Compressor Design Research Articles

USAGE OF TECHNICAL MEANS FOR ANNULAR GAS EXTRACTION TO INCREASE OIL WELL PRODUCTION

In recent years, the technology of annular gas extraction from wells has become increasingly widespread in the fields in order to improve the working conditions of the submersible pump due to increasing its filling and supply coefficients, as well as increasing depression on the formation. Some types of compressor designs have been developed and put into production, allowing the annular gas extraction from wells and forced injection into the pressure line of the well. One of the most well-known types of compressors is a piston pair driven by a piston from a rocking machine balancer. They were used at oil production facilities in the Orenburg, Ulyanovsk Regions, the Republics of Tatarstan and Bashkortostan, Udmurtia and other regions of the Russian Federation.In the fields of Sheshmaoil LLC, a complex for pumping gas from the annulus of a well and pumping it into the COGS product collection system has found mass usage, allowing gas to be taken from a group of wells and reducing pressure in the annulus to values close to 0.1 MPa. Hydraulic piston compressors, in which gas compression occurs using a high-pressure pump that drives the piston group of the compressor, have been tested.One of the main disadvantages of the developed types of compressors is the insufficient volume and pressure of the compressed gas. The article provides an analysis of the technological parameters of the compressors. As a result of research possible solutions to the problem are worked out.To achieve the largest pumping volumes of separated annular gas, the maximum permissible diameter of the compressor cylinder should not exceed 0.07 m in order to prevent significant resistance exerted by the piston rod on the balancer of the pumping machine.The most suitable region for the effective use of suspended compressors is the Ural-Volga Region at fairly depleted oil fields with at least 60–65 % water cut, oil well flow rate of no more than 10–15 tons/day and a gas factor of no more than 15–20 m3/t . At the fields of Western Siberia, suspended compressors cannot be used due to high flow rates and gas factors. Exceptions may be wells with a water cut of at least 80 % and flow rates of no more than 20–25 tons/day.The KOGS compressor unit, developed and widely implemented at Sheshmaoil Management Company LLC, showed positive results, consisting of an increase in flow rate and additional oil production. For further use of the unit in fields, especially for high-viscosity oil production, as well as operation in winter conditions, it is necessary to increase the maximum gas injection pressure.

Aerodynamic design of supersonic compressor cascade and vorticity dynamic diagnosis of flow field structure

High-load counter-rotating compressor plays a crucial role in reducing the axial length and weight of the compressor and increasing the thrust-to-weight ratio of the aero-engine. However, the boundary layer flow separation induced by shock waves in the channel of high adverse pressure gradient also brings more aerodynamic losses. This paper proposed a supersonic compressor cascade modeling method based on the unique inlet angle theory and the superimposing thickness on the suction surface method. It carried out aerodynamic optimization design of cascade with inlet Mach number of 1.85 combined with numerical optimization technology, vorticity dynamics diagnosis, and planar cascade experiment. The results show that multiple shock wave combination pressurization can be realized in the supersonic cascade channel. At the design point, the static pressure ratio is 3.285, and the total pressure recovery coefficient reaches 86.82%, and the experimental results of planar cascade also verify the correctness of the simulation method. In addition, the correlation laws between the distribution of the vorticity dynamic parameter, shock wave structure, and aerodynamic performance of cascade were analyzed by the vorticity dynamic flow field diagnosis method, which provides a beneficial reference for the subsequent compressor design.

압축기 형상 변화에 대한 유동해석 방법 연구

In this study, numerical analyses were conducted using ANSYS CFX code to predict the performance of a turbo compressor, and the results are compared with the experimental data. A compressor is a machine that plays an important role in various industrial fields. It supplies high-pressure gas by compressing the volume of gas received from outside. In this study, a numerical-analytical approach is presented to solve problems arising in the design and operation of turbo compressors. To simulate the complex flow phenomenon in the compressor, a frame-change model was applied to the rotator. Subsequently, a methodology considering compressible fluids and turbulence model was employed to accurately predict the flow around the impeller. Additionally, numerical analysis was performed using commercial CFD code, ANSYS CFX. This software exhibits excellent convergence and analysis accuracy when rotating and stationary areas are mixed, effectively predicting the compressor performance. The numerical analysis results using the CFX code were consistentwiththeexperimentaldata,indicatingthatCFXisasuitabletoolforpredictingtheperformanceofturbocompres sors.Itisalsoexpectedtobeusefulinthedesignandoperationofcompressorsinthefuture.

AN INTEGRATED APPROACH TO DESIGNING ROBUST GAS-BEARING SUPPORTED TURBOCOMPRESSORS THROUGH SURROGATE MODELING AND CONSTRAINED ALL-AT-ONCE MULTI-OBJECTIVE OPTIMIZATION

Abstract This research introduces an innovative framework to engineering design to tackle the challenges of robustness against manufacturing deviations and holistic optimization simultaneously in a multi-disciplinary, multi-subsystems context. The methodology is based on an application of ensemble artificial neural networks, which significantly accelerates computational processes. Coupled with the Non-dominated Sorting Genetic Algorithm III, this approach facilitates efficient multi-objective optimization, yielding a comprehensive Pareto front and high-quality design solutions. Here, the framework is applied to the design of gas-bearing-supported turbocompressors. These systems are challenging due to their sensitivity to manufacturing variations, particularly in the gas-bearing geometry, which can lead to rotordynamic instability. Additionally, the interdependencies between the subsystems, such as axial and journal bearings, rotor, compressor impellers, and magnets, necessitate a multidisciplinary approach that spans aerodynamics, structural dynamics, rotordynamics, mechanics, loss analyses, and more. A clear tradeoff between system efficiency, mass-flow range, and robustness has been identified for the compressor design. Higher nominal compressor mass-flows, i.e. increased nominal power, is suggested to decrease the hypervolume of feasible manufacturing deviations. Hence, there is a sweet power spot for gas-bearing supported turbomachinery. Further, the framework's computational efficiency is on par with that of a university cluster, while only employing a desktop computer equipped with a consumer-grade graphics card. This work demonstrates a significant advancement in the design of complex engineering systems and sets a new standard for speed and efficiency in computational engineering design.

Efficient enhancement of cryogenic processes: Extracting valuable insights with minimal effort

Cryogenic systems are widely used in industries but are known for their high energy consumption. Designing these systems involves numerous variables, objectives, and constraints. This study introduces an optimization approach applied to three cryogenic processes: Natural Gas Liquids (NGLs) recovery, Air Separation Unit (ASU), and propane mixed refrigerant (C3MR) liquefaction, focusing on minimizing energy input to enhance efficiency and LNG output in a mega LNG plant. Exergy analyses identified energy losses in compressors (47 %), columns (37 %), heat exchangers (10 %), and valves/mixers (5 %), highlighting the need for improved compressor design. Optimization showed that inefficiencies could be reduced by adding inter-cooled compression stages and isentropic/isothermal compression routes. The ASU optimization involved five independent variables with optimized conditions demanding 30 MW of compression power while achieving 51 % separation efficiency. Heat exchangers are the main source of exergy loss in the standalone C3MR cycle, accounting for 61.82 % of 69.0 MW followed by compressors ∼29.27 %. When simulated with utilities, total exergy loss increases to 249.0 MW, with compressors accounting for 78.34 %, exergy loss from heat exchangers drops to 17.94 %. Results affirm the practicality of the proposed method for optimizing complex cryogenic systems, providing valuable engineering insights and potential for significant energy savings.

Performance Analysis and Aerodynamic Design of Axial Flow Compressors

The main objective of the paper is to analyze theperformance of axial flow compressors and to generate asystematic design approach which enables to designsubsonic flow ones. In order to investigate the validity of this approach, the LP axial flow compressor of the RR SpeyMK511 turbofan engine is taken as an example. The designcalculations were based on thermodynamics, gas dynamics,fluid mechanics and empirical relations. The flow isassumed to be of two-dimensional compressible type withconstant axial and rotor blade velocities with a free-vortexswirl distribution. Design calculations includethermodynamic properties of the working fluid, number ofcompressor performance parameters such as, stagetemperature rise and number, flow and blade angles (bladetwist), velocity triangles and relative inlet Mach number atrotor blades tips as well as blades tip and hub diameters. Arepeated calculation is made to determine these parametersalong compressor stages. The variation of velocity whirlcomponents, air and blade angles, deflection and degree ofreaction from root to tip of the blades were also determined.The twist of the blades along the blade length is setaccording to the recommended values in order to obtainsmooth blade twist profile.

Viability assessment of large-scale Claude cycle hydrogen liquefaction: A study on technical and economic perspective

The competitiveness of hydrogen as a sustainable energy carrier depends greatly on its transportation and storage costs. Liquefying hydrogen offers advantages such as enhanced purity, versatility, and higher density, yet current industrial liquefaction processes face efficiency and cost challenges. Although various large-scale and efficient liquefaction concepts exist in the literature, they often overlook the economic and technical viability of such plants. Here, we addresses this issue by establishing a framework for modeling a large-scale hydrogen liquefaction concept and conducting both technical and economic assessments, with a specific focus on 125 tonnes per day (TPD) high-pressure hydrogen Claude-cycle concept. The technical analysis involves preliminary designs of key process components, while the economic assessment utilizes Aspen Process Economic Analyzer. Our findings indicate that at an electricity price of €0.1/kWh, the Claude-cycle liquefier concept yields a specific liquefaction cost (SLC) of €1.55/kgLH2. A sensitivity analysis was performed, which shows that electricity price has a significant influence on the economics. Further investigation on the compressors design shows that incorporating high-speed centrifugal compressors could reduce the SLC by 5.42% and potentially more. Scaling up to 250 and 500 TPD reveals further cost improvements, while cost projections indicate substantial declines as the technology matures. Ultimately, this paper presents novel cost-scaling and experience curves of hydrogen liquefaction technology, demonstrating the compelling economic viability of integrating large-scale hydrogen liquefaction into sustainable energy infrastructure.

Compact compressor based on unparallel gratings

The pulse compressor is one of the essential components in a high-power laser system, which is often bulky. Here, we propose a compact compressor based on a Treacy compressor with two unparallel gratings and a mirror. Two gratings provide a negative group delay dispersion, and the mirror has two functions. One is to make the beam enter the compressor twice, and the other is to make the optical path between the grating pair folded to reduce the volume of the compressor. The relation between the group delay dispersion and the incident angle in three-dimensional space is derived. The results show that a small spatial incident angle can produce a large negative dispersion when the perpendicular distance between the gratings is the same. The parameter limits of the designed structure are also discussed, and the volume of compact compressor under the simulated parameters is two-thirds of the conventional compressor when the constraints are satisfied. This work is applicable to the optimal design of grating-based compressors with different parameters.

End-to-end design of multistage high-pressure axial compressor for a promising aviation gas turbine engine

End-to-end design of multistage high-pressure axial compressor for a promising aviation gas turbine engine

Investigation of the minimum filling amount of ionic liquid in the multi-stage ionic liquid compressor

Ionic liquid compressors are the ideal solution for hydrogen refueling stations, and multi-stage compression is an inevitable choice for achieving high-pressure refueling, such as 90 MPa level. However, the initial filling amount of the ionic liquid in the compression chamber is lacking basis as the characteristics of gas-liquid two-phase flow during the reciprocating movement of the liquid piston are not understood. This study numerically investigates the variation characteristics of the gas-liquid interface in the compression chambers under different structural and operating parameters of a five-stage ionic liquid compressor. Based on the fluctuation feature of the phase interface, the minimum liquid piston heights in each stage that ensure effective sealing for the compression chamber with different stroke-to-diameter ratios (r) are determined. Finally, the mathematical relationship for calculating the minimum ionic liquid filling amount related to structural parameter r and suction pressure is established, which provides guidance for the design of the ionic liquid compressor.

Analysis and Optimization of the Performances of the Tandem Blade Radial Compressor Using the CFD

Centrifugal compressors are frequently used in both military and commercial areas because they can be easily manufactured and reach high-pressure compression ratios. The factor that limits the performance and operating range of compressors is flow instability. Many ideas have been put forward for performance improvement, but tandem blade radial compressors, which do not require an extra air system, have attracted the most interest. In this study, computational fluid dynamics (CFD) analyses were carried out on various parameters of the tandem blade (TB) radial compressor, and an optimization study was carried out to find the best design using a genetic algorithm on a whole operating curve. It was investigated how these parameters affected the efficiency and total pressure ratio between the determined lower and upper limits. The numerical analyses of the optimum design obtained as a result of the iterations were carried out. As a result of the iterations, three optimum designs were obtained and numerical analysis was carried out according to one of them, and then they were compared with the results in the literature. The general agreement of computational fluid dynamics and the literature data served as a validation for the computational approach. The error rates between the numerical analysis results and the experimental results in the literature were calculated for different flow rates and were found to be 1.98% as the highest and 0.35 as the lowest. The work carried out in this article will provide a valuable reference for future advanced tandem blade compressor designs.

Aerodynamic performance enhancement of centrifugal compressor using numerical techniques

Background Centrifugal compressors are dynamic machines utilizing a rotating impeller, efficiently accelerate incoming gases, transforming kinetic energy into pressure energy for compression. They serve a wide range of industries, including air conditioning, refrigeration, gas turbines, industrial processes, and applications such as air compression, gas transportation, and petrochemicals, demonstrating their versatility. Designing a centrifugal compressor poses challenges related to achieving high aerodynamic efficiency, surge and choke control, material selection, rotor dynamics, cavitation, erosion, and addressing environmental considerations while balancing costs. Optimizing maintenance, reliability, and energy efficiency are essential aspects of the design process. Methods The primary objective of this research is to comprehensively investigate and improve the aerodynamic performance of centrifugal compressors. To accomplish this, a comprehensive investigation of variables such as blade number and hub diameter, along with various turbulence models will be conducted. This approach will leverage numerical techniques to fill the significant gaps in the current literature regarding centrifugal compressor design and optimization. The study encompasses the evaluation of two turbulence models, namely Shear Stress Transport and K-epsilon. Furthermore, it delves into the fine-tuning of blade geometry, including variations in blade number and hub diameter, aiming to refine the design for optimal performance. Extensive analyses using Ansys CFX encompass key variables such as Pressure, Mach Number, Density, Velocity, Turbulence Kinetic Energy, and Temperature. Results Notably, the optimized pressure profile yielded remarkable results, achieving a substantial 36% improvement, demonstrating the tangible benefits of these design enhancements. Conclusion The outcomes of this research hold significant utility for engineers, manufacturers, and regulatory bodies, offering invaluable insights and guidance to enhance compressor performance and efficiency.

Technical Study for the Development of Air Brake Compressor in Electric Commercial Vehicles

<div>The development of electric commercial vehicles brought up novel challenges in the design of efficient and reliable air brake systems. The compressor is one of the critical components of the air brake system and is responsible for supplying pressurized air to the brake system. In this study, we aimed to gather essential information regarding the pressure and flow rate requirements for the compressor in the air brake system of electric commercial vehicles. We extensively analyzed the existing air brake systems utilized in conventional commercial vehicles. We examined the performance characteristics of reciprocating compressors traditionally employed in these systems. Recognizing the need for novel compressor designs tailored to electric commercial vehicles, we focused on identifying the specifics such as efficiency, performance characteristics, reliability, and cost of the compressor.</div> <div>Our study utilized theoretical calculations to ascertain the optimal pressure and flow rate parameters. By thoroughly evaluating vehicle brake standards and meticulously analyzing relevant data, we gained a comprehensive understanding of the performance requirements for compressors in electric commercial vehicle air brake systems. Our analysis considered various factors, including vehicle weight, stopping distance, and operational conditions, providing valuable insights into the specific needs of these systems.</div> <div>The research results serve as the foundation for developing compressors that are more efficient, reliable, and compatible with electric vehicles equipped with regeneration capabilities. Ultimately, implementing these improvements will raise the standard for safety, reliability, and overall performance in the air brake systems of electric commercial vehicles.</div>

Performance comparison of liquid, vapor, and liquid–vapor injection of single-screw compressor for an air-source heat pump

Refrigerant injection techniques are usually proposed to improve the performance and reliability of compressors when a single-screw compressor applied to an air-source heat pump works at low temperatures in winter. In this study, an experimental study was conducted to present the performance comparison of the single-screw compressor in the air-source heat pump under liquid, vapor, and liquid–vapor refrigerant injection at evaporation temperatures between −19 and −8 °C. The results indicate that, when the evaporation temperature decreases from −8 to −19 °C, the heating capacity under liquid–vapor and vapor injection increases by 16.7% and 12.7%, respectively, compared with that under liquid injection and that the COPh increment under liquid–vapor injection and vapor injection is, respectively, from 11.23% to 39.21% and from 17.18% to 30.82% compared with that under liquid injection. Therefore, the liquid–vapor injection method is conducive to the operation of the air-source heat pump at a lower ambient temperature. The experimental results can provide the basis for the future design of single-screw compressors applied to air-source heat pumps.

Multistage Compressor Design Based on Dimensional Zooming

Multistage Compressor Design Based on Dimensional Zooming

Geometric and thermodynamic analysis of a fully meshed double-scroll compressor

The double-scroll wrap can effectively increase the volume flow rate compared with the commonly used single-scroll structure, but its built-in volume ratio is extensively reduced. With the aim of improving its built-in volume ratio, this study presented a fully meshed double-scroll profile, or called modified double-scroll, and proposed a generation method for it; its profile equations as well as relationships between its geometric parameters were obtained, and effects of the geometric parameters on the compressor performance were analyzed. Moreover, thermodynamic characteristic and working process of the double-scroll compressor were numerically simulated and verified with its performance experiment. It is found that the proposed fully meshed double-scroll significantly increases the built-in volume ratio by 33.8 %; meanwhile, it increases the volume flow rate, reduces the friction velocity between the orbiting and fixed scrolls, and decreases scroll dimensions. The proposed fully meshed double-scroll can be applied to the design and manufacture of scroll compressors.

Multidisciplinary Design Methodology for Micro-Gas-Turbines—Part II: System Analysis and Optimization

Abstract Owing to their high specific energy capabilities, ultramicrogas turbines (UMGT) are a high-potential technology to provide portable electric power supply for applications with demand of less than 1 kW. UMGT conceptual design is challenged by small-scale effects augmenting interdisciplinary dependencies leading to highly coupled, nonlinear component interactions. This work provides a novel approach to conceptual UMGT design by combining reduced order component and system modeling with constrained multi-objective optimization. Hereby, Part I presents integrated design and performance modeling of compressor, turbine, combustor, and generator. In Part II, the heat engine and generator modules are merged into a system framework by establishing conceptual UMGT rotor geometry and engine design. Following bearing selection and lifetime assessment, experimentally validated reduced order models are developed for heat transfer and rotordynamic analysis. Using the elaborated framework, a constrained multi-objective system optimization of a 300 W engine is performed based on ten design parameters and comparing SiAlON and Inconel 718 as potential rotor materials available for additive manufacturing. Hereby, bearing lifetime, system efficiency, and specific power are maximized while meeting rotordynamic, structural, and thermal requirements. Evaluating the results, interdisciplinary effects are highlighted, and two optimum engine configurations are suggested.

FinFET-Based Low-Power Improved PDP 4:2 Approximate Compressor Design

In the era of low-power very large-scale integration design, approximate computing is a soaring design paradigm that assures energy-efficient circuit design at the cost of some accuracy. Multiplication is a very important operation of an arithmetic unit and compressor is the inherent part of the multiplier. In this paper, an energy-efficient design of a 4:2 approximate compressor is proposed. The inclusion of the extra leakage control transistors in the logic has led to leakage power reduction, which ultimately reduces the power dissipation in the circuits. The proposed 4:2 compressor is simulated at 10[Formula: see text]nm fin-field effect transistor (FinFET) technology. The proposed compressor has been verified for its functionality and robustness. The proposed design shows a power dissipation of 154.48[Formula: see text]nW and a delay of 9.16[Formula: see text]ps. In comparison to other 4:2 approximate compressors, the proposed compressor shows the least power dissipation, the lowest power delay product (PDP) and the highest robustness. The power dissipation of the proposed compressor is 92.84% less than that of the base compressor. The PDP of the designed compressor is 80.58% less than the minimum PDP among other compressors. The aging analysis for the negative bias temperature instability (NBTI) effect is also checked for the proposed compressor and compared with the existing designs.

New grating compressor designs for XCELS and SEL-100 PW projects

New grating compressor designs for XCELS and SEL-100 PW projects

A hybrid data-driven framework for loss prediction of MCA airfoils

The Multi Circular Arc airfoils family has gained significant popularity in axial compressor design due to its capability to achieve higher pressure ratios with lower losses compared to conventional NACA airfoils. However, modeling their aerodynamic performance for transonic axial compressors remains a challenging task. This research addresses this issue by developing a data driven model for Multi Circular Arc airfoils loss correlation utilizing an automated blade-to-blade flow solver, StarCCM, under specific flow boundary conditions. Since the data built in this research includes high dimensionality, it is subjected to dimensionality reduction using Principal Component Analysis while retaining as much of its important information as possible. What sets our research apart is the comparative analysis of hybrid machine learning approaches. We specifically combine classification techniques based on shock wave formation on the airfoil’s suction side with Multi-Layer Perceptron neural network methods. This unique combination allows for a comprehensive prediction of MCA loss as the main objective of the research. The results demonstrate that this surrogate-based approach provides accurate loss model with 97% of precision error for the classification which results in 0.99 and 0.94 of R2 for loss model related to the transonic and subsonic airfoils loss prediction.