In this paper, a zero-dimensional model for the design of radial turbo-expanders for ORC applications is discussed, with special reference to the estimation of losses and efficiency; a comparison between different fluids (R134a, R1234yf, R236fa, R245fa, Cyclohexane, N-Pentane) is presented and discussed, referring to a typical small-size application (50kW). In the model, different methods for the design of radial turbines are screened, with special attention to the estimation of losses, for which correlations from literature are used. Real Equations Of State (EOS) are applied to the expansion process in place of the traditionally adopted Mach relationships for ideal gas, which is a significant advancement for modeling organic fluids in ORC, often operating near to critical conditions. The results show that the total to total efficiency of the designed machines range between 0.72 and 0.80, depending on the considered fluid. Generally, higher efficiency (1.5–2.5% points) can be achieved adopting backswept-bladed rotors. The most significant losses come from the rotor secondary flows, due to the high curvature of blade profiles combined to the large pressure gradient. The best performing fluids are R236fa and R245fa, followed by R134a and R1234yf.
