EffiSeal
Exergy for Fortissimo+ Improved Sealing System
Turbomachinery design, computational fluid dynamics (CFD), and high-performance computing (HPC)
The objective of this project is to enhance the efficiency of Exergy International Srl’s radial outflow turbines for Organic Rankine Cycle (ORC) power plants by investigating and optimising advanced sealing technologies. Specifically, the project aims to compare the performance of traditional labyrinth seals with an innovative brush sealing system, which has the potential to significantly reduce internal leakage losses that impact turbine efficiency. By leveraging high-fidelity CFD simulations and high-performance computing (HPC) resources, the project seeks to validate internal performance models and demonstrate that the novel brush sealing solution can deliver a measurable increase in overall turbine and cycle efficiency—making Exergy's technology more competitive in the waste heat recovery market.
Exergy International Srl, a leader in ORC (Organic Rankine Cycle) power plant turbines, seeks to improve turbine efficiency by exploring alternative sealing technologies. This project aims to study and optimize two sealing systems—traditional labyrinth seals and innovative brush seals—using advanced CFD and HPC simulations. By minimizing leakage losses, Exergy aims to enhance turbine performance by up to 3%. The project involves collaboration between Exergy, EnginSoft (CFD experts), and LuxProvide (HPC provider), leveraging supercomputing resources to validate the effectiveness of these sealing systems in real-world conditions. The initiative targets waste heat recovery markets, especially where radial outflow turbines face efficiency challenges. Improved sealing technology is expected to increase Exergy's competitiveness, reduce power losses, and boost its market share in industries like geothermal and waste heat recovery. The project’s outcome will lead to new, optimized sealing systems for radial turbines, offering significant energy efficiency gains and strengthening Exergy's position globally.
The core innovation of the EFFiSeal project lies in the application of advanced brush seal technology to ORC radial outflow turbines—an industry first in this specific context. Unlike traditional labyrinth seals, brush seals offer near-zero leakage by maintaining tighter clearances, significantly reducing energy losses across turbine stages. This novel integration, supported by high-fidelity CFD simulations and experimental validation on a dedicated test bench, represents a transformative shift in turbine design. By combining cutting-edge HPC resources with pioneering engineering, EFFiSeal delivers a breakthrough solution that not only boosts performance in demanding WHR scenarios but also positions Exergy at the forefront of sustainable, high-efficiency power generation.
EnginSoft plays a pivotal role in the EFFiSeal project as the technology and simulation expert, responsible for developing and executing the high-fidelity CFD models that underpin the entire innovation process. Leveraging its deep expertise in turbomachinery and advanced numerical methods, EnginSoft will design, simulate, and optimise both the traditional labyrinth and the novel brush sealing systems across multiple operating conditions. Their contribution ensures accurate prediction, supports design validation, and enables the creation of a robust virtual testing environment. By harnessing the power of HPC infrastructure, EnginSoft enables Exergy to accelerate development cycles and bring a next-generation turbine sealing solution to market with confidence.
Exergy Srl | EnginSoft SpA | LuxProvide
This project has received funding from the European High-Performance Computing Joint Undertaking (JU) under grant agreement No 101163317. The JU receives support from the Digital Europe Programme. | Call identifier: FFplus_Call-1-Type-1
15 months
February 2025 – April 2026
Exergy Srl
Alessandro Arcidiacono
3
by Tina Crnigoj Marc | Arctur, FFplus Communication Lead
Futurities - Spring 2025
The Fortissimo project series, launched in 2014, has successfully supported European SMEs in adopting high-performance computing (HPC) to drive innovation. The series has facilitated over 130 experiments and led to 120 success stories across more than 20 EU countries. This success inspired the development of FFplus, which builds upon Fortissimo’s legacy. FFplus continues to support SMEs and startups by offering two tracks: one focusing on traditional HPC applications and another using generative AI for innovation studies. The project emphasizes collaboration with National Competence Centres (NCCs) in 33 European countries to reach SMEs and offer tailored support, such as application assistance and onboarding to EuroHPC systems.
FFplus accelerates SME innovation by addressing specific business challenges, using HPC and AI technologies to unlock potential otherwise difficult to exploit. It helps European companies, particularly in AI, enhance their competitiveness on the global stage. The project also utilizes state-of-the-art EuroHPC systems, providing significant resources to participating SMEs, enabling them to tackle large-scale challenges and develop new technologies.
As FFplus evolves, it adapts to the needs of SMEs, continually improving its approach based on past experiments and expanding its impact. Through these efforts, the project aims to enhance Europe’s industrial digitalization, strengthen its economy, and position startups as future industry leaders.
Read the article
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