An extensive research and development programme carried out at City University, London, has led to an improved level of understanding of how Lysholm twin screw machines may be used to recover power from two-phase flash expansion processes. The mode of operation of such machines is described together with the various types of rotor shapes used. Details are given of a computer simulation of the expansion process which was used to analyse 636 test results. These were obtained from earlier investigations as well as those of the authors and include three different working fluids, varying rotor profiles and sizes and power outputs of 5–850 kW. Good agreement was obtained between predicted and measured performance parameters and statistical analyses of the results indicate that this is unlikely to be improved without the development of more refined methods of two-phase flow analysis than are currently in use. Included in the tests are a set of measurements of pressure-volume changes within the expander carried out by the authors which confirmed a hitherto unappreciated feature of the expansion process. This is the relatively large pressure drop associated with the initial filling of the volume trapped between the rotors and the casing. The analytical technique thus developed was used both to explain the poor results of earlier studies with water expanders and to estimate optimum design performance. It is shown that, when expanding wet organic fluids, adiabatic efficiencies of over 70 per cent may be obtained at outputs of only 25 kW while multi-megawatt outputs are possible from machines no bigger than large compressors with efficiencies of more than 80 per cent. Two-phase screw expanders may be used not only for large-scale power generation in trilateral flash cycle (TFC) systems, but also in place of throttle valves in vapour compression systems to drive screw compressors in sealed ‘expressor’ units. The coefficient of performance of large refrigeration, air conditioning and heat pump systems may thereby be raised by up to approximately 8 per cent.

This paper presents a method of general geometrical definitions of screw machine rotors and their manufacturing tools. It describes the details of lobe shape specification, and focuses on a new lobe profile, which yields a larger cross-sectional area and shorter sealing lines resulting in higher delivery rates for the same tip speed. A well proven mathematical model was used to determine the optimum profile, compressor housing size, and compressor ports to achieve the superior compressors.