Numerical simulation and optimization of centrifugal compressor return channels: methods and results

Abstract

Abstract The authors actively use their engineering Universal Modelling Method for gas-dynamic design of centrifugal compressors for industrial partners. Currently, there are two approaches to improving the Method: improving the preliminary design and increasing the accuracy of gas-dynamic characteristics calculation. Computational Fluid Dynamics (CFD) methods give good results for the flow path stator part. Recently, massive CFD calculations of the vaneless diffusers (VLD) characteristics were generalized by a system of algebraic equations, which replaced the previous more complex mathematical model in the Method. Then, based on CFD optimization of a large series of return channels (RCh), corrections were made to the preliminary design of this element of the flow path. This paper presents the results of the joint CFD optimization of a vaneless diffuser and a return channel. Stator elements have many geometric parameters. For a stage with the flow rate coefficient of 0.0597 and the loading factor of 0.60, only the VLD relative radial length D 4/D 2, the number and the inlet angle of the return channel vanes were optimized. Engineering calculations and design experience predicted an optimal value of D 4/D2 within the interval 1.9 - 2.0. CFD optimization demonstrated almost linear reduction of the total head loss towards the end of the investigated range D 4/D2 = 2.3. After careful optimization of the U-bend, the optimization of D 4/D2 was repeated. The influence of on the loss coefficient has decreased, but the value of D 4/D 2 = 2.3 is still far from optimum. It significantly exceeds technically acceptable radial size. The result obtained influenced the design plan of future calculation experiments with a large series of stator elements of the stages in a practically significant range of design parameters.