International Research Journal of Engineering and Technology (IRJET) Volume: 12 Issue: 11 | Nov 2025
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e-ISSN: 2395-0056 p-ISSN: 2395-0072
Performance Enhancement of Tesla Turbine Pico-Hydro System Using a Plenum-Slot Nozzle Design Mukund Nalawade1, Gaurav Patil2, Niranjan Pagere3, Rahul Yadav4, Hrushikesh Patankar5, Rahul Pise6 1.Proffeser. Dr., Department of Mechanical Engineering, Vishwakarma Institute of Technology, Maharashtra, India 2,3,4,5,6,Student, Department of Mechanical Engineering, Vishwakarma Institute of Technology, Maharashtra, India
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Abstract - The growing need for sustainable and efficient energy production has led to new ways of using natural resources.
This study centers on the design, creation, and testing of a Tesla turbine model that includes a plenum nozzle for generating electricity. Modern production techniques such as 3D printing, machining, and laser cutting were used to build the model, with materials like ABS (Acrylonitrile Butadiene Styrene) and 0.4 mm mild steel sheet metal, as well as parts bought from commercial suppliers. The plenum nozzle was designed to ensure even flow and greatly cut down on pressure losses, reducing them from 35% in standard designs to under 1%, which allows for more effective water movement to the turbine discs. The prototype was tested at Vishwakarma Institute of Technology in Pune under three different water flow levels while keeping the water pressure constant. The findings showed that the turbine's performance improved with higher flow rates. This research supports the creation of eco-friendly energy options by improving the characteristics of how water enters the system. Keywords: 3D printing, ABS, Design, Efficiency, Laser cutting, Prototype, Sheet metal, Tesla turbine, Plenum nozzle.
1. INTODUCTION The Tesla turbine was first imagined by Nikola Tesla in 1906. In 1911, the Allis- Chalmers Manufacturing Company built one of the largest Tesla steam turbines. This turbine had a diameter of 1.5 meters, spun at 3600 revolutions per minute, and produced 500 kilowatts of power with a mechanical efficiency of 38%. However, over time, the discs of the turbine began to warp, which made it less competitive compared to traditional inertial turbines. In recent years, there has been growing interest in small-scale power generators for use in mobile, residential, and off-grid renewable energy systems. Conventional inertial turbines, such as Kaplan, Francis, and Pelton types, experience efficiency issues when made smaller. This is because the increased surface area relative to volume makes forces like surface tension, adhesion, and cohesion more influential than inertial forces, leading to lower efficiency in smaller versions. On the other hand, Tesla turbines convert flow energy into rotation by relying on the kinematic viscosity and surface effects of the working fluid, rather than inertia. This rotational energy can then be turned into electricity using generators, which makes the Tesla turbine suitable for smallscale power production. The design of the Tesla turbine relies on the sticky and thick characteristics of the working fluid to spin the tightly packed discs. A key part of the design is keeping the gaps between the discs very small, which helps create boundary layers that enhance energy transfer from the fluid, where adhesion and viscosity play the main roles. The fluid is introduced through a plenum nozzle at the outer edge, spirals inward while making many revolutions, and exits through central exhaust holes near the axle, as shown in Figure 1. The plenum nozzle ensures that water enters the rotor evenly around its circumference, avoiding high-velocity jets and pressure losses. Unlike traditional turbines, Tesla turbines do not need obstacles or vanes to generate inertial forces for energy transfer. Instead, as the fluid moves inward, it gradually transfers its momentum to the rotating discs, causing the rotor shaft to turn. Finally, the fluid exits through holes located at the central axis of the discs, completing the process of energy conversion. This paper describes the creation of a Tesla turbine integrated with a plenum nozzle for use in pico hydropower generation. Small hydropower systems are classified according to their power output: small hydropower ranges from 2.5 MW to 25 MW, mini- hydropower is less than 2 MW, micro-hydropower is under 500 kW, and pico-hydro- power is below 10 kW. The main objective of this project is to utilize the hydraulic energy from domestic water supply systems or overhead storage tanks, which are commonly installed on the rooftops of residential and commercial buildings. The installation of the Tesla turbine is shown in Figure 2. The turbine is integrated into a PVC pipeline that transports water from rooftop overhead tanks to residential areas for regular use. A bypass system made of PVC pipes is used to maintain a constant water supply during turbine maintenance or if there is a malfunction. In these situations, valve B is closed, and valve A is opened to redirect the water flow directly to the households. During regular operation, valve A is kept closed and valve B is left open, which lets water pass through the turbine. This arrangement helps maintain a constant flow of
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