designing the
of 10.5–25.4%. In later studies, Sagar et al. (Dhakal et al. 2015b) GWVPP system in this paper were based on a combination
experimented on conical basin to compare the results with of previous researchers’ optimized parameter settings as pre
cylindrical basin and found that conical basin has the max sented in Table 1 (Mulligan and Hull 2010, Raveendran et al.
imum efficiency of 36.84%, with optimized position of the 2016, Power, McNabola, and Coughlan 2015, Dhakal et al.
runner at 65–75% of the total Hbasin. Kueh et al. (Kueh et al. 2014).
INTERNATIONAL JOURNAL OF GREEN ENERGY 79
Figure 1. CAD drawing of the dome-basin model; (a) top-view and (b) side-view of the dome basin.
� 2 �
Table 1. Selected parameters for dome basin GWVPP system. @Vr @Vr Vθ2 @ρ @ Vr @Vr Vr @ 2 Vr
Config. Value Reference Vr þVz þ ¼v þ þ (3)
@r @z r ρ@r @r2 r@r r2 @z2
Winlet 0.30 m -
Wt_inlet 0.15 m Winlet /2 (Dhakal et al. (Dhakal et al. 2014)) � 2 �
Lt_inlet 1.35 m - @Vz @Vz @ρ @ Vz @Vz @ 2 Vr
Hinlet 0.15 m Hinlet = 1/3Hbasin (Christine et al. (Power, McNabola, Vr þVz þ ¼g þv þ þ (4)
and Coughlan 2015))
@r @z ρ@z @r2 r@r @z2
Dbasin 1.0 m -
Doutlet 0.20 m to 14% to 18% of Dbasin (Mulligan and Casserly (Mulligan
where Vθ , Vr , and Vz are the tangential, radial and axial
0.30 m and Hull 2010)) velocity, respectively; ρ is fluid density, g is acceleration due
30% (0.3Dbasin); (Raveendran et al. (Raveendran et al. to gravity, and v is kinematic viscosity of water.
2016))
The three-dimensional model of the GWVPP system was
modeled using commercially available software known as
Solidworks™. The Solidworks was imported into CFD analysis
The governing equation used in the CFD analysis software
software environment. CFD software was responsible for
was based on the continuity equation and Navier-stoke equa
meshing and performs the model fluid simulation. The bound
tion, which can be defined by Eq. 1 through Eq. 4 as derived by
ary conditions parameter is as shown in Figure 2.
Wang et al. (Wang, Jiang, and Liang 2010).
@Vr @Vz Vr 2.1.1. CFD model and mesh analysis of dome basin
þ þ ¼0 (1)
@r @z r The simulations were used to investigate the effect of the Rbasin
and the effect of Hbasin with optimized Rbasin on vortex velocity
� 2 �
@Vθ @Vθ Vr Vθ @ Vθ @Vθ Vθ @ 2 Vθ performance. These model designs were simulated via simula
Vr þ Vz ¼v þ þ tion software with Reynolds-averaged Navier-stokes equation
@r @z r @r2 r@r r2 @z2
and K-epsilon turbulence model (RANS K-ε). RANS K-ε is
(2)
a model used to simulate the average flow turbulence condition
80 Z. ESA ET AL.
and it is best suited for flow away from the boundary layer or
wall. This turbulence model was also used by the previous
GWVPP researchers in their study (Dhakal et al. 2015b,
Raveendran et al. 2016, Dhakal et al. 2014). With the assump
tion of steady-flow and no-slip wall condition, the working
fluids used in this CFD simulation were water and air. Water
covered all the domain with addition of air only at the open
free-surface. Water is assumed as an incompressible fluid with
the default of density and dynamic viscosity of 998.2 kg/m3 and
0.00089 Pa.s, respectively. The initial inlet velocity was set to be
0.1 m/s and the outlet pressure outlet at 101,325 Pa, and addi
tional gravity at negative Z direction. Solver settings used for
simulating the model include number of iterations at maximum
4000, tolerance factor of 1, and residual factor was set to 1000.
The model was meshed with coarser mesh and gradually the
meshing quality increased, especially at the region of interest:
Figure 3. Optimized meshing for CFD domain of dome-basin.
(i) inlet (ii) tangential inlet, and (iii) outlet of the model. Free-
quadrilateral mesh was applied to the free-surface and the
basin wall. Whereas the region of interest was meshed using
combination of triangular mesh and tetrahedral mesh. help in the fabrication of the shape of the basin for
Boundary layer refiner was added because its adaptive features experimentation purposes. The CFD analysis was carried
allow for optimized contact between different types of sizes out in two different cases. First case is to analyze the effect
meshed and this also help to minimize the meshing errors. The of Rbasin to different outlet; in this study, Rbasin – 0.5 m,
meshing was increased from ~70,000 number of elements to 0.6 m, 0.7 m, and 0.8 m will be simulated with different
~300,000 elements. Degree of freedom (DOFs) value was outlet – 0.3 m, 0.25 m, and 0.2 m. Second case is the effect
recorded for each tested element size. of Basin height on velocity development of the dome-basin
The increment in number of elements enable more precise with optimized Rbasin, where basin height will be set to
and accurate CFD analysis solution; the element size was 0.3 m, 0.4 m, and 0.5 m.
reduced till almost constant results were produced from pre
vious mesh element size. Figure 3 illustrates the meshed model
optimized for this research CFD simulation purposes. 2.2. Fabrication and experimental setup
The preliminary design of the dome basin was carried out
2.1.2. CFD parameters optimization analysis using CFD analysis. A series of cases were simulated by varying
The main objectives of this CFD analysis were to obtain the parameters that affect the vortex formation in the basin.
the velocity prediction from the designed dome-basin The best-found dome basin design was fabricated and tested
model and to determine the optimized parameter setting for this research. Two basins were fabricated for this research
of the dome-basin and the best position for installing the purpose, Wide-version dome basin and narrow-version dome
experimental turbine runner. This analysis will directly basin are shown in Figure 4.
INTERNATIONAL JOURNAL OF GREEN ENERGY 81
Curvature of the dome basins was selected based on CFD The dome-basin GWVPP system experimental setup was
simulation analysis results. The dome basins were 3D printed configured in a closed-loop system to preclude the wastage of
via fused deposition modeling (FDM) method to achieve the water. The experimental setup, as shown in Figure 5, consists of
accuracy of the curvature from the CFD analysis results. The several components such as: (i) pump; (ii) ball valve; (iii) flow
wide version dome has Dbasin of 0.65 m and Doutlet of 0.15 m; meter; (iv) channel with tangential inlet; (v) dome basin; and
ratio of 1.3:0.3. Whereas the narrow version dome basin has (vi) water tank.
Dbasin of 0.5 m and Doutlet of 0.1 m; ratio of 1:0.2. Both basins Six runner configurations were tested with the dome basin
have similar Hbasin of 0.25 m. In addition, experimental Doutlet GWVPP experimental setup. A simple 4-blades runner was
parameters of the basins can be adjusted by installing the outlet used for this testing purpose. Similar test runner approach
socket hole at the outlet of the basin. was found used by past researcher as it is easier to fabricate
Figure 4. (a) Wide version dome basin; (b) narrow version dome basin.
Figure 5. (a) schematic diagram of the experimental setup; (b) the fabricated experimental setup.
82 Z. ESA ET AL.
(Power, McNabola, and Coughlan 2015, Ullah et al. 2020). The runner rotates for a few seconds. RPM reading measurement
blades were made from 3-mm acrylic sheet, and the blades’ method was used to measure and calculate the angular velocity
mounting was made of 3D printed part. The configurations, (ω) of the shaft from Eq. 7. The power input and output of the
size, and blades’ profiles are shown in Table 2. The runner was experiments were measured with Eq. 6 and Eq. 7.
mounted vertically using a collar above of the basin. Runner Input power:
with drum mounting was used to harvest the vortex located at
Pin ¼ QρgH (6)
the middle of overall Hbasin, whereas the small mounting was
used to harvest vortex energy located near to the basin outlet. Output power:
The designated mountings responsible to hold the acrylic
blades for the turbine runner are shown in Figure 6. Pout ¼ τ�2πnrpm
In the experimental study, the torque measurement techni
que was adopted from Bajracharya et al. (Bajracharya, Ghimire, Pout ¼ τ�ω (7)
and Timilsina 2018) i.e. using a rope brake dynamometer. It is where Q is the flow rate in m3/s, ρ is the density of water, g is
one of the methods to measure the torque produced by the the gravity, H is the water head, ω is the angular velocity, nrpm
rotating shaft and the runner. The fabricated rope-brake
is the speed measured revolutions/min (RPM).
dynamometer, as shown in Figure 7, consists of spring balance,
Efficiency of the system was calculated by Eq. 8.
shaft wheel, pulley, rope, and dead weight. A spring balance
was attached to a rope. The rope was wound around the wheel Pout
η¼ � 100% (8)
and a dead weight was applied to the end of the rope to prevent Pin
the wheel from slipping.
Ten measurement readings from the spring balance scale and
A total of 30 sets of experimental configurations were made
tachometer were taken and their average was recorded to
for the dome basin GWVPP system by considering that there
increase the accuracy of the output data.
were various modular parameters used in this research such as:
i) dome basin types; ii) outlet configurations; and iii) blade’s
configurations. Each fabricated runner configuration has to be
3. Results and discussion
tested on both basins. There were three outlet configurations
for wide version basin and two outlet configurations for nar 3.1. CFD mesh dependency analysis of dome basin
row version dome basin. Figure 8 illustrates the experimental GWVPP system
setup configuration procedure conducted in this research. For
The CFD was run with the boundary conditions stated pre
each configuration, water was pumped into the system gradu
viously in section 2.1.1, where meshing was refined from
ally from 60 L/min to 100 L/min. Torque measurements were
~70,000 number of elements to its final computational ele
taken from the mechanical rope-brake dynamometer digital
ments of ~300,000 elements (Figure 9). The mesh configura
weight scale. Reading from the digital weight scale was
tions have the DOFs approximately ~95,000 up to ~570,000.
recorded and calculated using Eq. 5.
The final meshed size had about ~0.20% difference in produced
results from previous mesh element size. DOFs of approxi
τ ¼ r � F sin θ (5)
mately 480,000 (No. of elements: ~260,000) was chosen as
standard meshing setting for the rest of CFD analysis purposes.
where r is the radius of the wheel, 0.03 m, and F is the force
The final minimum and maximum element size for the free-
measured from the spring balance while θ is the angle between
triangular meshed boundaries was 1.5*10−4 m and 1.1*10−2 m,
the force (F) and the lever arm (blades of the turbine).
respectively, and free-quadrilateral meshed boundaries was set
For every variation in the flow rate, RPM of the testing
to minimum of 2.5*10−2 m and maximum of 6.5*10−2 m. The
runner was measured using digital tachometer. RPM readings
optimized mesh settings will be used for the case studies pre
were taken as the vortex fully formed inside the basin and the
pared for the analysis.
Figure 6. Solidwork model of test runner for dome basin system. (a) DR1; (b) DR2; (c) DC1; (d) DC2; (e) SC1; and (f) SC2.
CFD results also show a decrease in average velocity as Doutlet configuration of 0.2 m Doutlet, 0.6 m Rbasin and 0.5 m Hbasin;
decreases. Yaakob et al. (Yaakob et al. 2014) reported similar this configuration setting has the least average basin velocity
CFD analysis results of Doutlet effect in a cylindrical basin. produced at ~1.038 m/s. Another dominant parameter setting
In this next case study, the previously dominant Rbasin was that can be seen from the results was the 0.3 m Doutlet, 0.6 m
selected to be carried forward with CFD analysis. This study Rbasin and 0.5 m Hbasin. It shows the second highest achievable
was done to study the effect of basin height (Hbasin) by varying velocity inside the basin of 1.704 m/s, and also it has the highest
the height setting of previous height parameter. 0.3 m and average velocity results of 1.422 m/s. From this CFD analysis
0.5 m Hbasin were paired with the dominant Rbasin. The simula results, it is shown that the height and outlet parameter of the
tion results in Figure 11 show that the highest achievable system has a significant effect toward velocity production
maximum velocity of 1.768 m/s was produced from the inside the basin.
84 Z. ESA ET AL.
Figure 10. Effect of Rbasin with different Outlet parameter for dome-basin GWVPP
model.
Figure 8. The experimental setup configuration procedure for the dome basin
GWVPP system.
Figure 11. Effect of Basin height toward the dominant Rbasin parameter (outlet;
radius respectively).
Figure 12. The velocity map inside the dome-basin model for GWVPP system.
Figure 14. The average angular velocity results taken from narrow dome basin experiments. (a) Mid-height vortex flow; (b) bottom vortex flow.
86 Z. ESA ET AL.
Figure 15. The average angular velocity produced from the wide dome basin. (a) Mid-height of vortex flow; (b) bottom vortex flow.
Figure 16. The torque vs velocity graph of selected experimental results. (a)
Narrow basin, DR1Y configuration; (b) narrow basin, DR2Y configuration; (c) Figure 17. The selected maximum torque measured at maximum pump flow rate
wide basin, DR1Z configuration; (d) wide basin, DR2Y configuration; (e) narrow with configuration of (a) narrow basin, DR1Y; (b) wide basin, DR1Z; (c) narrow
basin, SC2X configuration and (f) wide basin, DR1X configuration. basin, DC2Y; (d) wide basin, DR2Y; (e) narrow basin, DR2Y; (f) wide basin, DC1Y; (g)
wide b basin, SC2X; (h) narrow basin, DC1X; (i) narrow basin, SC2X; (j) wide basin,
DC2X.
Figure 17 shows the selected maximum torque measured at
maximum pump flow rate. The highest torque recorded in the
experiments was produced by the SC2 blades configuration in The power (Pin) was calculated using Eq. 6. The Pin of the
narrow basin with Doutlet of 0.05 m. The torque produced from experimental GWVPP dome basin setup at maximum flow rate
the configuration is 0.141 N.m and angular velocity of 87.98 was 4.088 W. The power (Pout) of the experimental results was
rev/min. The lowest torque measured in the experiments was calculated by Eq. 7. The highest output results of the dome
0.0291 N.m at 85 rev/min. The results were measured from the basin GWVPP system was produced from the narrow type
wide dome basin with Doutlet of 0.15 m using DR1 blades basin with Doutlet of 0.05 m. The highest output was found at
configuration. From the experimental observations, the wide the lower bottom parts of basin, and harvested with SC2 blades
version dome basin has a poor performance with a large Doutlet configuration. It produced 1.3 W of power from the setup
configuration. This experimental Doutlet effect on the vortex configuration, and maximum efficiency was 31.77%.
velocity corresponds to the case “C” of the CFD analysis find Wide version dome basin with Doutlet of 0.15 m recorded the
ings in this research. The highest angular velocity was recorded lowest power output from the overall experiments. Lowest Pout
from the narrow basin measured at 112 rev/min with torque recorded in the experiment was 0.259 W with DC1 blades
measured at 0.039 N.m. High angular velocities were achieved configuration. The configuration has the lowest efficiency of
from the lightweight runner configuration while higher torques 6.33%. This result was due to the shorter blade wings in DR1
were achieved from the heavy runner configuration. Further configuration, and the water vortex air-core produced was
optimization of the blades is required to increase the efficiency widened as Doutlet of the basin increases [36]. DR1 and DR2
of the system and runner optimization specific for the dome blades’ configuration in this research experiments can be argu
basin parameter. ably not fully optimized for wide version dome basin.
INTERNATIONAL JOURNAL OF GREEN ENERGY 87
Table 3. The complete list of power produced and efficiency w.r.t to the system harvest vortex energy, the highest efficiency from the overall
configuration of the dome basin experimental analysis.
dome-shaped basin GWVPP system setup recorded was
Basin type Doutlet (m) Blade type Power out Efficiency 31.77%. The optimized location for placing the runner was
Narrow 0.10 DR1 0.459 11.22
Narrow 0.05 DR1 0.655 16.02
nearer to the system outlet. This result corresponds to the
Narrow 0.10 DR2 0.957 23.41 earlier CFD analysis, where highest vortex velocity was found
Narrow 0.05 DR2 0.983 24.05 near to the outlet of the system. By using both optimized Doutlet
Wide 0.15 DR1 0.259 6.33
Wide 0.10 DR1 0.284 6.95
parameter and vertical turbine configuration, this dome basin
Wide 0.05 DR1 0.534 13.07 GWVPP system can be expected to perform better in larger
Wide 0.15 DR2 0.331 8.10 scale size system.
Wide 0.10 DR2 0.571 13.97
Wide 0.05 DR2 0.554 13.55
Narrow 0.10 DC1 0.800 19.48
Narrow 0.05 DC1 0.823 20.14 Disclosure statement
Narrow 0.10 DC2 0.295 7.21
Narrow 0.05 DC2 0.380 9.29 No potential conflict of interest was reported by the authors.
Narrow 0.10 SC1 1.040 25.45
Narrow 0.05 SC1 0.896 21.92
Narrow 0.10 SC2 0.821 20.08
Narrow 0.05 SC2 1.300 31.77 Funding
Wide 0.15 DC1 0.412 10.07
Wide 0.10 DC1 0.430 10.52 This work was supported by the Universiti Brunei Darussalam [UBD/
Wide 0.05 DC1 0.456 11.15 RSCH/URC/RG(b)/2020/018].
Wide 0.15 DC2 0.795 19.46
Wide 0.10 DC2 0.570 13.94
Wide 0.05 DC2 0.886 21.68 References
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